Download - 1153 - Section 01.pdf

Operator's Manual

iSection 1 - Operating Instructions

Table Of ContentsOn Delivery 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Radio Frequency Or Electro Magnetic Interference (RFI Or EMI) 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Personnel Handling Pre‐Lift Check List for Link‐Belt Cranes 1-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Cab 1-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

Gauge And Control Panel 1-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

ii Section 1 - Operating Instructions

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

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

Diesel Fired Warm‐water Cab Heater 1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Start The Diesel Fired Warm‐water Cab Heater 1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Stop The Diesel Fired Warm‐water Cab Heater 1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Dependant Warm‐water Cab Heater (If Equipped) 1-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Start The Cab Heater 1-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Stop The Cab Heater 1-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Heater Shutoff (If Equipped) 1-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Conditioning (If Equipped) 1-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Column And Wheel 1-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Shifting The Transmission 1-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foot Operated Controls 1-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combination Steering 1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conventional Steer Mode 1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Wheel Steer Mode 1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4‐Wheel Steer Mode 1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crab Steer Mode 1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Steering Modes 1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Pump Disconnect (If Equipped) 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Engage The Main Pump 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Disengage The Main Pump 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Seat 1-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hour Meter 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Panel 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Disconnect Switches 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Diagnostic Connector 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outrigger Operation 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Extend Outrigger Beams 1-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Extend Outrigger Jacks - Raise The Crane 1-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Retract Outrigger Jacks - Lower The Crane 1-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Retract Outrigger Beams 1-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

iiiSection 1 - Operating Instructions

Crane System Controls 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Throttle 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Lock System 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing System 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Brake Pedal 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Control Lever 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Swing Lock 1-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Park Brake 1-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

360° Swing Lock 1-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Rope Winch System 1-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warm‐Up Procedure 1-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Winch Control Lever (If Equipped) 1-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Winch Control Lever 1-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Operation 1-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Control Switch(es) 1-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Speed Hoist Or Lower 1-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Disable 1-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum Rotation Indicators 1-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First Layer/Third Wrap Indicator (If Equipped) 1-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Hoist System 1-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Telescope System 1-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Extend Modes 1-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Telescope Mode Selection 1-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Telescope Control Pedal 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Extend The Boom Sections 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Retract The Boom Sections 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RCL Boom Telescope Screen 1-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Normal Operation Messages 1-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error Messages 1-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Telescope Operation 1-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Manually Retract A Boom Section 1-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Manually Extend A Boom Section 1-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

iv Section 1 - Operating Instructions

Fine Metering System (If Equipped) 1-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Operating In Wind And Lightning 1-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Angle Indicator 1-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti‐Two Block Warning System 1-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lockout Pin And Flag 1-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MicroGuard 540 Rated Capacity Limiter 1-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

To Select Rigging Mode 1-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cancel Audible Alarm And Reset Function Limiters 1-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Settable Alarms 1-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Angle, Length, Height, Radius, And Swing Operator Alarms 1-80. . . . . . . . . . . . . . . . . . . . . . . . . .

First Layer/Third Wrap Alarm (If Equipped) 1-86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Defined Area Alarm 1-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Date Setup 1-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering And Exiting The Operator's Cab 1-92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Break‐In Period 1-92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Starting Operations 1-92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Distortion Due To Thermal Effects Of The Sun 1-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Starting Procedure 1-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Shutdown Procedure 1-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Engine Starting 1-95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Engine Block Preheater 1-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jump Starting The Crane 1-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Operation 1-98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

vSection 1 - Operating Instructions

During Operation 1-98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Signals 1-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pick And Carry Operation 1-100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling The Crane 1-101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel 1-101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Highway Travel 1-102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Removal And Installation (If Equipped) 1-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Removal 1-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Installation 1-105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting The Crane 1-106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing The Crane 1-107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting The Crane 1-108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the crane as follows before transporting it: 1-108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suspension Height Adjustment 1-109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Storage 1-110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Short Term Storage 1-110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Long Term Storage 1-110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

vi Section 1 - Operating Instructions

Operator's Manual

1-1Section 1 - Operating Instructions

ÏÏ

ÌÌÌÌ

Figure 1-1Crane Nomenclature

1. Boom2. Operator's Cab3. Front Winch

4. Rear Winch5. Counterweight6. Rear Outrigger

7. Turntable Bearing8. Fuel Tank9. Front Outrigger

10. Boom Hoist Cylinder11. Hook Block12. Hook Ball

1 2 3 4 5

611 9 8 712

10

On DeliveryWhen a new crane is delivered, follow the instructionsoutlined in the latest version of Technical Bulletin Gen‐eral Series #213.

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

Safe operations of a hydraulic crane requires a welltrained, qualified operator. Crane operation is more in‐volved than it may appear, and operation by a carelessor unqualified person can result in a serious accident.

When a hydraulic crane is maintained and used prop‐erly it can be a safe, highly productive piece of equip‐ment, but if not used properly, it can be dangerous.

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

Figure 1-2Read and understand all points covered in thisOperator's Manual before operating the crane.

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

Do not deface or remove this label from the crane.

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

SAFETY INSTRUCTIONS

Operator's Manual

1-2 Section 1 - Operating Instructions

Figure 1-3Diesel exhaust fumes can be harmful.

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

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

Keep clear ofmoving parts toprevent seriousbodily injury.

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

Operator Awareness1. Read this Operator's Manual and heed it. The

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

his attention while operating a crane. Remem‐ber-operating is a full‐time job.

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

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

5. Keep your shoes clean. Before entering the opera‐tor's cab, wipe clean any mud, gravel, snow, ice,moisture, or grease from your shoes. Slipperyshoes could cause momentary loss of control ofcrucial foot operated controls.

Wrong

Figure 1-5Do not smoke when fueling, or fuel up near anopen flame.

6. Keep all walking surfaces (steps, ladders, plat‐forms, etc.) and non‐skid materials on the craneclean. Non‐skid materials are placed on the craneto assist operators and service personnel with safeaccess/egress to/from the crane and to/from ad‐justment and inspection areas. Do not allow non‐skid materials to become contaminated with mud,snow, ice, oil, paint, wax, etc. Any contaminationcan cause the non‐skid materials to become slick,reducing their effectiveness for safety while walk‐ing on the crane. If any non‐skid materials becomeineffective due to wear, age, or destroyed in anyway, they must be replaced.

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

8. To prevent movement of individual boom sections,shutdown the engine and ensure that the operatorhas properly vacated the operator's cab beforeputting hands or tools inside the boom. Unexpec‐ted movement of the boom sections could severfingers, hands, arms, etc.

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

sure that the rigging cannot slip off or pull awayfrom the load, or get out of position on the load.Be sure the load is rigged so it will not turn over.

b. Chains and slings must be of adequate size, ingood condition, and not twisted around eachother.

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

Operator's Manual


Figure 1-6Level the crane.

A 3 Degree Side Tilt CanReduce Capacities

By Over 50%.

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

WrongRight

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

e. When hoisting with single part line, especiallyin long falls applications, the design of wirerope and hook ball is crucial to minimize thepotential for uncontrolled wire rope and/orload rotation. Rotation‐resistant wire rope isrecommended for single part of line applica‐tions. See Wire Rope Capacity Chart in theCrane Rating Manual for the specific types ofrotation resistant wire rope recommended forthe crane.

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

loads carefully. Jerking the load, swinging andengaging swing brake roughly, and loweringthe load rapidly and slamming on brakes, willput shock loadings and possible side loadingson the boom. Unnecessary abuse labels theoperator as a beginner. Be a professional.

g. Do not wrap the winch wire rope around theload. Do not use discarded, worn, or dam‐aged wire ropes for slings. They may fail anddrop the load.

h. The crane must be level on a firm supportingsurface before making a lift. Use the bubblelevel to level the crane. Check its accuracy fre‐quently with a carpenter's level. Remember, athree degree side tilt can reduce capacities by50% or more.

Operator's Manual


Figure 1-7Do not let the load hit the boom or fly.

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

Can Cause This!

Wrong

Figure 1-8Do not use the boom to pull sideways.

Wrong

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

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

building or any other object. A dent or other dam‐age could result, which will weaken the boom or at‐tachment. If the damage is severe, the attachmentcould collapse. If a lattice or diagonal bracingmember on the fly is broken, cracked, or bent, con‐tact your Link‐Belt Distributor for repair proce‐dures. If the boom or fly is struck, or damaged byanything, STOP. The loading on a boom or attach‐ments increases as they are lowered, thereforetheir suspension systems could collapse duringlowering. Use another crane to lower a damagedboom or attachment.

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

13. Don't pull sideways on the boom, not even a little.Lift straight up on every load. Moving trucks, railcars, barges, or anything else pulling sideways onthe winch wire rope could buckle the boom or fly. Itcould also damage the swing mechanism. Pullingsideways on a boom or fly can overturn the crane.

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

15. Do not “two block” (pull the hook block, hook ball,and/or the load into the head machinery) as this

Operator's Manual


can cause winch wire rope and sheave breakageresulting in an accident.

16. After slack winch wire rope operation, make surethe winch wire rope is properly seated in sheavesand on drums before continuing to operate. Use astick or mallet to set the winch wire rope, not yourhands.

17. Do not lower the load beyond the point where lessthan three full wraps of winch wire rope are left onthe drum. This condition could occur when lower‐ing a load beyond ground level. If all the winch wirerope runs off the drum, the load will jerk whichcould break the winch wire rope.

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

19. Don't alter any part of the crane. Additions to orchanges in any part of the equipment can createloadings for which the crane was not designed.Such changes may seriously affect the usable ca‐pacities and make all capacities in the Crane Rat‐ing Manual invalid. Alterations can dangerouslyoverload or weaken critical parts and may causedisastrous failure.

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

21. When operating on outriggers, all beams must beequally extended; all fully retracted, all intermedi‐ate extended or all fully extended. Jacks must beextended so all tires are clear of the ground, andthe crane must be level. Be sure that pontoons areset on firm surface, adequate to support the block‐ing, pontoon, crane and load without settling, slip‐ping or collapsing. Blocking or matting under pon‐toons must form a smooth level surface under theentire pontoon. Do not block under outriggerbeams inside the pontoons as this reduces stabil‐ity. Blocking must be under pontoons only. Re‐member-there are tremendous loadings on pon‐toons and blocking - the weight of the entire craneplus any load.

Figure 1-9Crane level, all beams extended equally (allfully extended, intermediate extended, or fullyretracted) and tires clear of the ground.

Right

When blocking or matting under pontoons, besure that each pontoon is supported fully - no un‐supported pontoon area is permissible. Be surepontoons are on a smooth surface. Rough sur‐face, rocks, etc., under pontoons will cause un‐equal loadings, and can puncture them, causingthem to collapse.

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

Operator's Manual


Figure 1-10Watch that carrier!

Wrong

22. Cold weather operation requires some special at‐tention by the operator to allow for changes in eve‐ryday routines:a. Clean the crane, especially the boom, of accu‐

mulated amounts of ice or snow. Operatingthe crane with an ice covered boom is danger‐ous. The added weight of the ice or snow candrastically reduce the capacity of the crane.Also, falling ice may pose danger for groundpersonel.

b. Clean all snow and ice from steps, ladders,platforms, etc. to eliminate slippery walkingsurfaces.

c. If cold weather starting aids are provided onthe crane, use them. The use of aerosol start‐ing sprays can be dangerous if the manufac‐turer's directions are not closely followed.

d. Pay close attention to the gauges in the opera‐tor's cab when starting the engine. Normal“warm up” times will be longer. Be sure pres‐sures and temperatures are within normalranges before beginning operations.

e. Always handle flammable materials accordingto the manufacturer's instructions. Propane,diesel, or other fuel for auxiliary heaters can bedangerous if not properly handled. Do notstore such fuels on the crane.

Figure 1-11Fly Section Nomenclature

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

5. Connecting Lugs6. Head Machinery

Cross Shaft

1

23

4

5

6

f. Use caution when lifting any load during freez‐ing weather, as it may be frozen to the groundor the supporting surface. The added tension,to break the load free, could cause an unsus‐pected overload situation. Also, when the loaddoes finally break loose it could create an er‐ratic motion causing damage or injury.

g. At the end of the work shift, park the crane whereit will not freeze to the ground. Major damage tothe drive mechanism could occur while trying tofree the crane from a frozen surface.

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

24. Brake firmly in one application. Avoid fanning thebrakes. This could exhaust oil pressure so fast thatthe pump may not supply enough oil.

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

26. Shift the transmission to neutral before operatingthe crane. Crane operation can cause movementwhich can damage the transmission or drive line.When parking, shift to neutral and engage the parkbrake. Block wheels if not on a level surface.

Operator's Manual


Figure 1-12Handling The Fly Sections.

RightWrong

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

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

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

3

1

12

2

3

27. When operating with the boom at a high angle, usecare not to let the load hit the carrier.

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

29. Block under and between the fly sections whenloading them on a transport vehicle. When secur‐

ing the fly to a transport vehicle, it is best to use syn‐thetic webs or slings. If using wire rope slings, padthe fly to protect it from damage. Do not over‐tighten the tie downs or the fly may be damaged.Do not use chain tie downs, as they may dent anddamage the fly section.

30. Thoroughly inspect all the elements of the fly sec‐tion before installing it on the crane. Check eachmain chord, picture frame, diagonal, lattice, andconnecting lug for bends, dents, and cracked orcorroded welds. Picture frames must be square.Do not use any fly section that is even slightly dam‐aged. Consult your Link‐Belt Distributor for theproper repair procedures.

Operator's Manual


Figure 1-13Stay Away From Power Lines.

Wrong

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

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

Electrical Dangers1. All Electrical Power Lines Are Dangerous. Contact

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

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

block, hook ball, and load, at least 15 ft (4.57m)away from the electrical lines or as specified inthe “High Voltage Power Line ClearanceChart” or other distance specified by applica‐ble codes. Slow down crane operation.

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

And Boom Or Mast Lowered.

Normal Voltage, kV(Phase to Phase)

Minimum RequiredClearance, ft (m)

See Note 1

Operation Near High Voltage Power Lines

To 200 15 (4.57)

Over 200 To 350 20 (6.10)

Over 350 To 500 25 (7.62)

Over 500 To 750 35 (10.67)

Over 750 To 1000 45 (13.72)

Operation in Transit with no Load and Boom orMast Lowered

To 345 15 (4.57)

Over 345 To 750 16 (4.87)

Over 750 To 1000 20 (6.10)

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

High Voltage Power Line Clearance Chart

Operator's Manual


Figure 1-14Crane equipped with proximity warning deviceon the entire boom.

Shaded area shows “sensitivity zone” with full boom lengthsensor used, and adjusted for 15 ft. (4.57m) clearance. Contactcan be made outside this zone by the fall lines, winch wire rope,cab, etc. In such cases, the alarm will not sound, but the crane willbe electrified and deadly.

Wrong

c. Assume that every line is “Hot”.d. Appoint a reliable person equipped with a loud

signal (whistle or horn) to warn the operatorwhen any part of the crane is working aroundthe power line. This person should have noother duties while the crane is working aroundthe power line.

e. Warn all personnel of the potential danger.Don't allow unnecessary persons in the area.Don't allow anyone to lean against or touch thecrane. Don't allow ground workers to holdload lines, or rigging gear unless absolutelynecessary. In these cases use dry plasticropes as tether lines. Make certain everyonestays at least 15 ft (4.57m) away from the load,or as specified in the “High Voltage Power LineClearance Chart” or such distance as requiredby applicable codes.

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

Figure 1-15Crane equipped with proximity warning deviceon boom tip.

Shaded area shows “sensitivity zone” with the probe near theboom peak and adjusted for 15 ft. (4.57m) clearance. Contactcan be made outside this zone by the fall lines, winch wire rope,cab, etc. In such cases, the alarm will not sound, but the cranewill be electrified and deadly.

Wrong

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

h. When operating near radio or T.V. transmittingstations, high voltage can be induced in metalparts of the crane, or in the load. This can oc‐cur even if the crane is some distance from thetransmitter or antenna. Painful, dangerousshocks could occur. Consult trained electronicpersonnel before operating the crane to deter‐mine how to avoid electrical hazards.

2. What do you do if a power line is touched by acrane or load?a. Remain calm - think - a mistake can kill

someone.b. Warn all personnel to keep clear.c. If crane will still operate, try to move it away

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

Operator's Manual


Figure 1-16Crane equipped with insulated link.

1

1. Insulated Link

This Man Is Not Protected

Wrong

Figure 1-17Crane equipped with insulated link and boompoint guard.

1

1. Insulated Link

Wrong

d. Move away from contact in the reverse direc‐tion to that which caused the contact. Exam‐ple: If you swing left to the wire, swing to theright to break contact. Remember - once anarc has been struck, it will stretch out much far‐ther than you think before it breaks. Keep mov‐ing until the arc has been broken.

e. When the arc breaks, continue moving away un‐til you are at least 15 ft (4.57m) away (or as spe‐cified in the “High Voltage Power Line ClearanceChart” or as specified by local codes). Stop thecrane. Make a thorough inspection for cranedamage before further use. Contact your Link‐Belt Distributor and request “Crane InspectionAfter Contacting Power Line” form which lists ne‐cessary inspection items.

f. If you cannot disengage from the electricalline, and the crane is not on fire or no arc is cut‐

Figure 1-18If you must leave the crane, do not step off.Leap as far as you can with feet together andhop or shuffle away from the crane.

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

g. If you must leave the crane, don't step off.Leap from the crane as far as you can, landingwith feet together, then hop away from thecrane with feet together, or shuffle feet to keepthem close together. This could help preventpersonal injury.

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

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

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

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

wooden stick.e. Open magnet disconnect switch at magnet

control panel before connecting or discon‐necting leads.

Radio Frequency Or Electro MagneticInterference (RFI Or EMI)Certain areas may contain high Radio Frequency OrElectro Magnetic Interference (RFI or EMI). In theseareas the boom can act like an antenna and producean electrical current that may cause electrical shocksand/or the crane to malfunction. If operating in an areawhere these conditions may exist, test the crane orhave the area tested for the magnitude of this interfer‐ence before operating the crane. Operation may notbe possible or boom length may be limited. Complywith all local, state, and federal laws when operating inhigh RFI/EMI areas.

Operator's Manual


Figure 1-19No hook riders!

Wrong

Protective Equipment1. Always replace protective guards and panels be‐

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

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

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

4. Always wear a mask to prevent breathing any dust,smoke, fumes, etc. while cleaning, drilling, weld‐ing, grinding, sanding, etc. on any part of thecrane. Breathing dust, smoke, fumes, etc. can bevery hazardous.

5. The crane is equipped with a fire extinguisher in theoperator's cab. Make sure all personnel know thatone is available and where it is located. It must bekept in the crane at all times (except when need‐ed). Instruct all operating and maintenance per‐sonnel in proper use of the extinguisher. Check pe‐riodically to make sure it is fully charged and inworking order. Replace immediately if required.

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

7. When operating a crane equipped with any formof load indicating mechanism, overload warningsystem, or any automatic safety device, remem‐ber that such devices cannot replace the skill andjudgment of a good operator. For instance, suchdevices cannot tell when a crane is located on asupporting surface that will give away, that toofew parts of line are being used to lift a load, can‐not correct for the effects of wind, warn that the

Figure 1-20Use a signalman, back safely.

Wrong

device may be improperly adjusted, correct forside pulls on the boom, or for many conditionswhich could occur and create hazards. It requiresall the skill, experience, judgment, and safety con‐sciousness that a good operator can develop to at‐tain safe operation. Many safety devices can assistthe operator in performing his duties, but he shouldnot rely on them to keep him out of trouble.

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

ple, or endanger their safety. Remove all loose ob‐jects from load. All unnecessary personnel shouldleave the immediate area when crane is operating.

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

3. Do not carry passengers! There is only one seatand it is for the operator. Do not allow personnel toride on the carrier deck during operation or whiletraveling the crane. A fall from the crane can causedeath or serious injury.

4. Always look before you back up and post a signal‐man to guide you. Make sure the back up alarm isworking properly. Use the horn as a signal. Use acode such as one beep - stop, two beeps - for‐ward, and three beeps - backward. Make sureeveryone on the job site knows the code.

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

Operator's Manual


Figure 1-21Remove the keys from the ignition and post asign to make others aware of repair activity.

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

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

Signed:

DANGER

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

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

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

3. When performing repetitive lift applications, espe‐cially at or near maximum strength limited capaci‐ties, an inspection of the major structural areas ofthe crane, for cracks or other damage, should beconducted on a regular basis. (A non‐destructivetest such as magnetic particle or dye penetrantmay even be considered.) Along with inspectionfor cracks and damage, frequently check the criti‐cally loaded fasteners, such as the turntable bear‐ing mounting capscrews, to ensure they have notbeen stretched. Not only does frequent inspectionpromote safety, but it is also much easier and lessexpensive to perform a repair when a crack issmall, before it has a chance to traverse through astructural member. Any sign of cracks or damagemust be repaired before continuing operations.Consult your Link‐Belt Distributor for repairs.

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

limit of the boom hoist cylinders.b. Shutdown the engine, disengage the main

pump, and work all control levers back andforth to relieve pressure and relax the attach‐ment.

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

d. Bleed any precharge off the hydraulic reservoirbefore opening it or disconnecting a line.

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

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

5. When making repairs, which require welding, useproper welding procedures. Also the followingprecautions must be taken:a. All paint in the area should be removed to pre‐

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

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

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

d. Disconnect computers and other electronicequipment (such as rated capacity limiters andengine computers) to prevent damage. Con‐tact your Link‐Belt Distributor for proper proce‐dures.

e. If crane is equipped with the 12V to 24V con‐vertor located in the power panel, remove thefuses before welding.

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

Operator's Manual


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

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

7. Keep all walking surfaces (steps, ladders, plat‐forms, etc.) and non‐skid materials on the craneclean. Non‐skid materials are placed on the craneto assist operators and service personnel with safeaccess/egress to/from the crane and to/from ad‐justment and inspection areas. Do not allow non‐skid materials to become contaminated with mud,snow, ice, oil, paint, wax, etc. Any contaminationcan cause the non‐skid materials to become slick,reducing their effectiveness for safety while walk‐ing on the crane. If any non‐skid materials becomeineffective due to wear, age, or destroyed in anyway, they must be replaced.

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

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

WARNINGBattery posts, terminals, and related accesso‐ries contain lead and lead compounds. Washhands after handling.

Right

Figure 1-23Use a guard when inflating tires.

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

11. When using jumper cables to start an engine, besure to connect the negative post to negative post,and positive post to positive post. Always connectthe two positive posts first. Then make one nega‐tive post connection. Make the final negative con‐nection a safe distance from the battery. It can bemade on almost any bare metal spot on the crane.Any spark could cause the battery to explode. Re‐fer to “Jump Starting the Crane” in this Section ofthis Operator's Manual for the proper procedure.

12. Test the automatic winch brake by raising the loada few inches (centimeters) and holding. It shouldhold without slipping. It takes more braking powerto hold a load in the air when the drum is full of wirerope than when it is a few inches (centimeters)above the ground with only a few wraps on thedrum.

13. Always reduce pressure in hydraulic system tozero before working on any part of the system.

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

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

Operator's Manual


Figure 1-24Do not use an open flame near the battery.

Wrong

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

tional Safety And Health Act) regulations state “athorough inspection of all wire ropes shall be madeonce a month and a full written, dated, and signedreport of the wire rope condition be kept on filewhere readily available.” A visual inspection mustalso be performed daily. Replace any worn ordamaged wire rope. Pay particular attention towinch wire ropes. Check end connections (pins,sockets, wedges, etc.) for wear or damage.

2. Use at least the number or parts of winch wire ropespecified on the Wire Rope Capacity chart in theCrane Rating Manual to handle the load. Localcodes may require more parts of line than isshown. Check code requirements and use themwhere applicable.

3. Non‐rotating, rotation‐resistant, or spin‐resistant wireropes are recommended for single part of line ap‐plications. This is of utmost importance for long fallhoist line applications. Only if certain criteria are metmay a swivel hook ball be used with rotation resistantrope. Refer to “Hook Ball Usage With Rotation Re‐sistant Wire Rope” in Section 5 of this Operator'sManual.

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

5. Inspect head machinery and hook block often asdamaged or deteriorating sheaves can cause un‐due wear of the wire rope.

6. When reeving wire rope on the crane, do not stand,walk, or climb on the boom or attachment. Use aladder or similar device to reach necessary areas.

Figure 1-25Do not operate the crane with worn ordamaged wire rope.

Thursday . . . . .

”I thought I could savemoney by running thisrope until Friday”.

Wrong

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

with work site obstructions and other potential haz‐ards in the area which might lead to mishaps. Ifpossible, make any necessary arrangements toeliminate any potential hazards.

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

3. Be sure your work area is clear. Make sure youhave proper clearance for the crane, boom, andload. Don't swing, travel, lift, or lower loads, raiseor lower jacks, without first making sure no one is inthe way. If your vision is obscured, locate a signal‐man so you can see him, and he can see all areasyou can't. Follow his signals. Be sure you and thesignalman understand each other's signals. Seehand signal chart Figure 1-92. Use the horn tosignal or warn. Make sure everyone on the job siteunderstands signals before starting operations.

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

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

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

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

Operator's Manual


Figure 1-26Know your load.

”It looks likeabout 15 tons.”

Wrong

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

load. Use a scale or a load indicating system to de‐termine exact weight. Remember the weight youare lifting includes the weight of any lifting slings orgear, the hook block, hook ball, and any otherweight on the hook. If lifting off the boom with the flyinstalled, the weight of the fly and rigging must alsobe considered as part of the load. The total loadweight must never exceed the rated capacity of thecrane, as listed in the Crane Rating Manual, for theposition, boom length, load radius, and condition ofoperation being used. Remember - capacity chartratings in the Crane Rating Manual are based onideal conditions:a. Standing on firm, level surface.b. Calm wind.c. No side loads or out swing of load.d. Good visibility.e. Crane in top condition and equipped as when

leaving the factory.

Wrong

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

When such conditions can not be attained, loadsbeing handled must be reduced to compensate.The amount loads are reduced depends upon howgood or how poor actual operating conditions are. Itis a matter of judgment and experience. Some fac‐tors which may require reduction of capacities are:a. Soft or unpredictable supporting surfaces.b. Wind.c. Hazardous surroundings.d. Inexperienced personnel.e. Poor visibility.f. Fragile loads.g. Crane in poor condition.h. Condition and inflation of tires.

When in doubt, do not take a chance. Reduce rat‐ings more than you think you need. Avoid workinga crane in high winds. If you must work in a wind,reduce capacities as shown in “Wind SpeedRestrictions” in the Crane Rating Manual. Windblowing against the load and the boom produces aside load on the boom and reduces its capacity.

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

Operator's Manual


Wrong

Figure 1-28Do not push with the boom.

2. When operating off the main boom with the flyerected, deductions must be made for its weight.The weight of the fly must be subtracted to obtain a“NET” capacity. Failure to do so could result in anoverloading condition and cause boom failure. Re‐fer to the Crane Rating Manual for amounts to bededucted.

3. When operating off the main boom with the auxil‐iary lifting sheave installed, the weight of the auxil‐iary lifting sheave must be deducted. Refer to theCrane Rating Manual for amount to be deducted.

4. Do not lift two loads at the same time, even if thetotal load weight is within crane capacity. Loads onthe boom and fly at the same time, stress the boomand drastically reduce its ability to handle loads.Your full attention cannot be given to both loads,creating a dangerous situation.

5. Lifts where two or more cranes work together canbe hazardous and should be avoided. Such liftsshould be made only under the direction of a quali‐fied engineer. If a multiple crane lift is unavoidable,observe the following rules:a. The cranes must be level and located on firm

surfaces.b. The cranes should be the same size and ca‐

pacity, use the same boom length and bereeved similarly.

c. Cranes must be positioned so that each boompoint is directly over its load attaching point.The winch lines must be vertical during allphases of the lift.

d. The rigging must be placed so each crane liftsa share of the load well within the crane's ca‐pacity.

e. Be sure that during handling more load is nottransferred to any crane than it can handle.

f. Don't attempt to travel when making multiplecrane lifts.

g. Coordinate plans with the other operator be‐fore beginning to lift.

h. Use only one signalman.i. Use of an operable load and angle indicating

system is desirable.

Figure 1-29Safety Instruction Label

Operation under conditions whichexceed listed capacities may result inoverturning.

Swinging, extending, or loweringboom to radii where no capacities arelisted may result in overturning evenwithout a load.

6. Some capacities on hydraulic cranes are based onstrength of materials. In these cases, overloadswill cause something on the crane to break, beforeit will tip. Do not use signs of tipping as a warning ofoverload.

7. Don't lash a crane down. Lashing a crane downencourages overloading. Crane damage or injurycould result.

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

9. When performing repetitive lift applications, espe‐cially at or near maximum strength limited capaci‐ties, be aware that these applications may reducecomponent life. These applications include re‐peated lifting (or lifting and swinging) of near 100%strength limited capacities and repeated liftingmaximum moment loads. These applications mayfatigue the major structural portions of the crane.Although the crane may not break during these ap‐plications, they can reduce the fatigue life andshorten the service life of the crane. To improve theservice life, while performing repetitive lift applica‐tions, consider reducing the capacities to 70% ofmaximum strength limited capacities to reduce fa‐tigue cracking. Frequently perform a thorough in‐spection of all the structural areas of the crane.Any sign of cracks or damage must be repaired be‐fore continuing operations. Consult your Link‐BeltDistributor for repairs.

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

11. The boom must be extended in the correct mannerbefore making a lift. The capacities listed in theCrane Rating Manual for this crane are based onthe boom sections being extended in accordancewith each specific boom mode as described in theCrane Rating Manual.

Operator's Manual


Figure 1-30Pinch Point Label

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

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

14. Do not operate a hydraulic crane at radii or boomlengths where the capacity charts in the Crane Rat‐ing Manual shows no capacity. Don't use a fly notdesigned for your crane. Either of the above cantip the crane over or cause attachment failure. Insome cases, the crane can tip over with no load onthe hook, forward or backward! Also, if the boom isfully extended at a low angle, the crane may tip untilthe boom touches the ground. In any of thesecases, injury or crane damage could result.

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

Wrong

Figure 1-31Watch that side tilt!

A little side tilt whileworking over the end.......

.......Increases load radiuswhen swung over the side.

16. When extending or lowering a boom with a load,the load radius increases. As the load radius in‐creases, capacity decreases. If capacity is ex‐ceeded, the boom may bend or the crane may tipover. Sometimes at low angles, a hydraulic craneboom can be extended with a load, but cannot beretracted. This is because more power is availablein the boom cylinders to extend than to retract. Ifan operator extends the boom under load, he maynot be able to retract the boom and may get into adangerous situation.

17. Know the boom length. Don't guess. Use of an in‐correct boom length can cause an accident.

18. When lowering or retracting the boom, the load willlower. To compensate for this, the operator musthoist up on the winch wire rope. Otherwise, move‐ment of the load may cause an accident. When ex‐tending the boom, the load will raise. The operatormust hoist down the winch wire rope to keep theload in place. Extending the boom without winch‐ing down, can lead to “two blocking”. This is whenthe hook block, hook ball, and/or the load contactsthe head machinery. Two blocking can lead tosheave or wire rope damage.

Operator's Manual


Figure 1-32Watch that centrifugal force!

Wrong

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

12

19. The winch wire rope must be vertical when startingto lift. If not, the load will swing in, out, or sidewayswhen lifted from the ground. The crane will lean to‐ward the load when lifting heavy loads. This iscaused by elasticity of the crane and the boom.This lean will increase operating radius so the loadwill swing outward when it clears the ground. Thisout swing is dangerous to anything in the path ofthe load, and because of the increase in load ra‐dius may overload the crane. To overcome this outswing, boom up as the load is lifted so winch wirewire ropes remain vertical. When setting the loadon the ground, lower boom after the load touchesdown to avoid hook block and/or hook ball swingwhen it is unhooked from load.

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

21. Lifting heavy loads can cause the crane to tilt orlean toward the load. When swinging a load from

over the end to over the side, the tilt of the crane willincrease. Since tilt acts to increase load radius, itmust be compensated for when swinging the load.Swing slowly. Change boom angle (raise theboom) while swinging, to maintain a constant ra‐dius, and prevent in swing or out swing of load. Ifnot, a dangerous condition could result.

22. Watch out for centrifugal force when swinging aload. Swing gently. Centrifugal force tends to in‐crease load radius. This increase in radius couldoverload the crane and cause crane damage or tip‐ping. When stopping the swing, over swing of theload can side load the boom.

23. Keep the winch wire ropes as short as possible toprevent excessive swinging. Always use the short‐est boom length which will do the job. Remember- the shorter the boom, the better the capacity.

24. Due to inertia (weight), a load will momentarily tendto stay in position when the crane starts to move.For this reason do not back the crane away from asuspended load when handling near capacityloads. The inertia effect will tend to increase loadradius and decrease stability. Use hand lines as re‐quired to control the load.

25. Don't increase the counterweight. Don't add any‐thing to the crane that will act as additional counter‐weight. Remember that anything which hasweight, if carried behind the crane's center of grav‐ity, acts as counterweight. Adding counterweightaffects backward stability of the crane, particularlywhen working over the side. It also encouragesoverloading of the crane.

26. Working areas for cranes are defined per the Work‐ing Areas chart in the Crane Rating Manual. Permis‐sible loads, per the Crane Rating Manual, will varyfrom lifting quadrant to lifting quadrant. The opera‐tor must make sure capacity ratings are not ex‐ceeded regardless of which quadrant he is operat‐ing in, or when swinging from one quadrant to an‐other.

27. When working on tires, the tires must be inflated topressures shown on the Tire Inflation label locatedon the carrier and/or the Tire Inflation chart in theCrane Rating Manual or Tire Inflation chart in theCrane Rating Manual.

Operator's Manual


Traveling1. Traveling with a suspended load should be

avoided if possible. It is especially hazardouswhen terrain is rough or irregular, on a side slope,or in a hilly area. When traveling with a load, ob‐serve the following rules:a. Use a hand line to control the load and reduce

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

smooth, level route is not available, don't travelwith a suspended load. Grade the route to pro‐vide a smooth, level path. If it is not possible tograde the route, move the load by stepping.Level the crane on outriggers, lift the load andset it down ahead of the crane. Travel the un‐loaded crane beyond the load, level the craneon outriggers, lift the load, swing and set itdown farther along the route. Continue thisprocedure until the load is at its destination.

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

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

f. Don't travel with a load on soft ground. If thecrane sinks into ground, stability can be af‐fected to the point of tipping the crane.

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

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

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

j. Inflate tires as shown on the Tire Inflation labelor in the Crane Rating Manual when makinglifts on tires.

2. When traveling on the highway, road the cranesafely. Watch for narrow bridges and low clear‐ances. Check load limits, height, width, and lengthrestrictions in the area you are traveling. Makesure the crane complies with all regulations.

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

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

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

c. Lash down or otherwise restrain the hookblock and/or hook ball.

d. Check for maximum allowable travel speedand any other travel limitations. Don't exceedthese maximums. Crane damage or an acci‐dent could result.

e. Inflate tires as shown on the Tire Inflation labelor in the Crane Rating Manual when travelingon highway.

f. When traveling, outriggers must be fully re‐tracted.

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

4. If the crane must be towed, refer to “Towing TheCrane” in this Section of this Operator's Manual forspecific instructions.

Operator's Manual


Wrong

Figure 1-33Do not leave crane while a load is suspended.

Leaving The Operator's Cab1. Do not get on or off a crane in motion. When climb‐

ing on the crane, remain in three point contact withthe crane at all times (two hands and one foot ortwo feet and one hand). If a ladder is provided, useit.

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

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

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

3. Do not leave crane unattended with engine running.4. When changing work shifts be sure to notify the next

operator of any changes or problems with thecrane.

5. Hydraulic cylinders, left extended under load, often‐times have a tendency to drift in (retract) due to in‐ternal fluid passage in the cylinders and/or controlvalves. Do no shutdown the crane and leave it unat‐tended for extended periods of time, i.e. overnight,with the boom positioned over anything or the craneitself that the boom could damage if it should lower.For instance the boom hoist cylinder may drift allow‐ing the boom to lower and damage the enginehood. Position the boom over the front to avoid theengine hood on the rear of the crane.

Operator's Manual


Personnel Handling GuidelinesIntroductionThe following information is intended to provideLink‐Belt's recommended minimum requirementsthat must be followed when handling personnelwith a personnel basket or work platform (hereafterreferred to as a work platform) suspended by wirerope from the boom of Link‐Belt cranes. These re‐quirements are based upon several sources andare put forth in recognition of current industry prac‐tices. However, safety, when handling personnel,remains the full responsibility of job site manage‐ment and is dependent upon the responsible ac‐tion of every person on the job involved in the re‐lated work.

This information is intended to supplement and notto supersede or replace any more restrictive federal,state, or local regulations, safety codes, or insurancerequirements. It is intended to serve users of per‐sonnel work platforms in achieving the following ob‐jectives.1. Reduce risk of personal injuries to users and the

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

Link‐Belt cranes are designed and intended forhandling material. They are not normally equippedwith secondary systems or other devices required bypersonnel lift or elevator standards and are not inten‐ded for handling personnel for construction oramusement purposes. Use of cranes for these pur‐poses is hazardous and is not recommended byLink‐Belt. However, Link‐Belt understands that cir‐cumstances may occur (in construction work) whenlifting or lowering personnel on a materials handlingcrane load line is the only or the least hazardousmethod available to position personnel. In fact, Oc‐cupational Safety and Health Administration (OSHA)Part 29 CFR 1926.550(g) states “The use of a craneor derrick to hoist employees on a personnel workplatform is prohibited, except when the erection, use,and dismantling of conventional means of reachingthe work site, such as personnel hoist, ladder, stair‐way, aerial lift, elevating work platform, or scaffoldwould be more hazardous or is not possible becauseof structural design or work site conditions.”

Much corollary and supplementary information iscontained within the following resource documents

pertaining to both cranes and personnel work plat‐forms. Job site management must ensure all re‐quirements listed in these resource documents arefollowed for all personnel handling operations.� American National Standards Institute Reference -

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

� Power Crane and Shovel Association (PCSA) Bureauof the Association of Equipment Manufacturers(AEM) Reference - PCSA Standard No. 4.

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

� OSHA Part 29, CFR 1926.550 Cranes and Derricks.

AuthorizationAuthorized use of a work platform may be permittedonly after the following on‐site procedures have beenperformed:1. A competent person on the job site (job site man‐

ager) specifically responsible for the overall workfunction to be performed has determined thatthere is no practical alternative means to performthe needed work and has authorized a personnellifting operation.

2. For each instance of such lifting, a competent per‐son responsible for the task has attested to theneed for the operation by issuing a written state‐ment describing the operation and its time frameand itemizing that each of the on-site authoriza‐tion requirements has been met. The written state‐ment, after being approved by a qualified person,shall be retained at the job site. (Refer to PersonnelHandling Pre-Lift Check List For Link‐Belt Cranesin this Section for a sample check list.)

3. Review of crane inspection records has been con‐ducted to ensure the crane being used meets ap‐plicable provisions in ANSI B30.5 and B30.23.

4. Review of the work platform inspection recordsand specifications has been conducted to ensure itmeets applicable design standards (refer to ANSIA10-28).

5. Review of the personnel lifting operation practicesspecified in these instructions have been conduc‐ted with job site managers and crane operator(s),foreman, designated signal person, personnel tobe lifted, safety supervisor, and any other per‐son(s) who has jurisdiction over the operation toensure that they are aware of the hazards of the op‐eration and they are aware of provisions of theseinstructions that must be adhered to before andduring the personnel lifting operation.

Operator's Manual


Equipment1. The crane system shall be equipped with the fol‐

lowing:a. A fully functional working operational aid such

as a Rated Capacity Limiter (RCL) system - Asystem consisting of devices that sense craneloading, boom length (extendable boomsonly), boom angle, and also automaticallyprovide an audible/visual signal when theloading conditions approach, reach, and/orexceed the rated capacity values. When theActual Load exceeds the Rated Capacity, thesystem supplies a signal to a function cutoutsystem. The operational aid shall be equippedwith these additional devices:1. Anti-two block device to prevent damage

to the hoist wire rope, other crane com‐ponents, or attachments, and subsequentendangerment of personnel.

� It is required that the anti-two blockdevice warn both audibly and visually aswell as have the capability to cutout thecontrols/functions that may cause a twoblock condition.

2. Boom angle indicator.

� Cranes with extendable booms mustutilize a boom angle indicator having“high and low” set points and audible/visual alarm(s) capable of activatingfunction cutouts.

b. Boom hoist and load line shall have powerlowering and raising and shall have an auto‐matic brake which is applied when the applic‐able control is in neutral, or when the anti-twoblock device is actuated.

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

d. Each crane shall have a mechanical swingpark brake or swing lock capable of being setat any swing position, and shall have a variableswing brake or swing controls capable of stop‐ping the upper swing motion smoothly. Theswing brake must be properly maintained at alltimes to ensure its holding capability.

Note: All operational aids and equipmentmust be maintained in operable condition.

2. The work platform shall be designed by a qualifiedengineer competent in structural design. Its main‐tenance, and its attachment to the crane load line,is the responsibility of the job site management.

Their arrangement shall comply with the followingas a minimum:a. The work platform harness must be of suffi‐

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

b. Audible and visual alert systems shall beprovided to the personnel in the work platformto signal for assistance in the event of an emer‐gency.

c. Hooks on hook ball assemblies, hook blockassemblies, or other assemblies, shall be of atype that can be closed and locked, (with aworking safety latch) eliminating the hookthroat opening, and shall be full load-bearing,and contain a manual trigger release.

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

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

standing of the crane's maintenance, lubrication,and adjustment instructions as outlined in thisOperator's Manual.

2. The crane shall be maintained, lubricated, and ad‐justed, by a designated person, as specified in thisOperator's Manual.

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

4. All decal precautions and instructions shall bestrictly observed.

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

immediately prior to commencement of operation.(Refer to the Crane Operator's Manual and ANSIB30.5, Section 5, Section 5-2.1.2 and 5.2.4, andANSI B30.23 for the required inspection proced‐ures for the crane. Refer to ANSI A10-28 for in‐spection procedures required for the work plat‐form.)

2. The inspection shall be performed once daily whenthe crane is being used in work platform service oreach time the crane is converted from material lift‐ing to personnel handling operation. In the eventthe operator is replaced, a new inspection is re‐quired. Written documentation of all inspectionsmust be kept on the job site during personnelhandling operations.

3. Inspect the crane and work platform for any loose,damaged, or missing components.

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

Operator's Manual


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

6. Minimum load hoist and boom hoist wire ropesafety factors for the combined weight of the lift at‐tachments, work platform personnel, and toolsshall be 7:1 for manufacturer's specified construc‐tion wire rope and 10:1 for rotation resistant wirerope. (Note: A.P.I. applications require 10:1 for allwire rope construction.)

7. Telescopic Boom Cranes - The work platformshall be suspended from the main boom headsheaves only. Lattice Boom Cranes - The workplatform shall be suspended from the main boomhead sheaves only, or on a luffing attachment, theluffing jib head sheaves only. Do not suspend awork platform from any other lifting sheave(s) onany attachment.

8. Inspect the wire ropes, hoist drum brakes, boom,and other mechanical and rigging equipment vitalto the safe operation of the crane. A written recordof this inspection must be maintained on the jobsite.

9. In addition to other regular inspections, visual in‐spection of the crane and work platform shall beconducted immediately after testing and prior tolifting personnel. The following inspections shallbe conducted on extendable booms prior to liftingpersonnel:a. Full power style booms:

1. Inspection of all extension wire ropes atthe access points in the boom where theend connections are visible - Refer to thisOperator's Manual for inspection and ad‐justment procedures.

b. Pinning and latching style booms:1. Inspection of the latching mechanism,

sensors, and hydraulic/electrical circuit atthe access points.

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

3. Verification of the accuracy of the boomlength indicator. Refer to this Operator'sManual for the procedures.

10. The following inspections shall be conducted onfixed length style booms prior to lifting personnel:a. Inspection of all pendants, pendant links,

pendant spreader bars, and dead end lugsand links, etc.

b. Inspection of all mechanical linkages, shafts,drums, etc.

c. Inspection of all chord and lattice members ofall boom sections, luffing jib sections, and livemast, as equipped.

Crane Test ProceduresThe test procedures listed below shall be conductedat the following intervals:� Daily� When an operator is replaced� When, in the judgement of responsible job site man‐

agement, there has been a significant change in theconditions of the personnel lifting operation.

Note: No personnel shall ride the work platform dur‐ing any of the tests recommended in this Section.

1. The work platform shall be loaded with ballast attwo times the intended load. This load shall not ex‐ceed the rated capacity of the work platform. Donot exceed the rated lifting capacity of the applic‐able lift crane capacity chart. (Refer to ANSIA10.28 for suspended work platform testing andinspection.)a. This test load shall be tested for stability.

� The operator and signal person shall con‐duct this test.

� This test shall include movement of the workplatform through its entire intended range ofmotion, simulating the specific operation tobe undertaken.

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

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

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

3. With pinning and latching style extendable booms,a visual inspection shall be conducted to verify thatthe boom extend pins are properly set in the exten‐ded boom sections.

Operator's Manual


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

and fully understood by operating personnel. Itshall be available to them at all times.

2. Safety when handling personnel remains the fullresponsibility of job site management and is de‐pendent upon the responsible action of every per‐son on the job involved in the related work.

3. Mobile lift cranes shall be erected to obtain maxim‐um crane stability. The crane must be level and onfirm ground with the outriggers fully extended andthe tires clear of the ground before beginning anyoperation.

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

5. Unauthorized personnel shall not be in the operat‐or's cab on the lift crane, or near the lift crane whilea work platform is suspended from the load line.

6. Any operation in which a work platform is to be sus‐pended from the load line shall be carefullyplanned by the operator, supervisory personnel,designated signal person, and personnel to be lif‐ted prior to commencement of such operation.They are to be advised:a. That the crane does not have safety devices

normally used on personnel handling equip‐ment.

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

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

7. After positioning of the work platform:a. All brakes and locks on the lift crane shall be

set before personnel perform any work.b. With pinning and latching style extendable

booms, a visual inspection shall be conductedto verify that the boom extend pins are properlyset in the extended boom sections.

8. Telescope operation is not recommended with anyextendable boom with personnel in the work plat‐form.

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

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

11. The following actions and operations are strictlyprohibited when working with personnel suspen‐ded in a work platform:a. Cranes shall not travel while personnel are in

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

load lines with personnel suspended in a workplatform.

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

d. Work platform lifts shall be a single crane oper‐ation. A work platform shall not be lifted usingtwo cranes.

e. Hoisting of personnel shall be discontinuedupon indication of any dangerous weatherconditions, wind, or other impending danger.

f. The emergency manual mode operation ofpinning and latching style extendable boomsshall not be utilized.

g. Free-Fall (if equipped) shall not be used.12. Movement of the work platform with personnel

shall be done in a slow, controlled, cautious man‐ner with no sudden movements of the crane orwork platform.

13. Clear, unobstructed visibility between personnelon the work platform and the crane operator shallbe maintained at all times except where a desig‐nated signal person has been assigned and posi‐tioned such that he is visible to both. Such desig‐nated signal person shall have no other duties toperform when personnel are in the work platform.

14. Voice communication between work platform per‐sonnel, the crane operator, and designated signalperson, if assigned, shall be maintained.

15. If other cranes or equipment may interfere with thelifting of personnel, signals or other means of com‐munication between all crane or equipment oper‐ators shall be maintained to avoid interference withindividual operations.

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

17. Personnel in the work platform shall wear personalfall arrest systems. Anchors used for attachment ofpersonal fall arrest equipment shall be independ‐ent of any anchors being used to support or sus‐pend work platforms. Personnel shall keep allparts of body, tools, and equipment inside workplatform during raising, lowering, and positioning.

Operator's Manual


18. Personnel shall always stand firmly on the floor ofthe work platform and shall not sit or climb on theedge of the work platform or use planks, ladders,or other devices for attaining a work position. (Thisdoes not apply to offshore personnel transfer bas‐kets. Personnel must ride on the exterior of thistype of personnel handling device to assure great‐er safety of the operation.)

19. When welding is done by personnel in the workplatform, the electrode holders shall be protectedfrom contact with metal components of the workplatform. If electrically connected electrode hold‐ers contact work platform, work platform could bedropped due to burning/melting of wire ropes sus‐pending the work platform.

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

materials. However, due to the special conditionscommonly existing offshore, the use of cranes totransfer personnel between vessels or from a ves‐sel to a work platform is an established practice.The safety of the personnel, if a materials handlingcrane is used in transferring personnel, depends

upon the skill and judgment of the crane operatorand alertness of the personnel being transferred.Sea and weather conditions may create additionalhazards beyond the skill of persons involved.

This operation is approved by the American Petro‐leum Institute (A.P.I.). By adopting procedures forthis operation, the institute has determined that thetransfer of personnel may be performed safely un‐der certain offshore conditions. Therefore,whenever an offshore crane is used to transfer per‐sonnel, all persons involved in the operation mustknow and implement the A.P.I. procedures andverify that sea and weather conditions are withinsafe limits for the transfer.

In addition to all previous requirements in these In‐structions, A.P.I. 2C requires the following:

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

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

Operator's Manual


Personnel HandlingPre‐Lift Check List for Link‐Belt Cranes

1

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

Name: Title:

Signature: Date: / / Initials

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

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

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

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

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

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

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

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

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

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

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

10 Lifting personnel is allowed from:

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

jib head sheaves only

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

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

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

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

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

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

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

Operator's Manual


Figure 1-34Operator's Cab

1. Service Brake Pedal2. Throttle Pedal3. Crane Rating Manual Holder4. Gauge And Control Panel5. Rated Capacity Limiter Display6. Bubble Level

7. 360° Swing Lock (If Equipped)8. Seat Console Control Switches9. Operator's Seat10. Outrigger Control Box11. Travel Swing Lock Control12. Windshield Washer Reservoir

13. Operator's Manual Holder14. Fire Extinguisher15. Swing Brake Pedal16. Boom Telescope Pedal17. Fuse Panel

2

5

4

10

1712

14

9

16

15

138

6

3

1

87

11

Operator's CabLocated throughout the operator's cab are severalpanels which contain the controls, switches, and

gauges to operate and monitor crane operations. Re‐fer to Figure 1-34. The following is a description ofeach gauge, switch, or control in each panel, alongwith an explanation of their function and/or operation.

Operator's Manual


Figure 1-35Typical Fuse Identification Label - Always refer to the actual label on the crane.

BOOMPIN

RELAY

BOOMLATCHRELAY

C-1

5 B

-15

A-2

0

D-1

0 E

-15

F-5

G-5

H-2

0 J

-25

K-1

0 L

-10

M-5

T-5

N-1

0 P

-5 R

-5 S

-5

U-2

5 V

-15

W-5

X-1

0 Y

-5

Z-5

AA-

10 B

B-10

CC

-10

DD

-5

EE-

5 F

F-7.

5 G

G-5

HH

-10

JJ-

10

SPARE FUSES

Y-RCL COMPUTERZ-RCL DISPLAYAA-EMER STEER (OPT)BB-12 VOLT ACCESSORYCC-EXT LT (OPT),

DD-4 WHEEL DRIVEEE-RCL BYPASSFF-RCL BYPASSGG-GAUGE ALARMHH-WINCH CONTROL

JJ-PARK BRAKE, TRANSL-COMBINATION STEERM-WARNING LIGHTSN- WIPER, WASHERP-SWING ALARM, FANR-DRIS-HEATER RELAY, HEAT CTRLT-3RD WRAP INDICATOR (OPT)U-OUTRIGGERSV-TELESCOPE CONTROLW-FUNCTION LOCKOUTX-MAN TELE CTRL, AUTO/MAN BOOM

A-RUN RELAYS, GAUGES, START RELAYB-UPPER LIGHTSC-HAZARD, TURN LIGHTSD-DOME LIGHT, HORNE-BOOM LIGHTF-RCL DISPLAYG-STROBE LIGHTH-DRIVING LIGHTSJ-HEATER FANK-AXLE OSC. LOCK

HEATERFAN

RELAY

FRONTWINCHUP K/ORELAY

REARWINCHUP K/ORELAY CAVITY RATING

XX-

5 Y

Y-10

ZZ-

5

AAA

-7.5

BBB

-20

CC

C-5

DRIVINGLIGHTRELAY

4WDLO

RELAY

2WDHI

RELAY

NEUTRALSTARTRELAY

TRAVELALARMRELAY

RCLBYPASSRELAY

XX-FINE METERING (OPT)YY-TOP HATCH WIPERZZ-BRAKE, STEER WARNAAA-CTWT REMOVAL (OPT)BBB-DIESEL HEATER CTRLCCC- PUMP UNLOADER

WIND SPD (OPT)

Figure 1-36Top Hatch Wiper

1. Control Switch 2. Wiper Motor

1

2

Fire ExtinguisherA fire extinguisher is located in the operator's cab be‐low the left console. Refer to Figure 1-34. Raise theleft console to gain access to the extinguisher. It is an AB C type fire extinguisher, meaning it is capable of ex‐tinguishing most types of fires. The operator should befamiliar with its location, the clamp mechanism used tosecure it in place, and foremost the operation of the de‐vice. Specific instructions, regarding operation, aregiven on the label attached on the fire extinguisher. Acharge indicator on the fire extinguisher monitors thepressure within the tank. Check the indicator daily toensure the fire extinguisher is adequately charged andready for use.

Top Hatch WiperThe top hatch wiper is located in the top left corner ofthe cab roof. Refer to Figure 1-36. The switch for thetop hatch wiper is located on the wiper motor. Move theswitch to the “ON” or “OFF” position as desired.

Windshield Washer ReservoirCheck the windshield washer reservoir daily. The res‐ervoir for washer fluid is located in the lower right rear ofthe cab. Refer to Figure 1-34. Visual inspection candetermine if the washer fluid is adequate. Do not oper‐ate the washer when the reservoir is empty. Use spe‐cially formulated windshield washer fluid rather thanwater because specialty washer fluids contain addi‐tives that dissolve road grime and prevents freezing.

Operator's Cab Fuse PanelThe fuse panel is located in the lower left front corner ofthe operator's cab. Refer to Figure 1-34. Located be‐hind the fuse panel cover is a label which designatesthe electrical circuit protected by each fuse. Refer toFigure 1-35. Each fuse has a letter designation whichcorresponds to the upper electrical system as shownon the fuse identification label.

Bubble LevelThe bubble level is provided to assist the operator inleveling the crane on outriggers. It is located on theright cab wall. Refer to Figure 1-34.

Operator's Manual


Figure 1-37Gauge And Control Panel

1. Windshield Wiper/Washer Switch2. Stop Engine Indicator Light3. Check Engine Indicator Light4. Wait To Start Indicator Light5. Upper Lights Switch6. Boom Floodlight Switch (If Equipped)7. Rotating Beacon or Strobe Light Switch

(If Equipped)8. Gauge Lights Dimmer Switch9. Hydraulic Oil Temperature Gauge10. Fuel Level Gauge11. Coolant Temperature Gauge12. Tachometer13. Fine Metering Switch (If Equipped)14. First Layer/Third Wrap Indicator Switch

(If Equipped)15. RCL Display16. Ignition Switch17. Horn Button18. 12V DC Accessory Outlet19. Heater/Air Conditioner Selector Switch

(If Equipped)20. Heater or Fan Speed Switch21. Temperature Control Knob22. Check Gauges Audio Alarm23. Throttle Lock Switches24. Function Lockout Switch

4

17

5

6

7

1

24

16

22

19

23

11

9

10

12

18

8

15

20

21

2

3

14

13

Operator's Manual


Gauge And Control PanelA panel that contains the following controls, gauges,and indicators is located inside the right front corner ofthe operator's cab and is shown in Figure 1-37.

1. Windshield Wiper/Washer Switch

Rotate the wiper/washer knob clockwiseto activate the windshield wiper. Rotatethe knob to the first detent for low speed

wiper and to the second detent for high speed wip‐er. Pushing the wiper/washer knob sprays washerfluid on the windshield to clean the window.

2. Stop Engine Indicator LightThis red indicator light will illuminate alongwith an alarm buzzer to make the operatoraware of critical engine problems. When

this light illuminates stop operations immediatelyand shutdown the engine. Consult the enginemanufacturer's manual and determine the prob‐lem before any further operation of the engine.

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

3. Check Engine Indicator LightThis amber indicator light will illuminatealong with an alarm buzzer to make theoperator aware of minor engine problems.

When this light illuminates engine operation maycontinue. However, consult the enginemanufacturer's manual and determine the problemas soon as possible to avoid prolonged operation ofthe malfunctioning engine which could develop intoa major problem.

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

4. Wait To Start Indicator LightThis red indicator light will illuminate whenthe key switch is in the “ON” position toalert the operator not to crank the engine.

During cold weather conditions the light illumi‐

nates and glow plugs are activated that will heatthe engine cylinders. When the cylinders are warmenough the indicator light will go out and the en‐gine can be started. This aids in engine start‐up incold weather conditions. For more information re‐fer to “Cold Engine Starting” in this section of thisOperator's Manual.

5. Upper Lights SwitchThis switch operates upper floodlights.Push the left side of the switch to turn flood‐lights on, right side to turn them off.

6. Boom Floodlight Switch (If Equipped)This switch operates the boom floodlight.Push the left side of the switch to turn flood‐light on, right side to turn it off.

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

This switch controls the cab rotating bea‐con or strobe light. Push the left side of theswitch to turn it on, right side to turn it off.

8. Gauge Lights Dimmer Switch

This switch is used to control the dash lights. Ro‐tate the switch left to dim the dash lights or rotateright to brighten dash lights.

9. Hydraulic Oil Temperature GaugeThis gauge registers the hydraulic oil tem‐perature in the main return line. Normal op‐erating ranges vary with the oils used in dif‐

ferent climates. Refer to Section 2 of this Opera‐tor's Manual for proper oil viscosities and operat‐ing temperature ranges. If the hydraulic oil ex‐ceeds the maximum operating temperature, an in‐dicator light within the gauge will illuminate and analarm buzzer will sound. Shutdown the crane im‐mediately and correct the problem.

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

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

Operator's Manual


11. Coolant Temperature GaugeThis gauge registers the engine coolingsystem temperature. For proper coolingsystem operating temperature range, refer

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

12. TachometerThe tachometer registers engine speed in revolu‐tions per minute (rpm). Refer to the engine manu‐facturer's manual for suggested operating speeds.

13. Fine Metering Switch (If Equipped)This switch is used to activate the fine me‐tering system. Refer to “Fine MeteringSystem” in this Section of this Operator's

Manual.

14.First Layer/Third Wrap Indicator Switch(If Equipped)

Once the first layer/third wrap indicator sys‐tem is enabled, this switch allows the opera‐tor to select which winch drum(s) to monitor.

Enable the system through the RCL system usingthe operator settable alarm feature. Refer to “Mi‐croGuard 540 Rated Capacity Limiter” in this Sec‐tion of this Operator's Manual. Press the switch tothe “F” (Front), “B” (Both), or “R” (Rear) position asdesired. When the system is enabled, the audiblealarm will sound intermittently, and “First Layer” willappear in the warning message area to alert theoperator when the wire rope is down to the first lay‐er on the winch drum(s). The audible alarm willsound continuously and “Third Wrap” will appearin warning message area to alert the operatorwhen the wire rope is down to the third wrap on thewinch drum(s).

WARNINGThree (3) full wraps of wire rope must bemaintained on the winch drum at all timesduring operation. Wire rope failure mayoccur.

15. Rated Capacity Limiter DisplayThis displays the boom length, boom angle, loadweight, etc. Refer to “Crane Monitoring System” inthis Section of this Operator's Manual for completeoperating instructions.

16. Ignition SwitchThe ignition switch is the conventional, key oper‐ated, automotive type. It controls engineoff/on/start, accessories, and energizes the instru‐ment panel in the operator's cab.

17. Horn ButtonPress this button to sound the horn.

18. 12V DC Accessory OutletUse this outlet for electrical accessories.

CAUTIONDo not connect an accessory to any part of thecrane other than the accessory outlets orcigarette lighter. Damage to the crane'selectrical system may result. If it is necessaryto do so, contact your Link‐Belt Distributor.

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

If cab is equipped with air conditioning andheater, this switch selects which system tooperate. Press the top part of the switch to

turn the heater on, bottom part to turn the air condi‐tioning on.

20. Heater or Fan Speed SwitchThis switch controls the cab heater if cab isnot equipped with air conditioning. Pressthe top part of the switch to turn the unit on,

bottom part to turn it off. If cab is equipped with airconditioning, this switch controls the fan speed.

21. Temperature Control KnobTurn the temperature control knob to adjust thetemperature in the cab.

22. Check Gauges Audio AlarmThis buzzer alarm will sound to alert the operatorthat a gauge is detecting an abnormal operatingrange. The check engine or stop engine light willalso illuminate when applicable. The problemshould be repaired before operating the crane.

Operator's Manual


Figure 1-38Seat Console Control Switches

Left Right

1. Swing Park Brake Switch2. Horn Button3. Drum Rotation Indicator Switch4. Winch Control Switches

2 431

23. Throttle Lock SwitchesThese switches are used to hold the en‐gine at a constant speed. This providesthe operator with more flexibility for certainjob requirements. Refer to “Throttle LockSystem” in this Section of this Operator'sManual.

24. Function Lockout SwitchThis switch is used to disable hydraulicfunctions which are operated by the con‐trol levers and boom telescope foot pedal.

Press the bottom part of the switch to disable hy‐draulic functions and to prevent inadvertent opera‐tion of these controls. To allow normal operation ofthe control levers and boom telescope foot pedal,press the top part of the function lockout switch.The bottom part of the switch will illuminate to indi‐cate switch is in the ON position.

Seat Console Control SwitchesControl switches are located on the left and rightconsoles of the operator's seat. Refer to Figure 1-34and Figure 1-38.

1. Swing Park Brake SwitchThis switch is used to operate the swingpark brake to hold the upper in any posi‐tion over the carrier. The bottom part of the

switch will illuminate to indicate switch is in the ONposition. Refer to “Swing System” in this Section ofthis Operator's Manual for complete operating pro‐cedures.

2. Horn ButtonPress this button to sound the horn.

3. Drum Rotation Indicator Switch

This switch is used to activate the drum ro‐tation indicator system. To activate thesystem, press the bottom part of the

switch. Press the top part of the switch to deacti‐vate the system. The bottom part of the switch willilluminate to indicate switch is in the ON position.Refer to “Drum Rotation Indicators” in this Sectionof this Operator's Manual for complete operatingprocedures.

4. Winch Control Switches

These switches are used to control engag‐ing/disengaging the high speed hoist anddisabling the front and/or rear winch. Re‐

fer to “Wire Rope Winch System” in this Section ofthis Operator's Manual for complete operating pro‐cedures.

Operator's Manual


1. Heater/Pump2. Diesel Fuel Tank3. Coolant Reservoir

4. Coolant Reservoir Sight Gauge5. Diesel Fuel Filter

6. Diesel Fuel Shutoff Valve7. Diesel Fuel Tank Sight Tube

Figure 1-39Diesel Fired Warm‐water Cab Heater

1

2

3

4

56

7

Cab Heater OperationThis crane may be equipped with a diesel fired warm‐water cab heater or an optional engine dependantwarm‐water cab heater. Refer to the following instruc‐tions to operate the cab heater that is used on thecrane.

Diesel Fired Warm‐water Cab HeaterThis cab heater uses anti‐freeze circulating through theunit to provide heat. Anti‐freeze is stored in a reservoirlocated on the left side of the upper revolving frame.This anti‐freeze is heated by a diesel fired heater/pumpand circulated through the heat exchanger in the cab.The diesel fuel tank, for the system, is mounted on theleft side of the upper revolving frame. Refer toFigure 1-39. Diesel fuel should be #1, #2, or arctic.The fuel system is equipped with an inline filter andshould be changed every 2,000 hours of operation orannually, whichever occurs first. The anti‐freeze usedshould be the same type used in the crane's engine.Refer to engine manufacturer's manual for proper anti‐freeze selection.

Note: Operate the heater at least once a month for10 minutes.

Note: To improve heater performance when operat‐ing the crane in prolonged ambient temperaturesbelow -7°C (20°F), kerosene is the recommendedfuel.

WARNINGDiesel exhaust fumes can beharmful. Start and operatediesel cab heater in a wellventilated area. If it isnecessary to operate in anenclosed area, vent the exhaustto the outside.

To Start The Diesel Fired Warm‐water Cab Heater1. Before activating the heater, ensure that the diesel

fuel tank and the coolant reservoir are full.2. With the engine running, press the heater switch or

if crane is equipped with air conditioning, press thetop part of the heater/air conditioner selectorswitch to turn the heater on. Refer to Figure 1-37.

3. Turn the temperature control knob to the desiredsetting.

4. If cab is equipped with air conditioning, use the fanspeed switch to control the air flow into the cab. Ifcab is not equipped with air conditioning, use theheater/fan speed switch to control the air flow intothe cab.

To Stop The Diesel Fired Warm‐water Cab Heater1. Press the heater switch to the off position.2. During warm weather conditions or if the heater is

not going to be used for an extended period oftime, rotate the temperature control knob to thecoolest setting.

Operator's Manual


Figure 1-40Engine Dependant Warm‐water Cab Heater Shutoff

1. Shutoff Valve - Heater Return2. Shutoff Valve - Heater Supply

2

1

Engine Dependant Warm‐water Cab Heater(If Equipped)This cab heater uses engine coolant circulatingthrough the unit to provide heat. Normally the enginecoolant circulates through the heater in the cab regard‐less of whether the heater switch is turned on or not.During warm weather conditions, the operator maywish to shutoff the flow of hot engine coolant to theheater to reduce the temperature in the cab. Shutoffvalves are located on the engine to perform this func‐tion. Refer to Figure 1-40.

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

if crane is equipped with air conditioning, press thetop part of the heater/air conditioner selectorswitch to turn the heater on. Refer to Figure 1-37.

2. Turn the temperature control knob to the desiredsetting.

3. If cab is equipped with air conditioning, use the fanspeed switch to control the air flow into the cab. Ifcab is not equipped with air conditioning, use theheater/fan speed switch to control the air flow intothe cab.

To Stop The Cab Heater1. Press the heater switch to the off position.2. During warm weather conditions or if the heater is

not going to be used for an extended period oftime, rotate the temperature control knob to thecoolest setting.

Cab Heater Shutoff (If Equipped)

WARNINGShutdown the engine and allow it to coolbefore operating the heater shutoff valves.The valves may be hot and could causeserious burns.

1. Shutdown the engine and rotate the handles onthe shutoff valves clockwise to stop the flow of en‐gine coolant to the heater; Counterclockwise to re‐store it. Refer to Figure 1-40.

Air Conditioning (If Equipped)The operator's cab may be equipped with an air condi‐tioning unit. Use the following instructions to operatethe unit. Refer to Figure 1-37.1. Start the engine and allow all operating tempera‐

tures and pressures to reach their normal range.2. Press the bottom part of the heater/air conditioner

selector switch to activate the air conditioning unit.3. Press the fan speed switch to control the amount of

air blown into the cab.4. Turn the temperature control knob to the desired

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

selector switch to the off position.

Operator's Manual


1. Steering Wheel2. Transmission Oil Temperature Gauge3. Indicator Light Bars4. Voltmeter Gauge

5. Transmission Shift Lever6. Emergency Hazard Switch7. Transmission Gear Switch8. 4‐Wheel Drive/Range Switch

9. Combination Steering Switch10.Travel Park Brake Switch11.Tilt/Telescoping Column Lever12.Turn Signal/Horn/Driving Lights Lever

Figure 1-41Steering Column And Wheel

11

12

1

7

5

4

810

9

2

6

3

Operator's Manual


Steering Column And WheelThe following is a description of the controls on thesteering column along with an explanation of their func‐tion and/or operation. Refer to Figure 1-41.

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

Note: Relative direction of the steering wheel isbased on the position of the upper over thecarrier.

2. Transmission Oil Temperature Gauge

This gauge registers the oil temperature inthe transmission torque convertor. Normaloperating temperature range is

180-210°F (82-98°C). When the oil temperatureexceeds normal operating range an indicator lightwithin the gauge will illuminate and an alarm buzz‐er will sound. If the oil overheats, discontinue op‐eration, shift the transmission to neutral, and runthe engine at 1,000-1,200 rpm (do not stop the en‐gine if the cooling system is known to be in workingorder). Transmission oil temperature should soonlower. Always change the oil and filter after thetransmission oil has overheated. Refer to Section 2of this Operator's Manual for the correct oil changeprocedure.

3. Indicator Light Bars

Three indicator light bars are located on the steer‐ing column and contain the following indicatorlights:

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

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

there is no engine oil pressure after 10-15 sec‐onds of running time, shutdown the engine imme‐diately and repair the problem to avoid enginedamage.

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

to “Combination Steering” in this Section of thisOperator's Manual for complete operating proce‐dures.

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

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

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

Service Brake Warning - This light will illu‐minate to warn the operator of an immi‐nent brake failure. When this light illumi‐

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

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

4. Voltmeter GaugeThis gauge registers the charge in the bat‐tery and the output of the alternatorthrough the regulator. It should read 12

volts with the key on, and 12.5 to 14 volts with theengine running. When the charge or the voltage inthe battery is not within normal operating range anindicator light within the gauge will illuminate.

5. Transmission Shift LeverThe transmission shift lever is used to select theforward or reverse gear in the transmission. To putthe transmission in forward or reverse gear, the le‐ver is pushed up then pushed forward to engagethe forward gears, or pulled backward to engagethe reverse gears.

6. Emergency Hazard Switch

This switch controls the emergency hazardflashers. Push the switch to turn flashers on, pushthe switch again to turn them off.

7. Transmission Gear SwitchThis switch is used to shift the transmis‐sion. Press the top part of the switch forfirst gear, middle position for second gear,and bottom part of the switch for third gear.

Operator's Manual


8. 4‐Wheel Drive/Range Switch

This switch is used to select either the2‐Wheel drive mode or 4‐Wheel drivemode for the carrier power train by engag‐ing or disengaging the front drive axle.This switch also simultaneously selects

either high or low range speeds for the transmis‐sion. When the switch is in the “4‐WHEEL DRIVE”mode the transmission is in the low speed range.When the switch is in the “2‐WHEEL DRIVE” modethe transmission is in the high speed range. Bringthe crane to a complete stop and shift the transmis‐sion to neutral before changing the position of the4‐Wheel Drive Switch. The top part of the switchwill illuminate to alert the operator that 4‐wheeldrive mode has been engaged.

9. Combination Steering Switch

The crane is equipped with four different modes ofsteering in order to provide maximummaneuverability on the job site. Refer to“Combination Steering” in this Section of thisOperator's Manual for complete operatingprocedures.

10. Travel Park Brake Switch

This switch controls engaging and releas‐ing the park brake.

WARNINGDo not use the park brake to stop the crane inmotion (as a service brake) except in cases ofextreme emergency. Application cannot becontrolled.

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

the carrier service brake.b. Shift the transmission to neutral.c. Move park brake switch to “ON” position.d. Park brake indicator light should illuminate.

To Release Park Brakea. Apply the carrier service brake.b. Move park brake switch to the “OFF” position.c. The park brake indicator light should go out.

11. Tilt/Telescoping Column LeverThis lever controls the tilt (angle) and telescopingfunction of the steering column.

To change steering column height and angle:a. Bring the crane to a complete stop.b. Shift the transmission to neutral and engage

the park brake.c. Rotate the tilt/telescoping column lever.d. Position the steering wheel at the desired

height and angle and rotate lever to lock it inplace.

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

12. Turn Signal/Horn/Driving Lights LeverTurn Signal - Pull the lever down for left turn signal,push up on lever for right turn signal.

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

Driving Lights - Rotate the lever to the first detent to illuminate the parking lights, the second det‐

ent for headlights. Rotate the lever to the off position to turn all lights off.

Operator's Manual


Transmission ControlsThe transmission controls are located on the steeringcolumn. Refer to Figure 1-41. The transmission shiftlever controls all functions of the powershift transmis‐sion. The transmission contains three forward andthree reverse high range speeds in 2‐wheel drive modeand three forward and three reverse low range speedsin 4‐wheel drive mode. See “Traveling The Crane” inthis Section of this Operator's Manual for necessarypreparations before traveling the crane.

Shifting The Transmission1. Engage the park brake and place shift lever in neu‐

tral position. Start the engine. (Engine will startonly when transmission is in neutral.) Allow thetransmission oil temperature to reach normal oper‐ating range.

2. Engage travel swing lock and release the swingpark brake and the 360� swing lock, if equipped.

CAUTIONDo not leave the swing park brake or 360�swing lock engaged during pick and carryoperations or when traveling or transportingthe crane. Use the travel swing lock. Failure torelease the swing park brake and 360� swinglock during these operations may result indamage to the swing gear.

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

er service brakes, shift the transmission toneutral, and release the park brake.

b. Move transmission shift lever to the “F” posi‐tion.

Note: Relative direction of the crane isbased on the position of the upper over thecarrier.

c. Slowly release the service brake while usingthe throttle pedal to increase the engine speedallowing the crane to accelerate.

d. At full engine speed, press the transmissiongear switch to shift to the next gear. Repeat toshift through the desired gears.

4. Reverse Travela. With crane at a complete stop, apply the carri‐

er service brakes, shift the transmission toneutral, and release the park brake.

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

Note: Relative direction of the crane isbased on the position of the upper over thecarrier.

The travel/back‐up alarm will sound any‐time the transmission is shifted into re‐verse. It will also sound anytime the trans‐mission is shifted out of neutral and the up‐per is not positioned directly over the frontof the carrier.

c. Slowly release the service brake while usingthe throttle pedal to increase the engine speedallowing the crane to accelerate.

d. At full engine speed, press the transmissiongear switch to shift to the next gear. Repeat toshift through the desired gears.

Operator's Manual


Foot Operated ControlsThe following is a description of the foot controls in theoperator's cab along with an explanation of their func‐tion and/or operation. Refer to Figure 1-42.

1. Boom Telescope Control PedalDepress the toe of the pedal to extend the boom.Depress the heel to retract the boom. Refer to“Boom Telescope System” in this Section of thisOperator's Manual for complete operating instruc‐tions.

2. Swing Brake Pedal

The swing brake pedal is used to stop rotation ofthe upper over the carrier. Refer to “Swing System”in this Section of this Operator's Manual for com‐plete operating instructions.

3. Service Brake PedalThe carrier service brakes are controlled by thebrake pedal. Press the pedal down to apply theservice brakes. Release the pedal to release theservice brakes.

The distance the service brake pedal is moved de‐termines the braking force. Depress the pedal fullyonly in cases of emergency as this makes controlof the crane difficult.

4. Throttle PedalEngine speed is controlled by the throttle pedal.Press the throttle pedal down to increase enginespeed. Release the throttle pedal to decrease en‐gine speed.

Figure 1-42Foot Operated Controls

1. Boom Telescope Control Pedal2. Swing Brake Pedal

3. Service Brake Pedal4. Throttle Pedal

1 2 3 4

Operator's Manual


Conventional 4-Wheel Crab

Figure 1-43Steering Modes

Front Front Front

Rear Wheel

Front

Combination SteeringThe crane is equipped with four different modes ofsteering in order to provide maximum maneuverabilityon the job site: conventional, rear wheel, 4‐wheel, andcrab steer. Each steer mode provides slightly differentmaneuverability to meet job site requirements. Refer toFigure 1-43 for illustration of the different steermodes.

Conventional Steer Mode

This steer mode is similar to that of an automobile. Inthis steer mode, the front wheels may be turned ineither direction and the rear wheels remain stationary.Use this steer mode for all extended or high speedtravel.

WARNINGDo not use rear wheel, 4‐wheel, or crab steermode for extended or high speed travel assteering behavior may be unfamiliar and aloss of crane control could occur.

Rear Wheel Steer Mode

This steer mode is similar to that of a fork truck. In thissteer mode, the rear wheels may be turned in either di‐rection and the front wheels remain stationary. Use thissteer mode for job site travel only; not for extended orhighway travel.

4‐Wheel Steer Mode

This steer mode allows steering with all four wheels.The front wheels turn in one direction and the rear

wheels turn in the opposite direction. This results in agreatly reduced turning radius that allows extra ma‐neuverability in certain job site conditions. Use thissteer mode for job site travel only; not for extended orhighway travel.

Crab Steer Mode

This steer mode allows steering with all four wheels.The front and rear wheels turn simultaneously in thesame direction which moves the crane in the diagonalpath of travel. This gives the operator another methodof maneuvering the crane where job site conditions re‐quire it. Use this steer mode for job site travel only; notfor extended or highway travel.

Changing Steering Modes

The rear wheel offset light, located on the steering col‐umn in the indicator light bars (Figure 1-41), is de‐signed to assist the operator in changing steeringmodes by determining when the rear wheels arestraight. This light will come on anytime the rear wheelsare not in‐line with the carrier. Use the following proce‐dure when changing steering modes:1. Bring the crane to a complete stop.2. Turn the steering wheel until the rear wheel offset

light goes off.3. Move the steer switch to the conventional steering

mode.4. Check all wheels for proper alignment by traveling

the crane a short distance, straight ahead, to en‐sure it tracks straight.

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

Operator's Manual


Figure 1-44Hydraulic Pump Disconnect

1. Engine Jogging Button2. Pump Disconnect Control Handle

2

To Operate: Pull to disengage-Push toengage. Do not attempt to engage ordisengage pump with engine running.

If necessary use engine jogging button, locatednext to lever, to momentarily rotate pump drivespline.

PUMP ENGAGEMENT

1

Hydraulic Pump Disconnect(If Equipped)The hydraulic pump disconnect (if equipped) is used toengage and disengage the main hydraulic pump. Dis‐engaging the main pump aids in engine start‐up by re‐ducing cranking resistance. It also allows for disen‐gaging the pump for highway travel. Refer toFigure 1-44.

The crane is equipped with an engine jogging button,located beside the disconnect control handle, to aid inengaging the hydraulic pump.

Note: In extremely cold weather, it is recommendedthat the pump be allowed to cycle without a load for3-5 minutes at low engine speed. Throttle engineto half throttle and cycle the boom telescope for an‐other 3-5 minutes. This will help prevent cold oilfrom damaging the main pump.

To Engage The Main Pump1. Warm up the engine using the normal start‐up and

warm‐up procedure.2. Park the crane and engage the park brake.

3. Shift the transmission to neutral and shutdown theengine.

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

4. Push the pump disconnect control handle to thelimit of its travel. If control handle can not bepushed to the limit, push and release the enginejogging button and push the handle to the limitagain.

To Disengage The Main Pump1. Park the crane and engage the park brake.2. Shift the transmission to neutral and shutdown the

engine.

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

3. Pull the handle out, to the limit of its travel.

Operator's Manual


Figure 1-45Operator's Seat

32

1

5

4

6

1. Seat and Console ReleaseLever

2. Seat Release Lever3. Seat Height Adjustment

Lever4. Arm Rest Height Adjustment

Knob

5. Seat Back Adjustment Lever6. Seat Belt7. Tool Box8. Fire Extinguisher

CONSTRUCTION EQUIPMENT

87

Operator's SeatThis 6‐way adjustable seat is controlled by manualcontrols. Refer to Figure 1-45.

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

1. Seat And Console Release Lever

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

2. Seat Release Lever

Move the seat release lever to the left and hold. Po‐sition the seat as desired and release the lever tolock the seat in place.

3. Seat Height Adjustment Lever

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

4. Arm Rest Height Adjustment Knob

Loosen the knob on the inside of the arm rest.Position the arm rest as desired and tighten knobto lock the arm rest in place.

5. Seat Back Adjustment Lever

Raise the lever and adjust the seat back to the de‐sired position. Release the lever to lock the seatback in place.

6. Seat Belt

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

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

7. Tool Box

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

Operator's Manual


Hour MeterThe hour meter is located on the right rear of the cranebehind the engine grille. Refer to Figure 1-46. Thehour meter registers engine operating hours. It is use‐ful in determining lubrication and maintenance sched‐ules.

Power PanelThe power panel is located on the right rear of the cranebehind the engine grille. Refer to Figure 1-46. Thepower panel contains two resettable type circuit break‐ers and three fuse blocks which service the crane'selectrical system as follows:

�105 amp resettable circuit breakerUpper Fuses (Item 5).

�105 amp resettable circuit breakerEngine Air Inlet Heater (Engine Grid Heater) (Item 4).

�Fuse Block 1 (Item 10)(2) 5 amp and (1) 7.5 amp fuse to protect other circuits.

�Fuse Block 2 (Item 11)(1) 5 amp, (1) 25 amp, and (1) 30 amp fuse to protectthe air conditioner (if equipped) and engine controlmodule (ECM).

�Fuse Block 3 (Item 12)(1) 30 amp fuse to protect the oil cooler.

Battery Disconnect SwitchesThe battery disconnect switches are located on theright rear of the crane behind the engine grille. Refer toFigure 1-46.

CAUTIONIgnition switch should be shut off at least 30seconds prior to turning disconnect switchesto the “OFF” position.

Major damage may occur to the electronicequipment from welding on the crane prior toturning disconnect switches to the “OFF”position.

Ignition switch should be shut off at least 30 secondsprior to turning disconnect switches to the “OFF” posi‐tion. Move the disconnect switches to the “Off” positionbefore welding on the crane to protect the crane's elec‐tronic components from damage due to an electric arctype welder.

Note: If the batteries are disconnected, the start‐uptime for on‐board computer systems will be longerthan normal.

Figure 1-46Power Panel

1. Hour Meter2. Battery Disconnect Switches3. Engine Diagnostic Connector4. 105 Amp Circuit Breaker5. 105 Amp Circuit Breaker6. Coolant Level Module

7. A/C Relay8. Start Relay9. 100 Amp Run Relay10. Fuse Block 111. Fuse Block 212. Fuse Block 3

5

4

12

10

11

1

2

36 7 8 9

Engine Diagnostic ConnectorThe engine diagnostic connector is located on the rightrear of the crane behind the engine grille. Refer toFigure 1-46. The connector allows the engine servicetechnician to attach the engine diagnostic data reader(DDR) for diagnosing engine problems. When thecheck or stop engine light illuminates, contact the en‐gine service technician to retrieve the fault codes andrepair the engine.

Outrigger OperationThe outriggers can be used in any one of threepositions; fully retracted, intermediate extended, orfully extended. The outriggers are controlled byswitches located on a hand held control box connectedby a cable (Refer to Figure 1-47 ) and the extendposition levers located on the outrigger boxes (Refer toFigure 1-48). Each outrigger switch (Left Front, LeftRear, Right Front, Right Rear) controls all functions ofthat outrigger beam and jack cylinder. The modeswitch controls outrigger cylinder direction,extend/retract. The extend position levers control theextend length of the beams. They allow for beams tobe fully extended, or limits them to intermediateextended lengths based on the selected position of theextend position levers.

Operator's Manual


Figure 1-47Outrigger Switches

1. Beam - Left Front2. Jack - Left Front3. Extend Mode - Beam/Jack4. Retract Mode - Beam/Jack5. Beam - Left Rear

6. Jack - Left Rear7. Jack - Right Rear8. Beam - Right Rear9. Jack - Right Front10.Beam - Right Front

10

9

5

8

1

3

4

6

7

2

Link‐Belt®

OUTRIGGERS

LEFT RIGHT

The outrigger pontoons must set on a smooth, solidsurface flush with ground with no hills or valleys underthem or they may be damaged or destroyed. If there isany doubt as to the ground conditions, use mats underthe pontoons. Check pontoons before and during op‐erations. If they are allowed to settle, they may losetheir effectiveness, and make continued operationsunsafe.

A bubble level is located in operator's cab, to assist indetermining when crane is level. Refer to Figure 1-50.

The hand held, tethered control box stores on the rightside wall of the cab near the operator's seat. The con‐trol box allows the operator to remotely control all out‐rigger functions.

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

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

park brake, shift the transmission to neutral, andshutdown engine. Engage main hydraulic pump.

2. Remove the pontoons from storage, and attachone to each outrigger jack.

WARNINGPontoons must be attached to outrigger jacksbefore crane is set on outriggers. If pontoonsshould settle, the jacks could disengage fromthe pontoons, causing a loss of stability.

3. Determine the outrigger position desired. Set theextended position levers as required. (Refer toFigure 1-48.)

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

4. Start the engine.5. Push an outrigger switch to the beam position

and hold.6. Push the mode switch to extend mode on position

and hold until the beam reaches the selectedposition; intermediate extended or fully extended.

7. When beam reaches selected position, releaseboth switches.

8. Repeat Steps 5-7, for each outrigger beam, untilall the beams are set to the selected position.

Note: As conditions warrant, a proficient craneoperator may operate multiple beams such asone end or side at the same time.

9. If the intermediate extended beam position is to beused, visually check that all beams are properlypositioned in the intermediate extended position.All beams must be extended until the stop platecontacts the extend position lever and the arrow isaligned with the outrigger box collar. Refer toFigure 1-48.

Operator's Manual


Figure 1-48Outrigger Extend Position Lever

1. Outrigger Box Collar2. Extend Position Lever3. Outrigger Beam

4. Stop Plate (For Intermediate Position)5. Alignment Arrow (For Intermediate Position)

1

3

4

Fully Retracted

3

2

1

5

Intermediate Extended

Fully Extended

2

2

3

1

Operator's Manual


10. Set the rated capacity limiter to the proper settingto match the position of the outrigger beams.

WARNINGWhen making lifts with the crane onoutriggers, all outrigger beams must beequally extended; fully retracted,intermediate extended, or fully extended.

When making lifts with the outrigger beams inthe intermediate extended position, theextend position lever must be in theintermediate extended position. Visuallycheck that all outrigger beams are extendeduntil the stop plate contacts the extendposition lever and the arrow is aligned with theoutrigger box collar before beginningoperations.

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

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

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

(fully retracted, intermediate extended, or fully ex‐tended), push an outrigger switch to the jack posi‐tion and hold.

CAUTIONWhen the hoist line is tied off to the crane orany solid object, the winch system can beoverloaded causing major winch, wire rope,or crane damage. Do not extend boom, raiseor lower the boom, or raise the crane onoutriggers unless wire rope is spooled off thedrum to prevent tension on the wire rope.

2. Push the mode switch to extend mode on andhold until the jack cylinder is fully extended.

3. Release both switches.4. Repeat Steps 1-3 for each outrigger jack.5. Raise or lower jacks as required to level the crane.

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

Note: A bubble level is provided on the rightside cab wall to assist in determining when thecrane is level.

6. Check that all tires are clear of the ground and pon‐toons are not settling.

WARNINGAll capacities listed in the Crane Rating Manual,when on outriggers, are based on all tires clearof the ground, all outrigger beams equallyextended (fully retracted, intermediateextended, or fully extended), using the properchart for the outrigger position and the cranesetting level on a firm, solid surface. Majorreductions in the crane lifting capacity andunsafe operating conditions can result if theseconditions are not met.

To Retract Outrigger Jacks - LowerThe Crane1. Fully retract the boom. Swing the upper over the

front of the carrier and engage the travel swing lock.2. Fully boom down.

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

3. Push an individual outrigger switch to the jackposition and hold.

4. Push the center mode switch to retract mode onposition and hold until the jack cylinder is fullyretracted.

5. Release both switches.6. Repeat Steps 3-5 for each outrigger jack.

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

To Retract Outrigger Beams1. Set the extend position levers in the fully retracted

position. (Refer to Figure 1-48.)2. Push an individual outrigger switch to the beam

position and hold.3. Push the center mode switch to the retract mode on

position and hold until the beam is fully retracted.4. Release both switches.5. Repeat Steps 1-4 for each beam.

Note: As conditions warrant, a proficient craneoperator may operate multiple beams such asone end or side at the same time.

6. Store all pontoons in the brackets provided.

Operator's Manual


Crane System ControlsThe following pages, along with Figure 1-50, give de‐tailed instructions of individual controls related to craneoperation. It is essential that the operator knows thefunction of each control and its duty in the overall op‐eration of the crane.

WARNINGRead and understand all “Operating Safety”procedures as well as all other operatinginstructions in this manual before attempting tooperate the crane. Operation of the crane byunqualified personnel may result in anaccident.

Engine ThrottleThe crane is equipped with a throttle pedal to controlthe engine speed. Press pedal down to increase en‐gine speed; release to decrease engine speed.

Throttle Lock System

The throttle lock system gives the operator the ability toset and hold a specific engine speed. Refer toFigure 1-37. This provides the operator with moreflexibility for certain job requirements.

To lock the throttle, press the top part of the throttle lockswitch and release. Press the throttle pedal untilthe desired engine speed is reached and press and re‐lease the adjustment switch . The engine shouldcontinue to run at a constant speed when the throttlepedal is released.

To increase throttle lock setting, either press and holdthe top part of the adjustment switch until desiredengine speed is reached and release switch, or pressthe throttle pedal until the desired engine speed isreached and press and release the adjustment switch.

To decrease throttle lock setting, press and hold thebottom part of the adjustment switch until desiredengine speed is reached and release switch.

To return to idle, press the bottom part of the throttlelock switch and release.

Figure 1-49Keep Clear of Pinch Points

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

Swing Brake Pedal

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

Swing Control Lever

The control lever, on the left side of the operator's seat,is used to operate the swing function of the upper.Move the control lever to the position to swing left;move it to the position to swing right.

WARNINGDo not exceed maximum boom angles listedon the “Backward Stability - Maximum BoomAngle” chart in the Crane Rating Manual or theBackward Stability label in the operator's cab.Crane may tip over backwards causingpersonal injury and/or crane damage.

Operator's Manual


Figure 1-50Crane Controls

1. Fire Extinguisher2. Hydraulic Control Lever

(Swing, Front Winch)3. Swing Brake Pedal4. Boom Telescope Pedal5. Service Brake Pedal6. Throttle Pedal7. Crane Rating Manual Holder

8. RCL Display9. Bubble Level10.Hydraulic Control Lever (Swing)11.Hydraulic Control Lever (Front Winch)12.Hydraulic Control Lever (Rear Winch)13.Hydraulic Control Lever (Boom Hoist)14.Swing Park Brake Switch15.360° Swing Lock (If Equipped)

16.Horn Button17.Drum Rotation Indicator Switch18.Front Winch Control Switch19.Rear Winch Control Switch20.Hydraulic Control Lever

(Boom Hoist, Rear Winch)21.Outrigger Remote Control Box22.Travel Swing Lock Control

6

20

22

9 15

2

4

7

18

1

16 17

21

8

3

Seat Console Control Switches

Left Right

19

5

Single Axis Controls (If Equipped)

Left Right

1112

10

13

14

Operator's Manual


To Swing The Upper1. Compare the boom configuration and length to the

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

2. Ensure that all personnel are out of the swing path.Dangerous pinch points are created during swing‐ing.

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

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

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

4. Release the swing brake pedal and begin to en‐gage the swing control lever.

To Stop Upper Swing1. Ease swing control lever into the neutral position.2. Apply the swing brake to bring the upper to a com‐

plete stop.3. Engage the swing park brake as required.4. Check engagement of the swing park brake by try‐

ing to swing right, then left. The upper should notswing.

Travel Swing Lock

Use the travel swing lock to lock the upper directly overeither the front or rear of the carrier. The travel swinglock will engage in these two positions only. Use of thetravel swing lock is mandatory when traveling or trans‐porting the crane and during pick and carry operations.

To Release The Travel Swing Lock1. Fully apply the swing brake pedal.2. Pull the travel swing lock lever up.

Note: In order to disengage the travel swing lock,it may be necessary to swing the upper slightly torelieve the pressure on the swing lock pin.

3. Move the lever to the right and release. The levershould remain in the released position.

To Engage The Travel Swing Lock1. Position the upper directly over either the front or

rear of the carrier. Fully apply swing brake pedal.

2. Pull the travel swing lock lever up and to the left.Then push the lever down to the locked position.

Note: In order to engage the travel swing lock, itmay be necessary to swing the upper slightly toalign the swing lock pin and retaining ring on thecarrier deck.

3. Check the engagement of the travel swing lock bytrying to swing the upper right, then left. The uppershould not swing.

Swing Park Brake

The swing park brake is a multiple disc type brake andis used for holding the upper, in any position, over thecarrier during normal, stationary crane operations. En‐gage the travel swing lock and release the swing parkbrake for pick and carry and anytime the crane is trav‐eled or transported. An indicator light on the bottompart of the rocker switch, located on the left seat con‐sole (Figure 1-50), will illuminate when the swing parkbrake is applied.

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

To Release The Swing Park Brake1. Fully apply the swing brake pedal.2. Push the top part of the swing park brake rocker

switch on the left seat console to release the parkbrake. The indicator light will go out. Refer toFigure 1-50 for rocker switch and indicator lightlocation.

To Apply The Swing Park Brake1. Rotate the upper to the desired position over the

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

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

2. Push the bottom part of the swing park brake rock‐er switch on the gauge and control panel to apply

Operator's Manual


the park brake. Indicator light will illuminate. Referto Figure 1-50 for rocker switch and indicator lightlocation.

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

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

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

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

position.

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

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

CAUTIONDo not attempt to engage 360°swing lock withthe upper in motion. This practice will result indamage to the swing mechanism. Use swingbrake pedal to stop rotation of the upper.

2. Move the 360°�swing lock lever to the “Engage”position.

Note: In order to engage the 360° swing lock, itmay be necessary to swing the upper slightly toallow the swing lock pawl to engage in the turn‐table gear teeth

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

Wire Rope Winch SystemThis system controls raising and lowering the winchlines. The system is equipped with a two speed motorthat, when activated, will approximately double winchline speed. The controls for the system are shown inFigure 1-50. Review the following for control descrip‐tions and brief summary of operation.


WARNINGCold weather operation of the winch requiresa warm‐up procedure. Failure to properlywarm‐up the winch may result in brakeslippage. Warm‐up the winch beforebeginning crane operations.

Warm‐Up Procedure

A warm‐up procedure is recommended at each start‐up and is essential at ambient temperatures below40°F (4°C). Allow the engine to run at idle speed, withthe main hydraulic pump engaged and the winch con‐trol lever(s) in neutral, for several minutes. Once the hy‐draulic oil begins to warm, operate the winch at lowspeed, with no load, lifting and lowering only the hookblock or hook ball until warm oil circulates throughoutthe winch.

Operator's Manual


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

Do not lift a load to the point where the hookblock, hook ball and/or the load contacts thehead machinery. “Two blocking” coulddamage the hook block, hook ball, wire rope,and/or the head machinery. Always keep thehook block, hook ball, and/or the load a safedistance from the boom.

Front Winch Control Lever (If Equipped)This lever controls the front winch drum. Pull this con‐trol lever back to the position to lift the load. Pushthis control lever forward to the position to lowerthe load. Refer to “Winch Operation” for more specificinstructions.

Rear Winch Control LeverThis lever controls the rear winch drum. Pull this con‐trol lever back to the position to lift the load. Pushthis control lever forward to the position to lowerthe load. Refer to “Winch Operation” for more specificinstructions.

Winch OperationThe following is a brief description of the basic proce‐dure for operating the wire rope winch. Crane opera‐tions are to be performed only by a qualified operatorwho has read and fully understands the entire contentof this manual.

To Lift A Load: Attach the hook block or hook ball tothe load. Position head machinery directly above theload, and pull the control lever back toward the opera‐tor.

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

To Hold A Load: Return the control lever to the neutralposition. The automatic brake in the winch system willhold the load in position.

To Lower A Load: Push the control lever forward. Re‐turn the control lever to neutral to stop the load.

Winch Control Switch(es)This switch is used to control engaging/disengaging thehigh/low speed hoist and disabling the front or rearwinch. Refer to Figure 1-50.

High Speed Hoist Or Lower

Press the winch control switch to the high speed(� �) position. Move the control lever to the or

position. The high speed hoist will activate afterengaging the control lever.

Note: Using the high speed hoist reduces the maxi‐mum line pull by approximately half. The highspeed hoist button can be activated at anytime dur‐ing either winch mode. Switching the high speedhoist button before engaging the winch controllever will make the system work smoother.

To Return To Standard Winch Mode: Press winchcontrol switch to the low speed (� �) position.Winch will return to standard speed.

Winch Disable

Press the winch control switch(es) to the disable ( )position to disable the winch(es) to prevent inadvertentoperation of the winch(es) while using the control le‐vers to perform other operations.

Drum Rotation IndicatorsThis system is used to monitor winch drum speedsthrough the use of a mechanical signaling devicemounted inside each of the winch control levers. To acti‐vate the system, push the bottom part of the drum rota‐tion indicator switch , on the right seat console(Figure 1-50), to the “ON” position (indicator withinswitch will illuminate). Place your thumb over the end ofthe control lever being used. As the winch drum rotates,a mechanical signal will be felt with your thumb. The fre‐quency of the mechanical signal is a direct indication ofthe winch drum speed. Push the top part of the drumrotation switch to deactivate system.

Operator's Manual


First Layer/Third Wrap Indicator (If Equipped)The crane may be equipped with a first layer/third wrapindicator system. This system allows the operator tomonitor the wire rope windings on the drum(s) . Enablethe system through the RCL system using the operatorsettable alarm feature. Refer to “MicroGuard 540Rated Capacity Limiter” in this Section of this Opera‐tor's Manual. Once the first layer/third wrap indicatorsystem is enabled, press the first layer/third wrapswitch to the “F” (Front) position to monitor the frontdrum only, “B” (Both) to monitor both drums, or “R”(Rear) to monitor the rear drum only. When the systemis enabled, the audible alarm will sound intermittently,and “First Layer” will appear in the warning message

area of the RCL display to alert the operator when thewire rope is down to the first layer on the winchdrum(s). The audible alarm will sound continuouslyand “Third Wrap” will appear in warning message areato alert the operator when the wire rope is down to thethird wrap on the winch drum(s).


Operator's Manual


Figure 1-51Boom Nomenclature

1. Base Section2. T1 Section

3. T2 Section4. T3 Section

5. T4 Section6. Boom Head Machinery

65421 3

Boom Hoist SystemRaising and lowering the boom is controlled by theboom hoist control lever located on the right arm rest.Refer to Figure 1-50.

WARNINGDo not exceed maximum boom angles listedon the “Backward Stability - Maximum BoomAngle” chart in the Crane Rating Manual or theBackward Stability label in the operator's cab.Crane may tip over backwards causingpersonal injury and/or crane damage.

To Raise The Boom (Boom Up): Move the right con‐trol lever to the position.


To Lower The Boom (Boom Down): Move the rightcontrol lever to the position.

CAUTIONWire rope must be spooled off the winch drumas the boom is lowered. Failure to do so maycause two blocking.

To Stop The Boom: Ease the right control lever intothe neutral position.

Boom Telescope SystemThe crane is equipped with a five section boom. Thefive section boom consists of a base, T1, T2, T3, and aT4 section. Refer to Figure 1-51.

One telescope cylinder and one pin/latch cylinder areused to sequentially telescope one section at a timeand pin that section to the next adjacent section in oneof 3 positions: 0%, 50%, or 100% extension for eachsection. The operation of these cylinders is a combina‐tion of computer control and operator input. The com‐puter controls which section is being extended or re‐tracted, all pinning and unpinning operations, direc‐tion, and in some cases the speed of the telescope cyl‐inder. The operator controls whether to extend or re‐tract the boom and the speed at which to extend or re‐tract the boom.

The telescope feature has three modes of operation(Refer to Figure 1-52):

� EM1 extends all sections 100% for a max boomlength of 140 ft (42.7m).

� EM2 extends only the T1, T2, and T3 to 100% for amax boom length of 115.8 ft (35.3m). T4 section re‐mains fully retracted.

� EM3 extends T1, T2, and T3 to 50% for a maximumboom length of 76.5 ft (23.3m). The T4 section re‐mains fully retracted. Maximum rated capacities areonly available when all the sections are pinned to‐gether or the boom is fully extended.

Note: When utilizing the EM3 boom mode, ensurethe boom sections are pinned together or are at themaximum length for boom mode EM3 before liftingthe allowable capacity loads. Utilize the boom pin‐ning information on the RCL boom telescopescreen to confirm a “Pinned” condition.

There is a 10,000 lb (4 536kg) capacity allowed onlyfor the weight of the rigging while telescoping theboom between fixed boom lengths. Do not attemptto extend or retract the boom with more than 10,000lb (4 536kg) of rigging while utilizing boom modeEM3.

Operator's Manual


Boom Extend ModesBOOM

LENGTH(FT)

BOOM TELESCOPE LENGTH (Ft)

BaseT4 T3 T2 T1

Extend Base

38 ft (11.6m)

140 ft (42.7m)

T4 T3 T2 T1

50 12.0

60 22.0

70 24.2 7.8

80 24.2 17.8

90 24.2 25.1 2.7

100 24.2 25.1 12.7

110 24.2 25.1 22.7

120 24.2 25.1 25.9 6.8

130 24.2 25.1 25.9 16.8

140 24.2 25.1 25.9 26.8

BOOMLENGTH

(FT)

BOOM TELESCOPE LENGTH (Ft)

BaseT3 T2 T1

Extend Base

38 ft (11.6m)

115.8 ft (35.3m)

T4 T3 T2 T1

50 12.0

60 22.0

70 25.1 6.9

80 25.1 16.9

90 25.1 25.9 1.0

100 25.1 25.9 11.0

115.8 25.1 25.9 26.8

BOOMLENGTH

(FT)

BOOM FIXED LENGTH (Ft)

BaseT3 T2 T1

Extend Base

38 ft (11.6m)

76.5 ft (23.3m)

T4 T3 T2 T1

50.7 12.7

63.7 12.7 13.0

76.5 12.7 13.0 12.8

Figure 1-52Boom Extend Modes

Boom Telescope Mode Selection

The boom modes can be changed only when theboom is fully retracted. If a boom mode change isattempted before the boom is fully retracted, themessage “Retract Boom” will be displayed and the boommode will not change. To change or select a boommode, refer to “MicroGuard 540 Rated CapacityLimiter” in this Section of this Operator's Manual.When a boom mode is selected, the telescope

controller's first command requires the telescopepedal to be pressed and held to move the telescopecylinder into alignment with the first boom section thatis to be extended for the boom mode selected.

This movement of the telescope cylinder must beallowed to finish before any other telescope functioncan happen. Be patient and allow the system tocomplete these functions before attempting otherfunctions.

Operator's Manual


Boom Telescope Control PedalThe telescope control pedal is located in the left front ofthe operator's cab floor. Refer to Figure 1-50. De‐press the toe of the telescope control pedal to extendthe boom. Depress the heel of the telescope controlpedal to retract the boom.

To Extend The Boom Sections1. Park the crane on a firm level surface, engage the

park brake, and shift the transmission to neutral.2. Review the appropriate capacity chart in the Crane

Rating Manual to establish boom length, angle,and load limitations.

3. Set the Rated Capacity Limiter to the desiredtelescope mode. Refer to “MicroGuard 540 RatedCapacity Limiter” in this Section of this Operator'sManual.

Note: Mode changes can only be made when theboom is fully retracted. When a mode change isselected, the computer requires the telescopepedal to be pressed and held to move the tele‐scope cylinder to line up with the first section tobe extended. Allow this operation to finish beforecontinuing. If a boom mode change is attemptedbefore boom is fully retracted, the message “Re‐tract Boom” will be displayed in the TelescopeOperation Mode display on the RCL Boom Tele‐scope screen and the boom mode will notchange.


CAUTIONWire rope must be spooled off the winchdrum(s) as the boom is extended. Failure todo so may cause two blocking.

4. Depress the toe of the telescope control pedal toextend the boom. Allow time for the telescope cyl‐inder to latch to the correct section and pull the pinbetween sections. The computer will then acceler‐ate the boom section up to a speed proportional tothe amount the telescope pedal is depressed. Re‐leasing the pedal will stop telescope operation.

Note: The telescope control pedal is springloaded and should return to the neutral positionwhen released.

Note: In very cold weather, the latch and pin cylin‐der will not function as fast as normal due to thechange in the viscosity of the hydraulic oil. Allowextra time for this function in very cold weather.

5. Depressing the toe of the pedal will begin telescop‐ing. When the section nears the point where thesection will be pinned to the adjacent section, thecomputer automatically slows down the speed ofthe telescope cylinder. It is not necessary to re‐move your foot from the pedal or reduce theamount the pedal is depressed, this is done auto‐matically. The section will actually be extendedslightly past the pinning point and then slowly re‐verse direction to gently load up the pin and unloadthe latches that attach the telescope cylinder to thesection being extended.

Note: The RCL system is equipped with an alter‐nate screen for visual feedback about what isoccurring while telescoping the boom. Pressthe Display/Select button on the RCL display toaccess this screen. Refer to RCL Boom Tele‐scope Screen and Figure 1-53.

CAUTIONIf a load is suspended while telescoping, theload will lower slightly during the pinningoperation. This is more noticeable with asingle part of line.

6. Continue to depress the toe of the telescope con‐trol pedal until the desired boom length isachieved. When the desired boom length isachieved release the telescope control pedal.

To Retract The Boom Sections1. Depress the heel of the telescope control pedal.

Note: As the boom is retracted, the hook blockor hook ball will lower. Winch up as required tokeep the hook block or hook ball in the desiredposition.

Note: In very cold weather, the latch and pin cylin‐der will not function as fast as normal due to thechange in the viscosity of the hydraulic oil. Allowextra time for this function in very cold weather.

Operator's Manual


1. Telescope Cylinder Length (In Inches)2. Latch State3. Telescope Operation Mode Display

4. CAN Message And Diagnostic Access5. General Diagnostic Message Area

6. Pin State7. Boom Length (In Feet)

Figure 1-53RCL Boom Telescope Screen

1

XX.XX ft

CAN Diagnostics

XX.XX in

Pin and Latch Status

NOT PINNED NOT LATCHED

STARTUP

General Diagnostic Messages

2

4

5

6

7

3

PINNED LATCHED

RCL Boom Telescope Screen

The RCL system is equipped with an alternate screenfor visual feedback about what is occurring while tele‐scoping the boom. Press the Display/Select button onthe RCL display to access this screen. Refer toFigure 1-53. The screen will display a graphic repre‐sentation of the boom at the top of the screen and willdisplay the boom length in feet and the telescope cylin‐der location in inches. Just below the boom graphic,the pin and the latch status and the telescope opera‐tion mode will be displayed. Below this is an area that

displays the various CAN bus information and errormessages. Display of this screen is a personal prefer‐ence as the boom can be telescoped with the mainworking screen displayed.

The following charts list the operation and error mes‐sages displayed in the Telescope Operation Mode Dis‐play.

Note: To clear boom telescope error codes, shut‐down and restart the engine. If this does not clearthe codes contact your Link‐Belt Distributor.

Operator's Manual


Normal Operation Messages

Message Meaning What Is Happening

E_Ret

Extend - Cylinder Retract.

Telescope cylinder is retracting at maximumspeed to line up with the next section to be ex‐tended.

Boom is PINNED and NOT LATCHED. Tele‐scope cylinder moves at maximum speed re‐gardless of pedal position within retract range.Boom will not enter this condition unless pin/latch state is PINNED and NOT LATCHED.

E_SRB

Extend - Slow Retract Bottom.

Extending boom at slow speed near the 0% pinlocation. Telescope cylinder is retracting.

Telescope cylinder is latching into the next sec‐tion to extend and is unpinning it at the 0% pinlocation.

E_SEB

Extend - Slow Extend Bottom

Extending boom at slow speed near the 0% pinlocation. Telescope cylinder is extending.

Telescope cylinder is latching into the next sec‐tion to extend and is unpinning it at the 0% pinlocation.

E_Ext

Extend - Boom Extend.

Extending boom at speed proportional to ex‐tend pedal input.

Section is LATCHED to telescope cylinder andNOT PINNED. Boom will not enter this conditionunless pin/latch state is NOT PINNED andLATCHED.

E_SRT

Extend - Slow Retract Top.

Extending boom at slow speed near the 50% or100% pin location. Telescope cylinder is retract‐ing.

Pin is being engaged in the hole and the tele‐scope cylinder is retracting to gently load up thepin and unload the latches.

E_SET

Extend - Slow Extend Top.

Extending boom at slow speed near the 50% or100% pin location. Telescope cylinder is extend‐ing.

Pin should be fully engaged in the hole and thetelescope cylinder is extending out slightly sothe latches can disengage from the section.

StopExt Boom Stop Extend.Boom has finished extending. No further actionis required.

R_Ret

Retract - Cylinder Retract.

Telescope cylinder is extending at maximumspeed to line up with the next section to be re‐tracted.

Boom is PINNED and NOT LATCHED. Tele‐scope cylinder moves at maximum speed re‐gardless of pedal position within retract range.Boom will not enter this condition unless pin/latch state is PINNED and NOT LATCHED.

R_SET

Retract - Slow Extend Top.

Retracting boom at slow speed near the 50% or100% pin location. Telescope cylinder is retract‐ing.

Telescope cylinder is latching into boom sectionto be retracted. Cylinder is retracting at slowspeed.

R_SRT

Retract - Slow Retract Top.

Retracting boom at slow speed near the 50% or100% pin location. Telescope cylinder is extend‐ing.

Telescope cylinder is LATCHED into boom sec‐tion and pulling the pin. Cylinder is extending atslow speed to gently unload the pin so it can bepulled.

R_Ext

Retract - Boom Extend.

Retracting boom at speed proportional to retractpedal input.

Boom section is LATCHED to telescope cylinderand NOT PINNED. Boom will not enter this con‐dition unless pin/latch state is NOT PINNED andLATCHED.

R_SEB

Retract - Slow Extend Bottom.

Retracting boom at slow speed near the 0% pinlocation. Telescope cylinder is retracting.

Telescope cylinder is easing the boom section toa stop at the 0% pinning location for that section.

Operator's Manual


Normal Operation Messages

What Is HappeningMeaningMessage

R_SRB

Retract - Slow Retract Bottom.

Retracting boom at slow speed near the 0% pinlocation. Telescope cylinder is extending.

Boom section has been PINNED at 0% locationand the telescope cylinder is slowly extendingback out to unload the latches and allow themtime to fully disengage from the section.

StopRet Stop Retract.Cylinder is moving to a different boom sectionduring an extend mode change.

Neutral Telescope pedal is centered.No input from the operator is being sensed bythe controller.

Release Pin and unlatch from incorrect section.

Telescope cylinder is not lined up with correctsection to be moved. Controller is automaticallypinning and unlatching from the incorrect sec‐tion and moving to line up with correct section.

ExtSlwLCylinder is extending slowly while latching andunpinning.

Telescope cylinder is moving slowly to allow pin/latch state to reach a valid state.

CAUTIONShutting the crane power off and restarting itcould potentially shear the bolts in the basesection cover plate. Allow controller to get toR_Ext or E_Ext.

RetSlwLCylinder is retracting slowly while latching andunpinning.


CAUTIONShutting the crane power off and restarting itcould potentially shear the bolts in the basesection cover plate. Allow controller to get toR_Ext or E_Ext.

ExtSlwPCylinder is extending slowly while pinning andunlatching.


RetSlwPCylinder is retracting slowly while pinning andunlatching.


Operator's Manual


Error Messages

Message Meaning How To Clear Message

Cur1ErrTelescope valve section 1 current error. Control‐ler is not detecting the correct current.

Check all wires and connectors between thetelescope controller and the telescope valve so‐lenoids. Error may occur during manual boomoperation. Shutdown and restart crane to clear.

OvrLoadRCL system has detected an overload conditionwhile operator is trying to extend boom.

Decrease radius or reduce load.

CylErrInvalid Cylinder Position. (Cylinder position wasnot received by the controller or position re‐ported is outside the valid range.)

Check all wires and connectors to the CylinderPosition Encoder. Using the remote controlbox, fully retract the boom, pin the boom, andunlatch the telescope cylinder. Using the re‐mote control box, fully retract the telescope cyl‐inder until it bottoms out. Request to Zero Tele‐scope Cylinder Position.

PdlErrInvalid Pedal Input Signal. (Anytime arm rest isin the up position, PdlErr will be displayed.)

Check all wires and connectors to the pedal. Donot press the pedal to its maximum stroke in thedirection that gives the error.

CAUTIONThe boom section may start moving as soonas the pedal is moved from maximum stroke.

Int_Err Internally Detected Error.Something is wrong internally in the telescopevalve controller. Controller must be repaired orreplaced by a qualified technician.

PdlCtr?Telescope pedal was not centered upon start‐ing the crane.

Center the pedal.

Sw_ErrSwitch Error - invalid or unexpected combina‐tion of switch inputs.

Shutdown crane and restart to see if error cor‐rects itself. Check all switches for proper opera‐tion and that switch inputs are getting to the tele‐scope valve controller.

Re-Zero Re-Zero Telescope Cylinder.

An error has occurred that may cause the boomlength to be incorrect. The telescope cylindermust be re-zeroed with the boom fully retrac‐ted.

BmLErr Boom Length Error.

External length reel does not match internallycalculated boom length. Re-zero and span ex‐ternal reel. Re-zero telescope cylinder if stillnot fixed.

Operator's Manual


Figure 1-54Emergency Boom Telescope Control Switches

1. Extend/Retract Switch2. Boom Telescope Remote Control Box3. Pin/Latch Switch

4. Indicator Lights5. Activate Switch

3

1

Right Side of Upper Cab

Manual mode isintended only foremergency operation.

Improper operation ofthe boom in manualmode can cause majordamage to the boom.

CAUTION

54

2

Emergency Telescope Operation

WARNINGManual mode is intended for emergencyoperation only. Improper operation of theboom in manual mode can damage internalcomponents of the boom. This can lead tocrane damage, property damage, or possiblypersonal injury.

The crane has been designed with the ability to tele‐scope the boom manually. This is intended only foremergency operation. Note the following restrictions:

� Do not telescope the boom in manual mode with a loadon the hook. Set the load down before telescoping.

� Use the holes provided in the side of each boom sec‐tion to visually check to ensure that pins and latchesare fully engaged or disengaged before movingboom sections or the telescope cylinder.

� Clear all unauthorized personnel from the area sur‐rounding the crane. Ensure that all authorized per‐sonnel are well out of the way of all moving parts.

The emergency telescope control switches are locatedon a boom telescope remote control box stored in thetool box under the operator's seat. To enable theswitches, connect the cord to the electrical connectoron the lower right corner of the operator's cab. To en‐able the extend/retract and pin/latch switches, move

and hold the activate switch to the “ACTIVATE” posi‐tion. Refer to Figure 1-54.

WARNINGWhen the emergency telescope control box isconnected to the upper, the RCL system auto‐matically changes to rigging mode. The RCLsystem is not operational when in the riggingMode. Disconnect the remote control box,turn the ignition switch to the “OFF” position,and return the RCL system to normal opera‐tion before operating the crane.

When the emergency telescope control box is con‐nected to the upper, the RCL system automaticallychanges to the rigging mode. All function limiters ex‐cept anti‐two block are disabled when the RCL is in therigging mode.

To Manually Retract A Boom Section


Operator's Manual


1. If the telescope cylinder is not already latched to thesection to be retracted, move the pin/latch switch tothe “PIN” position (up) and visually check to ensurethat the telescope cylinder is not latched to a section.The NOT LATCHED indicator light should illuminate.

2. Using the Extend/Retract switch, telescope the cylin‐der out until the latches align with the holes in the rearof the section to be retracted. The PIN CENTEREDindicator light will illuminate when the cylinder is cen‐tered with the pin. Refer to the following chart for ap‐proximate telescope cylinder positions.

Extend ModeBoom Length Telescope Cylinder Length

±0.25 ft ±0.25 in

EM1

140.0 322.9

113.2 322.9

87.3 322.9

62.2 322.9

EM2

115.8 322.9

89.0 322.9

63.1 322.9

EM3

76.5 155.0

63.7 167.7

50.7 175.3

3. Move the Pin/Latch switch to the LATCH positionand visually check to ensure that the latches havefully engaged the section. The LATCHED indicatorlight should illuminate.

4. Use the Extend/Retract switch to telescope the cyl‐inder in or out slightly as needed to allow thelatches to fully engage the section.

5. When the latches are fully engaged (LATCHED indica‐tor light illuminated), telescope the cylinder out slightly[1-2 in (2.5-5.0cm)] to unload the pin. The pin willpull when it is unloaded. The NOT PINNED indicatorlight should illuminate.

6. When the pin is pulled, the section can be re‐tracted. Be sure to winch up while retracting thesection to maintain tension on the wire rope so itwill spool correctly.

7. When the section is fully retracted, move the Pin/Latch switch to the PIN position. The PINNED indi‐cator light should illuminate.

8. Extend the cylinder slightly [.5 in (1.3cm)] to un‐load the latches and allow them to disengage fromthe section. Visually check to ensure that thelatches are fully disengaged from the section be‐fore retracting another section. The NOTLATCHED indicator light should illuminate.

9. Repeat this operation until boom is fully retracted.10. Disconnect remote control box, turn the ignition

switch to the “OFF” position, and return the RCLsystem to normal operation before operatingcrane.

To Manually Extend A Boom Section


1. If the telescope cylinder is not already latched to thesection to be extended, move the Pin/Latch switch tothe PIN position and visually check to ensure that thetelescope cylinder is not latched to a section. TheNOT LATCHED indicator light should illuminate.

2. Press the Extend/Retract switch to telescope the cyl‐inder until the latches align with the holes in the rearof the section to be extended. The PIN CENTEREDindicator light will illuminate when the cylinder is cen‐tered with the pin. Refer to the following chart for ap‐proximate telescope cylinder positions.


±0.25 ft ±0.25 in

EM1

38.0 33.0

62.2 22.0

87.3 11.7

113.2 1.0

EM2

38.0 22.0

63.1 11.7

89.0 1.0

EM3

38.0 22.0

50.7 11.7

63.7 1.0

3. Press the Pin/Latch switch to the LATCH positionand visually check to ensure that the latches havefully engaged the section.

4. Telescope the cylinder in or out slightly as neededto allow the latches to fully engage the section.

5. When the latches are fully engaged (LATCHED indica‐tor light illuminated), retract the cylinder slightly to un‐load the pin. The pin will pull when it is unloaded. TheNOT PINNED indicator light should illuminate.

CAUTIONWire rope must be spooled off the winchdrum(s) as the boom is extended. Failure todo so may cause two blocking.

6. When the pin is pulled the section can be ex‐tended. Be sure to winch down while extendingthe section to avoid two blocking. Refer to the fol‐

Operator's Manual


lowing chart for approximate telescope cylinderlengths where the correct pin holes are located.


±0.25 ft ±0.25 in

EM1

140.0 322.9

113.2 322.9

87.3 322.9

62.2 322.9

EM2

115.8 322.9

89.0 322.9

63.1 322.9

EM3

76.5 155.0

63.7 167.7

50.7 175.3

7. When pin is lined up with the hole it is to be pinnedinto, move the Pin/Latch switch to the PIN position.

8. Visually check to verify that the pin has fully engagedthe pin hole. If it has not engaged the pin hole, tele‐

scope the cylinder in the direction required to alignthe pin with the hole. The pin will pop into the holeand the PINNED indicator light should illuminate.

9. Retract the cylinder to load up the pin. If this isdone at a high boom angle further retraction of thecylinder will unload the latches and allow them todisengage from the section. If this is done at a lowboom angle, the cylinder must be extended slightlyto unload the latches and allow them to unlatchfrom the section.

10. When the cylinder is not latched to the section, itcan be retracted to align with the next section to beextended and the process can be repeated to ex‐tend other boom sections as required.

11. Disconnect remote control box, turn the ignitionswitch to the “OFF” position, and return the RCLsystem to normal operation before operatingcrane.

Operator's Manual


1. Swing Left2. Swing Right

3. Boom Down4. Boom Up

1

2

3

4

Figure 1-55Fine Metering Valve

FINE METERINGVALVE GUIDE

NV2��NV4

NV3NV1

Fine Metering System(If Equipped)This fine metering system is used to adjust the crane'shydraulic functions to certain job functions or for set‐tings that are comfortable to the operator. The system

is for precise controlled operation and heavy lift capac‐ity with slower speed. Use for jobs where accuratepositioning is more important than speed. The systemis activated by the fine metering switch located on thegauge and control panel. Refer to Figure 1-37 forswitch location.

Operator's Manual


1. Anemometer2. Transmitter3. Bushings4. Bowtie Hair Pin

Figure 1-56Wind Speed Indicator

1

2

Main Boom

Fly Base

Fly Tip

3

4

Crane Monitoring SystemA crane monitoring system is available to assist the op‐erator in safe operation of the crane. The following sys‐tems outline some of the aids used for monitoringcrane conditions during operation.

Wind Speed IndicatorThe crane may be equipped with a wireless windspeed indicator integrated into the Rated CapacityLimiter system. The indicator is used to monitor windspeeds at the main boom head or the fly head when

erected. Refer to Figure 1-56. An anemometertransmits wind speed data to the display unit in theoperator's cab. Refer to “Wind Speed Restrictions” inthe Crane Rating Manual for more information on windspeed restrictions.

CAUTIONRemove the anemometer assembly from theboom head or fly during transport to preventdamage to the unit.

Operator's Manual


Operating In Wind And Lightning

Avoid working a crane in high winds and when there isa liklehood of lightning. Rated lifting capacities do notaccount for the effects of wind on a suspended load orboom. Lifting capacities should be considered accept‐able for wind speeds up to 20mph (32km/h) and appro‐priately reduced for wind speeds greater than 20mph(32km/h). If you must work in a wind, reduce capacitiesto those listed in “Wind Speed Restrictions” chart in theCrane Rating Manual. Wind blowing against the loadand the boom produces a side load on the boom andreduces its capacity. When lifting loads which havelarge surface areas in a wind, such as building panels,the movement of the load may pose a danger to work‐men or building structures. Out swing of a load will in‐

crease the load radius, and may overload the crane.This could lead to boom failure or the crane tipping.Monitor the wind speed using the wind speed indicator.Stop lifting operations, ground the load, fully retractand lower the boom to horizontal if wind speed ex‐ceeds the maximum allowed listed in “Wind SpeedRestrictions” chart in the Crane Rating Manual. Usethe following table as a general guide.

DANGERIf there is a likelihood of lightning,immediately stop lifting operations, groundthe load, and fully retract and lower the boomin the boom rest.

Wind ScaleWind Speed Wind Strength

Inland Wind Effectmph km/h Beaufort Scale WMO* Description

<0.6 <1 0 Calm Calm, smoke rises vertically.

0.6 to 3.1 1 to 5 1 Light AirSmoke drift indicates wind direc‐tion, wind vanes remain still.

3.7 to 6.8 6 to 11 2 Light BreezeWind felt on face, leaves rustle,wind vanes begin to move.

7.4 to 11.8 12 to 19 3 Gentle BreezeLeaves and small twigs con‐stantly moving, light flags exten‐ded.

12.4 to 17.4 20 to 28 4 Moderate BreezeDust, leaves, and loose paper lif‐ted, small tree branches move.

18.0 to 23.6 29 to 38 5 Fresh BreezeSmall trees in leaf begin to sway.Crested waves form on inlandwaters.

24.2 to 30.4 39 to 49 6 Strong BreezeLarger tree branches moving.Telegraph wires whistle. Umbrel‐las used with difficulty.

31.1 to 37.9 50 to 61 7 Near GaleWhole trees moving. Resistancefelt walking against wind.

38.5 to 46.0 62 to 74 8 GaleBreaks twigs off trees. Resist‐ance felt walking against wind.

46.6 to 54.1 75 to 87 9 Strong GaleSlight structural damage. Slateblows off roofs.

54.7 to 62.8 88 to 101 10 StormTrees broken or uprooted. Con‐siderable structural damage.

* World Meteorological Organization

Operator's Manual


Figure 1-57Boom Angle Indicator

Boom Angle IndicatorA mechanical type boom angle indicator is mounted tothe right of the operator's cab on the base section ofthe boom. Refer to Figure 1-57. It must be adjustedproperly and the crane must be level for the unit to ac‐curately indicate boom angles. Even under these con‐ditions its readings are only approximate. When mak‐ing near capacity lifts, measure the load radius to deter‐mine crane capacity. Check the adjustment of theboom angle indicator daily to ensure its accuracy. Re‐fer to “Boom Angle Indicator Adjustment” in Section 3of this Operator's Manual.

Anti‐Two Block Warning SystemIntegrated into the Rated Capacity Limiter System is ananti‐two block (ATB) warning system. An anti‐twoblock warning system is an electromechanical systemdesigned to alert the operator before the hook block,hook ball, and/or the load contacts the head machineryof the main boom, auxiliary lifting sheave, or fly. When atwo block situation is imminent, an audio/visual alarmis activated to alert the operator of the pending danger.When the alarm activates it is essential that the opera‐tor discontinue operations immediately, and correctthe two‐block situation.

Three basic components are used to make up the anti‐two block system. The anti‐two block weight, anti‐twoblock switch with lockout pin, and the display unit in theoperator's cab. Refer to Figure 1-58 and Figure 1-59.

An anti‐two block weight is suspended from the headmachinery switch where lifts are to be made and isused to hold the switch in the “working” position.When the anti‐two block weight is lifted by the hookblock, hook ball, or the load, it allows the switch to acti‐vate the audio/visual alarm on the display unit in the op‐erator's cab. In addition to the audio/visual alarm,function limiters will be activated.

CAUTIONDo not allow the load to spin out of controlwhen hoisting. The anti‐two block weight maybecome entangled with the wire rope andcould damage the anti‐two block system, wirerope, or boom. Use rotation resistant wirerope during single part line hoistingapplications, especially when long fall liftsare involved.

The added feature of hydraulic function limiters, pre‐vents the operator from continuing crane functionswhich will cause a two block situation to occur. Thecrane functions of winch up, boom down, and boomextend are disabled when the anti‐two block weight islifted. These functions will remain disabled until the twoblock situation is corrected or the “cancel alarm”switch on the display unit is utilized.

The main boom head must always have an anti‐twoblock switch. Each of the added attachments used onthe crane must employ a similar head machineryswitch as well, in order for that particular attachment tobe monitored by the system.

The plug assembly is connected to the jumper assem‐bly on the boom head when operating from the mainboom. It is connected to the jumper assembly on theattachment when operating from that attachment.

Check that all the harness connections between the at‐tachments are properly joined and test the system be‐fore beginning operations. Test the system by manual‐ly lifting the ATB weight and verifying that the function ofwinch up, boom down, and boom extend are disabled.

Operator's Manual


Figure 1-58Anti‐Two Block Weights And Switches

1. Jumper Assembly2. Plug Assembly3. Anti‐Two Block Switch4. Anti‐Two Block Weight5. Lockout Pin & Flag

Lockout Pin Installed(Switch Inactive)

53

4

21

Lockout Pin Stored(Switch Active)

5

WARNINGMAIN BOOM ATB IS DISABLEDWHEN LOCK OUT PIN IS IN HOLE. TO OPERATE MAIN BOOMATB, REMOVE PIN AND STOREIN STORAGE HOLE BEHIND SWITCH. FAILURE TO HAVEFULLY OPERATIONAL ATB SYSTEMCOULD RESULT IN SERIOUSINJURY OR DEATH.

LOCK OUT PIN HOLE

Lockout Pin And Flag

The lockout pin is used to hold the main boom anti‐twoblock switch in the “working” position, the same ashaving a two block weight suspended from the switch.

When operating from the main boom the lockout pinand flag must be in the stored position. When operat‐ing from an attachment only, the lockout pin must beinstalled in the main boom head anti‐two block switch.

When both main boom and attachment are reeved foroperation, lockout pin and flag must be removed fromswitch and properly stored.

Note: When using main boom and attachment, anti‐two block weights must be suspended from theanti‐two block switch on each attachment.

Operator's Manual


Figure 1-59MicroGuard 540 Rated Capacity Limiter

1. Bar‐Graph2. Pre‐Alarm Indicator3. Overload Indicator4. Parts‐of‐Line Display5. Maximum Rated Capacity Display6. Actual Load Display

7. Working Area Display8. Configuration Selection Buttons9. Cancel Alarm Button10. Operator Alarms Button11. Crane Setup Button12. Display/Select Button

13. Warning Message Area14. Boom Length Display15. Brightness Buttons16. Load Radius Display17. Boom Angle Display18. Boom Head Height Display

154.0ft

7,300lbs max

500lbs

54.5

94.0ft

140.0ft

FULL EXT 28800 35' Fly@2 23' Tip

1

1

13

5

6

8

15

32

14

17

12 11 10 9

18

7

4

16

Operator's Manual


MicroGuard 540 Rated CapacityLimiterThe following describes the function and operation ofthe MicroGuard 540 Rated Capacity Limiter. The sys‐tem is intended to aid the operator in the efficient op‐eration of the crane by continually monitoring the loadand warning of an approach to an overload or unsafecondition.

WARNINGAlthough the system will alert the operator ofan approaching overload or unsafe condition,it remains the responsibility of the operator tooperate the crane safely at all times.

This system must never be substituted for thegood judgment of the crane operator using safeoperating procedures. The operator is solelyresponsible for safe operation of the crane.

!!THIS SYSTEM IS AN OPERATOR'S AID -NOT A SAFETY DEVICE!!

System Description

The system monitors crane functions by means of highaccuracy sensors and continuously compares the loadwith a copy of the crane capacity chart which is storedin the computer memory. If an overload is approached,the system warns by means of audible and visualalarms and is configured to cause function limitation.

The MicroGuard 540 Rated Capacity Limiter providesthe operator with a continuous display of:� Rated Capacity� Actual Load� Percentage of Rated Capacity� Radius of the Load� Angle of the Main Boom� Crane Configuration� Length of the Main Boom� Height of the Main Boom Head

An additional feature of the system is the provision ofoperator settable alarms. These alarms, when proper‐ly set, provide a method of obstacle avoidance. This isachieved by means of minimum and maximum boomangle, maximum load radius, maximum boom headheight, left and right swing, and defined area alarms.These alarms can be programmed for each job siteand set rapidly for the prevailing site conditions therebyaiding the operator in safe operation of the crane.

Figure 1-60Overhead Bar‐Graph And External Light Bar(If Equipped)

2

3

1. Green Lights - Percent‐age of Rated Load

2. Amber Lights - Ap‐proaching Overload

3. Red Lights - Overload

1

2 31

Display Unit

The following is a description of the control buttons, in‐dicators, and windows on the display unit. Refer toFigure 1-59.

1. Bar‐Graph

The Bar‐Graph is a series of twelve colored lights whichgives a visual indication of how much of the crane's ca‐pacity is being used and the rate at which an overloadis being approached. Each green light represents 10%of the crane's rated capacity is being used. Yellow indi‐cates 90-99.9%, and the red lights indicate an over‐load.

Note: System may be equipped with an overheadbar‐graph or an external light bar which operatessimilar to the bar‐graph on the display. Refer toFigure 1-60.

2. Pre‐Alarm Indicator

The Pre‐Alarm (yellow) Indicator illuminates at a pre‐set value of 90% of Maximum Rated Capacity and pro‐vides a visual indication of an approach to an overload.

Operator's Manual


3. Overload Indicator

The Overload Indicator (red) illuminates at a pre‐setvalue of 100% of Maximum Rated Capacity and pro‐vides a visual indication of Maximum Allowed Load. Itwill also illuminate whenever a wire rope limit is exceed‐ed. Function limiters will occur simultaneously for anOverload, Wire Rope Limit or a Two Block condition,but function limiters will not occur when exceeding anoperator settable alarm. An audible alarm will soundand a message will appear in the warning messagearea for all 4 conditions.

4. Parts‐of‐Line Display

Parts‐of‐Line displays the parts of line currently se‐lected for the winch in use.

5. Maximum Rated Capacity Display

The Maximum Rated Capacity is a digital display of themaximum permitted capacity. It is derived from a copyof the crane's capacity chart which is stored in the com‐puter memory and is the reference capacity for any lift‐ing operation. It is dependent on the configuration cur‐rently selected, which is shown in the crane setupscreen, and which determines the section of the ca‐pacity chart to be used as the rated capacity reference.

6. Actual Load Display

The Actual Load Display is a digital display whichshows total load suspended below the boom or flyhead. It includes the load, any slings, pins, or tackleused to secure the load and the hook block or hookball.

7. Working Area Display

This area displays a graphical representation of the al‐lowable lifting quadrant(s) based on the selected con‐figuration. A quadrant not allowed will be filled red, anallowable quadrant will be filled green.

8. Configuration Selection Buttons

These buttons are used during the crane configurationselection routine. Refer to “Configuration Selection” inthis Section of this Operator's Manual.

9. Cancel Alarm Button

This button is used to silence the audible alarm whenthe alarm has occurred as a result of either an Over‐load, a Two Block, Wire Rope Limit, or an Operator Set‐table alarm. It is also used to reset the function limitrelay when it is necessary to by‐pass function limitwhich has occurred as a result of either an Overload ora Two Block alarm.

10. Operator Alarms Button

This button is used to start the operator settable alarmsroutines. Refer to “Operator Settable Alarms” in thisSection of this Operator's Manual.

11. Crane Setup Button

This button is used to start the configuration selectionroutine. Refer to “Configuration Selection” in this Sec‐tion of this Operator's Manual.

12. Display/Select Button

This button is used to access the boom telescopescreen for visual feedback about what is occurringwhile telescoping. Refer to “Boom Telescope System”in this Section of this Operator's Manual.

13. Warning Message Area

The Warning Message Area displays text messages ofvarious alarms which may occur during normal opera‐tion of the system. When an alarm occurs, the rectan‐gular area fills in red.

14. Boom Length Display

The Boom Length Display gives a continuous indica‐tion of the boom length in feet (m). It is the distancefrom the centerline of the boom foot pin to the centerline of the boom head machinery.

15. Brightness Buttons

These buttons are used to adjust the display bright‐ness.

16. Load Radius Display

The Load Radius Display gives a continuous indicationof the radius of the load in feet (m). It is the horizontaldistance from the centerline of rotation to the centerlineof the hook.

17. Boom Angle Display

The Boom Angle Display gives a continuous indicationof the angle of the main boom relative to horizontal.

18. Boom Head Height Display

The Boom Head Height Display gives a continuous dis‐play of the height of the boom head shaft or attachmenthead shaft in feet (m) above ground level, that is thevertical distance from the ground to the working headshaft.

Operator's Manual


System Operation

The following is a list of procedures which are used tooperate the multiple features of the Rated CapacityLimiter. Use these procedures in conjunction with theprevious display unit control descriptions.

System Self‐Test

At start‐up the system automatically performs a self‐test after which all lamps, audible alarms, and digitaldisplays will be functionally tested and all memoryareas checked for accuracy. If faults in the system aredetected during a test, the warning message area willshow the words SYSTEM FAULT. If the words SYSTEMFAULT occur, press the Display/Select button to dis‐play the diagnostic screen. The diagnostic screen listsinformation about the fault condition by means of an er‐ror code. Contact your Link‐Belt Distributor for detailsof the fault codes.

Note: If the batteries have been disconnected inter‐rupting power to the computer, the start‐up time foron‐board computer systems will be longer thannormal.

System Bypass

In emergency situations, the Rated Capacity Limitercomputer can be bypassed. The computer is locatedon the back of the operator's cab. There is a RCL Sta‐tus keyswitch adjacent to the computer to bypass thesystem. Move the key to the “Bypass” position to by‐pass the system. For emergency use while the systemis bypassed, refer to “System Inoperative or Malfunc‐tioning” that follows.

WARNINGThe MicroGuard 540 is not operational whenthe computer is bypassed. Bypass thesystem in emergency situations only.

System Inoperative Or Malfunctioning

When operational aids are inoperative or malfunction‐ing, the following recommendations for continued useof the crane should be followed or the crane should beshutdown.1. Steps shall be taken to schedule repairs and recal‐

ibration immediately. The operational aids shall beput back into service as soon as replacementparts, if required, are available and the repairs andrecalibration can be carried out. Every reasonableeffort must be made to expedite the repairs and re‐calibration.

Figure 1-61Rated Capacity Limiter Computer

1. RCL Status Keyswitch 2. Computer

21

2. When the rated capacity limiter is inoperative ormalfunctioning, the designated person responsi‐ble for supervising the lifting operations shall es‐tablish procedures for determining load weightsand shall ascertain that the weight of the load doesnot exceed the crane ratings at the radius wherethe load is to be handled.

3. When a boom angle or radius indicator is inopera‐tive or malfunctioning, the radius or boom angleshall be determined by measurement.

4. When the anti‐two block warning device is inopera‐tive or malfunctioning, the designated person re‐sponsible for supervising the lifting operationsshall establish procedures, such as assigning anadditional signal person, to furnish equivalentprotection. This does not apply when lifting per‐sonnel in load line supported baskets. Personnelshall not be lifted in load line supported basketswhen the anti‐two block devices are not function‐ing properly.

5. When a boom length indicator is inoperative or mal‐functioning, the designated person responsible forsupervising the lifting operations shall establish theboom length at which the lift will be made by actualmeasurement or markings on the boom.

6. When a level indicator is inoperative or malfunction‐ing, other means shall be used to level the crane.

7. In situations where inconsistency exists, verifiedweights, measured radii, boom lengths, and au‐thorized crane capacities must always take prece‐dence over indicator readings.

Operator's Manual


Configuration Selection

In the normal operational mode the system is programmed to remember the last configuration selected. Each timethe system is powered up it will automatically default to that configuration. Only when the crane is rigged differentlymust a new configuration be selected. Use the following procedure to select the crane configuration.

Note: When selecting configurations allowed on outriggers, all beams must be equally extended; all fullyretracted, intermediate extended, or fully extended.

Depending on how the crane is equipped or which selections have been made, some screens shown may notappear or may not appear as illustrated. The system cannot be programmed for configurations not allowedby the capacity charts listed in the Crane Rating Manual.

Figure 1-62Carrier Selection

�

1. From the normal working screen press the CRANE SETUP button. The normal working screen will change andgraphically display the crane configurations that can be selected from the crane set up screen. Press the corre‐sponding configuration selection button to select the carrier configuration.

2. The crane setup screen will change and graphically display the carrier options. Press the corresponding config‐uration selection button to select the desired carrier configuration. If rigging is desired, refer to “To Select Rig‐ging Mode” in this Section of this Operator's Manual.

WARNINGThe MicroGuard 540 is not operational when in the RIGGING/TRAVEL Mode. Return the MicroGuard540 to normal operation before operating the crane.

3. Press the CRANE SETUP button to return to the crane setup screen.

Operator's Manual


Figure 1-63Counterweight Selection

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4. On the crane set up screen, press the corresponding configuration selection button to select the counterweightoptions. Press the corresponding configuration selection button to select the installed counterweight.


Figure 1-64Boom Extend Mode Selection

�

6. On the crane set up screen, press the corresponding configuration selection button to select the boom modeoptions. Press the corresponding configuration selection button to select the desired boom mode.

Note: Consult the Crane Rating Manual to determine the best boom mode to maximize lifting capacity atworking radius. Boom mode options will only be displayed when the boom is fully retracted and the tele‐scope cylinder unlatched from all boom sections.


Figure 1-65Auxiliary Head Selection

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8. On the crane set up screen, press the corresponding configuration selection button to display the auxiliary liftingsheave fitted or not fitted. Press the corresponding configuration selection button to select the desired auxiliarylifting sheave position.


Operator's Manual


Figure 1-66Nothing Erected Selection

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10. On the crane set up screen, press the corresponding configuration selection button to display the fly options.Press the corresponding configuration selection button to select the installed, erected fly, if required.a. If nothing erected is selected, the attachment screen will return to the crane setup screen.

Figure 1-67Erected Attachment Selection

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� �

b. If erected attachment is selected, the attachment screen will change and graphically display the availableattachments as required.

Figure 1-68Erected Attachment Offset Selection

c. If erected attachment is selected, the attachment screen will change and graphically display the availableoffsets as required.

d. Press the corresponding configuration selection button to select the installed offset angle.e. Press the CRANE SETUP button to return to the crane setup screen.

Operator's Manual


Figure 1-69Stowed Attachment Selection

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11. If the crane is equipped with a fly and was not selected as an erected attachment, press the correspondingconfiguration selection button to select Fly Jib. Press the corresponding configuration selection button to selectStowed Attachment. Press the corresponding configuration selection button to select the actual stowed attach‐ment.


Figure 1-70Winch Configuration

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13. Press the corresponding configuration selection button to select the winch configuration.

Figure 1-71Winch Selection

a. Press the corresponding configuration selection button to toggle between the front and rear winch until thewinch to be used is displayed.

Operator's Manual


Figure 1-72Lifting Point Selection

b. Press the corresponding configuration selection button to scroll through the available lifting points until theactual lifting point, for the winch selected, is displayed.

Figure 1-73Parts Of Line Selection

c. Press the corresponding configuration selection button to scroll through the available parts of line until theactual parts of line, for the winch selected, is displayed.

d. Repeat Steps a thru c for the other winch, if required.14. Press the CRANE SETUP button to return to the crane setup screen.

Note: A change to any selection can be made at anytime during the configuration routine. When at thecrane set up screen, simply press the desired configuration button to go directly to that sub‐routine.

15. Press the CRANE SETUP button to return to the normal working screen and graphically display the crane con‐figuration as previously selected.

Operator's Manual


Figure 1-74Normal Working Screen Examples

In this example the crane is setup on fully extended outriggers (1), boom mode EM2 (2),28,800 lb counterweight (3), fly base erected at 2 degree offset (4), fly tip stowed (5), therear winch available with the main boom head and the front winch selected (6), with thewinch wire rope reeved over the fly base (7), with one part of line (8), and 360 degree ca‐pacities with the boom currently positioned over the rear (9).

In this example the crane is setup on intermediate extended outrig‐gers (1), boom mode EM1 (2), 9,600 lb counterweight (3) 58' flystowed (4), the front winch available with the auxiliary head and therear winch selected (5), with the winch wire rope reeved over themain boom head (6), with three parts of line (7) and 360 degree ca‐pacities with the boom currently positioned over the rear (8).

119.0ft

6,700lbs max

500lbs

44.5

110.0ft

115.8ft

FULL EXT 28800 35' Fly@2 23' Tip

1

91.0ft

12,200lbs max

1000lbs

53.5

50.0ft

90.0ft

INT EXT 9600 58' Fly

3

1

2

3

4

5

67

8

9

1

2

3

4

56

7

8

Operator's Manual


Figure 1-75Normal Working Screen Examples

In this example the crane is setup for stationary on tires (1), boom modeEM1 (2), no counterweight (3), front winch not in use and the rear winchselected (4), winch wire rope reeved over the main boom (5), with threeparts of line (6), the 58' fly stowed (7) and directly over the front capaci‐ties with the boom currently positioned over the front (8).

In this example the crane is setup on fully retracted outriggers (1), boommode EM1 (2), 9,600 lb of counterweight (3), winch wire rope reevedover the main boom (4), 58' fly stowed (5), front winch not in use andthe rear winch selected (6), with three parts of line (7), and 360 degreecapacities with the boom currently positioned over the front (8).

83.0ft

4,600lbs max

500lbs

53.0

50.0ft

90.0ft

RETRACT 9600 58' Fly

3

43.0ft

2,900lbs max

250lbs

28.5

65.0ft

80.0ft

STATIONARY 0 58' Fly

36

5

2

3

1

4

8

7

7

4

2

3

1

6

8

5

Operator's Manual


To Select Rigging Mode

The CRANE SETUP push button is also used to selectRIGGING. This mode is used to facilitate rigging andtravel of the crane by inhibiting function limiters and theaudible alarm while selected. To resume crane opera‐tion, select proper outrigger or tire configuration perthe proper procedure.

WARNINGThe MicroGuard 540 is not operational whenin the RIGGING/TRAVEL Mode. Return the Mi‐croguard 540 to normal operation before op‐erating the crane.

1. From the normal working screen press the CRANESETUP button. The crane setup screen willchange and graphically display the carrier options.

2. Press the corresponding configuration selectionbutton to select RIGGING mode. Refer toFigure 1-76.

Cancel Audible Alarm And Reset Function Limiters

The CANCEL ALARM button is used to cancel theaudible alarm when the alarm has occurred as a resultof either an Overload, a Two Block alarm, a Wire RopeLimit, or an Operator Settable alarm. The audible alarmmay be canceled by pressing and releasing the CAN‐CEL ALARM button. The audible alarm remains can‐celed until the condition which caused the alarm hasbeen removed. For example, if the audible alarm wascanceled because of an overload condition, it will re‐main canceled until the overload condition is removed.However, if a different alarm, e.g. two block condition,was to occur when the audible alarm was still canceledfor an earlier overload condition, the new alarm condi‐tion would cause the audible alarm to be re‐started.

WARNINGOnce the function limiters have beenby‐passed, the crane is no longer protectedagainst the condition that initially caused thefunction limiters to occur.

Note: The CANCEL ALARM feature is a temporaryfunction. The audible alarm or function limit is auto‐matically reset when the condition which causedthe alarm is no longer present.

Figure 1-76Rigging Mode Selection

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Rigging ModeSelected

The CANCEL ALARM is also used to reset the functionlimiters when it is necessary to by‐pass the function limit‐ers which has occurred as a result of either an Overload,a Two Block alarm, or a Wire Rope Limit. Function limitersare reset by first canceling the audible alarm (as de‐scribed above) and then pressing and holding the CAN‐CEL ALARM button for about 3 seconds, after which thefunction limiters will be reset to allow normal operation.However, should another different alarm condition occurwhen the function limiters had previously been over‐rid‐den, then the newly occurring alarm condition wouldcause the function limiters to activate again.

Operator Settable Alarms

Some alarms occur automatically as a result of limita‐tions imposed by the capacity chart. The operator hascontrol over additional alarms which can be set to oper‐ate within the normal chart limitations which are in addi‐tion to, those already set by the chart.

Operator settable alarms will be stored in the computermemory, even if the crane is shutdown, until they arecleared. Refer to Figure 1-77.

Alarms which are available for operator use are:� Maximum and Minimum Boom Angle� Maximum and Minimum Head Height� Maximum and Minimum Load Radius� Maximum and Minimum Boom Length� Left and Right Swing� Operator Defined Area� First Layer/Third Wrap

Operator's Manual


Figure 1-77Operator Settable Alarms

1

�

WARNINGThe operator settable alarms are a warningdevice. All functions remain operational whenentering the operator defined bad area. Forsafe operation, adequate distance must bemaintained to allow for operator reaction timeto avoid entering the bad area. It is theresponsibility of the operator to set pointswhich ensure that the crane's boom,attachment, load, rigging, etc. maintains asafe working distance and complies with localsafety regulations.

Setting Angle, Length, Height, Radius, And SwingOperator Alarms1. From the normal working screen press OPERA‐

TOR ALARM button to access the Operator Set‐table Alarm screen.

2. Press the corresponding selection button to selectthe desired alarm to be set.

WARNINGAvoid positioning the boom, attachment, load,rigging, etc. into the bad area when setting thealarm values.

When selecting the alarm values, ensure thatthe load will maintain a safe distance from theobstacle.

3. Place the crane in the desired position dependingupon the alarm to be set. The numerical value dis‐played will be the current position of the crane.

Note: If an alarm had been previously set, thenumerical value displayed will be the previous‐ly set alarm value and indicated by the icon.The previous alarm must first be disabled, thenset the new alarm. Refer to “To Disable Opera‐tor Settable Alarms” in this Section of this Oper‐ator's Manual. Alarms which are disabled areindicated by the icon.

4. Press the corresponding selection button to set thealarm value.

5. When all alarm values are set, press the OPERA‐TOR ALARM button to return to the alarmscreen.

6. Press the corresponding selection button to setanother alarm if desired. When all desired alarmsare set, press the OPERATOR ALARM button toreturn the normal working screen.

7. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approachingthe alarm set point, the audible will sound intermit‐tently and a warning message will appear in thewarning message area. When exceeding thealarm set point, the audible alarm will sound con‐tinuously and a warning message will appear inwarning message area.

Note: An alarm icon will appear on the normalworking screen to alert the operator that an op‐erator alarm has been set.

8. Use the following examples to understand the useof the procedure.

Operator's Manual


Figure 1-78Boom Angle Alarm

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WARNINGIf crane or obstacle is moved or if a differentsize load is lifted, the alarm(s) must be reset.

WARNINGCheck the crane's current configuration,capacity chart, and Working Areas chart in theCrane Rating Manual to ensure safe, stableoperation under conditions described in thefollowing examples.

To Set Minimum Angle Alarm

Refer to Figure 1-78.

Example: To have an alarm whenever the boom isbelow a 30 degree angle, use the followingprocedure:

1. From the normal working screen, Press the OPER‐ATOR ALARM button to access the alarmscreen.

2. Press the corresponding button for Boom AngleLimits .

3. Move the boom to a 30 degree angle.4. Press the corresponding button for “Set Min Angle

at” to enter the alarm. The displayed value will bethe alarm setting. The will appear to indicatethat the alarm is set.

5. Press the OPERATOR ALARM button to returnto the alarm screen. Press the OPERATOR ALARM

button again to return to the normal workingscreen.

6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching

30 degree boom angle, the audible alarm willsound intermittently and “Minimum Angle” will ap‐pear in the warning message area. Whenever theboom is lowered to or below 30 degrees, the audi‐ble alarm will sound continuously and “MinimumAngle” will appear in warning message area.

To Set Maximum Angle Alarm


Example: To have an alarm whenever the boom isabove a 60 degree angle use the followingprocedure:

1. From the normal working screen press the OPER‐ATOR ALARM button to access the alarmscreen.

2. Press the corresponding button for Boom AngleLimits .

3. Move the boom to a 60 degree angle.4. Press the corresponding button for “Set Max Angle

at” to enter the alarm. The displayed value will bethe alarm setting. The will appear to indicatethat the alarm is set.



6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching60 degree boom angle, the audible will sound in‐termittently and “Maximum Angle” will appear inthe warning message area. The audible alarm willsound continuously whenever the boom is raisedabove 60 degrees and “Maximum Angle” will ap‐pear in warning message area.

Operator's Manual


Figure 1-79Boom Length Alarm

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To Set Minimum Length Alarm


Example: To have an alarm whenever the boom length isretracted to 60 feet (18.3m) or less, use thefollowing procedure:

1. Press the OPERATOR ALARM button to accessthe alarm screen.

2. Press the corresponding button for Boom LengthLimit .

3. Retract the boom so that the length is 60 feet(18.3m).

4. Press the corresponding button for “Set MinLength at” to enter the alarm. The displayed valuewill be the alarm setting. The will appear to in‐dicate that the alarm is set.



6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When retracting to60 foot (18.3m) boom length, the audible alarm willsound intermittently and “Minimum Length” willappear in the warning message area. The audiblealarm will sound continuously whenever the boomlength is retracted to 60 feet (18.3m) or less and“Minimum Length” will appear in the warning mes‐sage area.

To Set Maximum Length Alarm


Example: To have an alarm whenever the boom lengthexceeds 75 feet (22.9m), use the followingprocedure:


2. Press the corresponding button for Boom LengthLimit .

3. Extend the boom so that the length is 75 feet(22.9m).

4. Press the corresponding button for “Set MaxLength at” to enter the alarm. The displayed valuewill be the alarm setting. The will appear to in‐dicate that the alarm is set.



6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching75 foot (22.9m) boom length, the audible alarm willsound intermittently and “Maximum Length” willappear in the warning message area. The audiblealarm will sound continuously whenever the boomlength exceeds 75 feet (22.9m) and “MaximumLength” will appear in the warning message area.

Operator's Manual


Figure 1-80Boom Height Alarm

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To Set Minimum Height Alarm


Example: To have an alarm whenever the boom tip heightis lowered to 30 feet (9.1m) or less, use thefollowing procedure:


2. Press the corresponding button for Boom HeightLimit .

3. Lower the boom and/or adjust the boom angle sothat the tip height is 30 feet (9.1m).

4. Press the corresponding button for “Set MinHeight at” to enter the alarm. The displayed valuewill be the alarm setting. The will appear to in‐dicate that the alarm is set.



6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching30 foot (9.1m) boom tip height, the audible alarmwill sound intermittently and “Minimum Height” willappear in the warning message area. The audiblealarm will sound continuously whenever the boomtip height exceeds 30 feet (9.1m) and “MinimumHeight” will appear in the warning message area.

To Set Maximum Height Alarm


Example: To have an alarm whenever the boom tip heightexceeds 75 feet (22.9m), use the followingprocedure:


2. Press the corresponding button for Boom HeightLimit .

3. Extend the boom and/or adjust the boom angle sothat the tip height is 75 feet (22.9m).

4. Press the corresponding button for “Set MaxHeight at” to enter the alarm. The displayed valuewill be the alarm setting. The will appear to in‐dicate that the alarm is set.



6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching75 foot (22.9m) boom tip height, the audible alarmwill sound intermittently and “Maximum Height”will appear in the warning message area. The au‐dible alarm will sound continuously whenever theboom tip height exceeds 75 feet (22.9m) and “Maxi‐mum Height” will appear in the warning messagearea.

Operator's Manual


Figure 1-81Load Radius Alarm

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To Set Minimum Radius Alarm


Example: To have an alarm whenever the boomradius is 45 feet (13.7m) or less, use thefollowing procedure:


2. Press the corresponding button for Load Radius Li‐mit .

3. Retract the boom and/or adjust the boom angle sothat the radius is 45 feet (13.7m).

4. Press the corresponding button for “Set Min LoadRadius Limit at” to enter the alarm. The displayedvalue will be the alarm setting. The will appearto indicate that the alarm is set.



6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching45 foot (13.7m) boom radius, the audible will soundintermittently and “Minimum Radius” will appear inthe warning message area. The audible alarm willsound continuously whenever the boom radius is45 feet (13.7m) or less and “Minimum Radius” willappear in warning message area.

To Set Maximum Radius Alarm


Example: To have an alarm whenever the boomradius exceeds 95 feet (29m), use thefollowing procedure:


2. Press the corresponding button for Load Radius Li‐mit .

3. Extend the boom and/or adjust the boom angle sothat the radius is 95 feet (29m).

4. Press the corresponding button for “Set Max LoadRadius Limit at” to enter the alarm. The displayedvalue will be the alarm setting. The will appearto indicate that the alarm is set.



6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching95 foot (29m) boom radius, the audible will soundintermittently and “Maximum Radius” will appear inthe warning message area. The audible alarm willsound continuously whenever the boom radius ex‐ceeds 95 feet (29m) and “Maximum Radius” willappear in warning message area.

Operator's Manual


Figure 1-82Swing Alarm

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To Set Left And Right Swing Alarms


Example: To have an alarm whenever the LEFTSWING AND RIGHT SWING exceedpre‐determined alarm points, use thefollowing procedure:


2. Press the corresponding button for More Options.3. Press the corresponding button for Swing Limits

.

Note: Both the left and right swing alarms mustbe set for the system to determine the operatorset working area.

4. Swing the boom to the left alarm point.5. Press the corresponding button for “Set Left Swing

at” to enter the left alarm point. The displayed val‐

ue will be the left alarm setting. The will appearto indicate that the alarm is set.

6. Swing the boom to the right alarm point.7. Press the corresponding button for “Set Right

Swing at” to enter the right alarm point. The dis‐played value will be the right alarm setting. The will appear to indicate that the alarm is set.



9. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approachingthe set alarm point, the audible alarm will sound in‐termittently and “Swing Alarm” will appear in thewarning message area. The audible alarm will acti‐vate whenever the swing exceeds the alarm pointsand “Swing Alarm” will appear in warning messagearea.

Operator's Manual


Figure 1-83First Layer/Third Wrap Alarm

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or�

First Layer/Third Wrap Alarm (If Equipped)

The crane may be equipped with a first layer/third wrapalarm indicator system for the winch drum(s). Whenthe system is enabled, the audible alarm will sound in‐termittently, and “First Layer” will appear in the warningmessage area to alert the operator when the wire ropeis down to the first layer on the winch drum(s). The au‐dible alarm will sound continuously and “Third Wrap”will appear in warning message area to alert the opera‐tor when the wire rope is down to the third wrap on thewinch drum(s).


1. Press the OPERATOR ALARM button to access thealarm screen.

2. Press the corresponding button for More Options.3. Press the corresponding button for First Layer or

Third Wrap until the word “Enabled” appears.4. Press the OPERATOR ALARM button to return

to the alarm screen. Press the OPERATOR ALARM button again to return to the normal working

screen.5. Select the winch drum to monitor by using the

winch drum selector switch located on the gaugeand control panel. Refer to Figure 1-37.

Operator's Manual


Figure 1-84Operator Defined Area Alarm

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Operator Defined Area Alarm


The operator defined area alarm, when set, will definean imaginary vertical plane between two set points tooptimize the working area. When approaching theplane, the audible alarm will sound intermittently, andthe message “Bad Working Area” will appear in thewarning message area. When passing the plane, theaudible alarm will sound continuously and the mes‐sage “Bad Working Area” will appear on the warningmessage area. Use the following procedure,Figure 1-84, and Figure 1-85 to set the operator de‐fined area alarm.

WARNINGThe operator defined area alarm is a warningdevice. All functions remain operational whenentering the operator defined bad area. Forsafe operation, adequate distance must bemaintained to allow for operator reaction timeto avoid entering the bad area. It is theresponsibility of the operator to set pointswhich ensure that the crane's boom,attachment, load, rigging, etc. maintains asafe working distance and complies with localsafety regulations.

Operator's Manual


Setting Operator Defined Area Alarm1. From the normal working screen press the OPER‐

ATOR ALARM button to access the OperatorAlarm screen.

2. Press the corresponding button for More Options.3. Disable any previously set left and right swing

alarms if required. Refer to “To Disable OperatorSettable Alarms” in this Section of this Operator'sManual.

Note: The left and right swing alarms must becleared prior to setting the defined area alarm.

4. Press the corresponding button for Defined AreaAlarm .

WARNINGAvoid positioning the boom, attachment, load,rigging, etc. into the bad area when setting theleft or right alarm points.

When selecting the left and right alarm points,ensure that the load will maintain a safedistance from the obstacle. Also ensure thatthe two points are set so that the tailswing ofthe crane will not enter the bad area.

Note: For best results, the two points should beseparated by a minimum of 10 ft (3m) or 30 de‐grees.

5. Position the boom, attachment, load, rigging, etc.to the left alarm point and press the correspondingbutton for “Set Left Area at” to enter the left alarmpoint. The displayed value will be the left alarm set‐ting. The will appear to indicate that the leftalarm point is set.

6. Position the boom, attachment, load, rigging, etc.to the right alarm point and press the correspond‐ing button for “Set Right Area at” to enter the rightalarm point. The displayed value will be the rightalarm setting. The will appear to indicate thatthe right alarm point is set.

7. When both alarm points are set, press the OPERA‐TOR ALARM button to return to the alarmscreen. Press the OPERATOR ALARM buttonagain to return to the normal working screen.

8. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approachingthe plane, the audible alarm will sound intermittent‐ly and the message “Bad Working Area” will ap‐pear on the warning message area. When passingthe plane, the audible alarm will sound continuous‐ly and the message “Bad Working Area” will ap‐pear on the warning message area.

WARNINGIf crane or obstacle is moved or if a differentsize load is lifted, the area alarm must bereset.

To Disable Operator Settable Alarms1. From the normal working screen press the OPER‐

ATOR ALARM button to access the OperatorAlarm screen.

2. Press the corresponding selection button to selectthe desired alarm to be disabled.

3. Press the corresponding button for each alarm.The icon indicates the alarm has been cleared.

4. When all alarms are disabled press theDISPLAY/SELECT button to return to the alarmscreen.

Operator's Manual


Figure 1-85Operator Defined Area Alarm

Operator's Manual


Figure 1-86Typical Crane Attachment Setup (Provided for correct identification of attachments)

5

4

2

1

1. Offset Lattice Fly Tip Section2. Offset Lattice Fly Base Section3. Fly Extension With Sheaves4. Fly Extension Without Sheaves5. Auxiliary Lifting Sheave6. Five Section Boom7. Front Winch8. Rear Winch

7 8

3

6

Operator's Manual


Figure 1-87Time Date Setup

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Access Code Required.Contact Distributor.

Time Date Setup

Access code required. Contact your Link‐Belt Distrib‐utor.

Operator's Manual


Figure 1-88Left Console Warning Label

To prevent personal injury do not attemptto enter the operator's cab prior to raisingthe left console stand.

WARNING

Entering And Exiting TheOperator's CabEntering or leaving the operator's cab could be hazard‐ous if certain aspects are not taken into consideration.The elevation of the carrier deck and operator's cabalone could cause serious injury if someone was to fall.For this reason ladders are mounted on each side ofthe carrier to provide easy access to the carrier deckand operator's cab. Numerous hand grips are also at‐tached to the cab as well as non‐skid safety strips onthe surface of the carrier deck, to provide safe entry tothe cab. Use these features to make climbing on thecrane as safe as possible. Remain in three point con‐tact with the crane at all times (two hands and one footor two feet and one hand).

One more feature which is available to ease entry andexit of the operator's cab, is the adjustable operator'sseat. Move the seat back as required to allow safe en‐try. The release lever on the forward left hand side ofthe seat allows movement of the seat forward andbackward. This feature also provides operator comfortduring crane operation. Refer to “Operator's Seat” inthis Section of this Operator's Manual for completeseat operating instructions.

Inside the cab two separate features are provided toprevent accidental operation of the hydraulic controlswhile entering or exiting the operator's seat.

1. Function Lockout SwitchThis switch is used to disable the hydraulic func‐tions which are operated by the control levers andboom telescope foot pedal. The switch is locatedon the RCL console. Refer to Figure 1-37. Movethe switch to the “DISABLE” position to prevent in‐advertent operation of these controls. To allow nor‐mal operation of the control levers and the boomtelescope pedal, move the function lockout switch

to the “OPERATE” position. This switch must al‐ways be moved to the “DISABLE” position beforeentering or exiting the operator's seat.

2. Movable Left Side ConsoleThe left side console is hinged at the rear to allowthe operator to pivot the console up, out of the waywhile entering or exiting the upper cab. A springassists movement of the console.

Lifting the left arm rest enables the console to pivotup, out of the way for ease of entry and exit. It alsoperforms the same duty as the function lockoutswitch, described above, disabling all hydraulicfunctions related to the control levers and boomtelescope foot pedal. Make sure the side consoleis rotated up, out of the way before attempting toenter or exit the upper cab.

Break‐In PeriodOperate a new crane at half throttle for the first twenty(20) hours of operation. A break‐in period under mod‐erate loads will assist in providing long, trouble‐freeperformance.

Before Starting OperationsBefore starting daily operations, make the followingchecks and inspections:

Engine

Check fuel, oil, and cooling systems for proper fluid lev‐els. Check for leaks. Repair or fill as required. Refer toengine manufacturer's manual for additional details.

Gear Cases

Visually inspect all gear cases for leaks or damage. Ifleaks or damage exist, repair and fill case to proper lu‐brication level.

Hydraulic System

Check all hoses for chafing, bulging, or other damage.Replace as necessary. Inspect hydraulic system for ex‐ternal leaks. Repair as needed. Check hydraulic reser‐voir oil level. Add oil if necessary.

Lubrication

Lubricate the crane as outlined in Section 2 of this Op‐erator's Manual.

Note: Operators may have nothing to do with lubri‐cation or maintenance of the crane, but it could beadvantageous for them to be familiar with it. Knowl‐edge of preventive maintenance makes the opera‐tor more aware of malfunctions in the crane so re‐pairs can be made with a minimum of downtime.

Operator's Manual


Tires And Rims

Check tire inflation. Inflate to pressures per the “TireInflation” label on the hydraulic reservoir or the TireInflation Chart in the Crane Rating Manual. Checkwheel lug nut torque, each day, for the first five (5) daysof operation and every 100 hours of operation thereaf‐ter. Refer to Section 3 of this Operator's Manual for ad‐ditional information on tires and rims.

Wire Rope And Sheaves

Inspect all wire rope and sheaves for damage or dete‐rioration. Replace as necessary. Refer to Section 3and Section 5 of this Operator's Manual for additionalinformation on wire rope.

General Inspection

Visually inspect the entire crane for loose or missingcotter pins or bolts, or damaged fly chords or lattices.Check for oil or fluid leaks. Make repairs as needed.

Electrical System

Check the operation of all lights, windshield wipers,horns, turn signals, etc. Repair as needed.

Brakes

Start the engine and check park brake and servicebrake operations. Adjust or repair as needed.

Controls

Check all controls for proper operation and adjust‐ment. Repair as needed.

Fire Extinguisher

A fire extinguisher is located in the operator's cab un‐der the left console. Refer to Figure 1-45. It is an A B Ctype fire extinguisher, meaning it is capable of extin‐guishing most types of fires. The operator should befamiliar with its location, the clamp mechanism used tosecure it in place, and foremost the operation of the de‐vice. Specific instructions, regarding operation, aregiven on the label attached on the fire extinguisher. Acharge indicator on the fire extinguisher monitors thepressure within the tank. Check the indicator daily toensure the fire extinguisher is adequately charged andready for use.

Carrier Suspension

Check that the oscillation suspension is properly adjus‐ted and functioning normally. Refer to “SuspensionHeight Adjustment” in this Section of this Operator'sManual. During pick and carry operations and/or whentraveling the crane, damage to the axles, cylinders, andother suspension components can occur if the oscillationsuspension is not properly adjusted. Oscillation cylin‐ders which are not properly adjusted can leave suspen‐sion components unprotected from shock loads whichcan lead to major crane damage.

Boom Distortion Due To Thermal EffectsOf The SunThe heat from the sun may have a thermal effect on thesides of telescopic booms causing the sides of theboom to expand (lengthen). The sides of the boommay not expand equally if the boom is extended forlong periods of time with only one side of the boom ex‐posed to the sun. The unequal expansion may causeboom distortion (the boom may “deflect” to one side).This is more noticeable with long boom lengths and/orlong booms with long lattice flys attached to the boom.

For example, a 100 ft (30.5m) main boom, with a 50°F(10°C) temperature differential between the two sidesof the boom, may cause the centerline of the mainboom head to “deflect” as much as 3 ft (0.9m) off thecenterline of the crane. Attaching a 50 ft (15.2m) latticefly to the same boom may cause the centerline of the flyhead to “deflect” as much as 10 ft (3.0m) off the center‐line of the crane. This “deflection” to one side creates a“side load” on the boom and/or fly. Side load on aboom or fly, whether induced by the load or thermal ef‐fects, is dangerous and shall be avoided.

Prior to lifting any loads, inspect the boom or boom andfly combination to ensure they are straight. If the boomor boom and fly combination is not straight, ensure thatall the boom wear pads are properly adjusted.

If the boom is distorted due to temperature differentialon the sides of the boom, reposition the boom to allowthe thermal effects from the sun to equalize the temper‐atures of the side walls of the boom to eliminate the dis‐tortion before lifting a load.

Operator's Manual


Engine Starting Procedure

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

Before attempting to start the engine, the operator shouldcarefully read and understand the engine startinginstructions in the engine manufacturer's manual andthis Operator's Manual. Attempting to start or run theengine before studying these instructions may result inengine damage. The operator should learn and obey allapplicable “Rules of the Road” and if not already acompetent driver, obtain instructions to attain thesenecessary skills. With the crane fully serviced and theoperator familiar with all gauges, switches, controls, andhaving read and fully understood this entire manual, startthe engine using the following procedures:

WARNINGDiesel exhaust fumes can beharmful. Start and operateengine in a well ventilated area.If it is necessary to operate in anenclosed area, vent the exhaustto the outside. Properlymaintain the exhaust system toits original design.

1. Walk around the crane to verify that there are nopersons under, or in close proximity to the crane.

2. Engage the park brake.3. Shift the transmission to neutral. (Engine will not

start unless the transmission is in neutral.)4. Sound the horn twice in succession, wait 10-15

seconds while making a visual check to verify thatthere are no persons under or in close proximity tothe crane.

5. Turn the ignition switch to the on position to ener‐gize the engine electrical system.

6. If required, allow the Wait To Start indicator light togo out.

7. Turn the ignition switch to the start position. Re‐lease the ignition switch immediately after the en‐gine starts. If the engine fails to start in 30 seconds,release the ignition switch and allow the starter mo‐tor to cool a few minutes before trying to startagain. If the engine fails to start after four attempts,refer to the engine manufacturer's manual for in‐structions.

8. Warm Up - Run the engine at low throttle with noload while engine is warming up. Observe the fol‐lowing instruments for proper indications.a. Engine Oil Pressure - If there is no oil pressure

after the engine runs 10-15 seconds, shut‐down the engine immediately and repair theproblem to avoid major engine damage. Referto engine manufacturer's manual for proper oilpressure operating range.

b. Coolant Temperature Gauge - Observe thecoolant temperature gauge to ensure engineis warming up to the proper operating temper‐ature. For proper cooling system operatingtemperature range, refer to the engine manu‐facturer's manual.

c. Battery Gauge - Observe indicator to ensurebattery and electrical system is working prop‐erly. The gauge should indicate 12.5 to 14.0volts while engine is running. (It should read12.0 volts when the key is on, without the en‐gine running.)

9. When the engine has thoroughly warmed up, afterall pressures and temperatures are within operat‐ing ranges, and all daily checks have been made,the crane is ready for operation.

Engine Shutdown Procedure1. Fully lower the boom and lower any load to the

ground and properly secure it.2. Engage the travel swing lock.3. Throttle the engine back to idle.4. Shift the transmission to neutral and engage the

park brake.5. Turn the ignition switch to the “OFF” position.6. Remove the ignition keys from the cab and lock the

door if the crane is to be left unattended.

Operator's Manual


Cold Engine StartingTo help ignition in cold ambient conditions, glow plugsare used to warm the cylinders prior to starting the en‐gine. This improves combustion efficiency which aidsin starting a cold engine. With the key in the ON posi‐

tion, the ECM senses ambient air temperature then de‐termines if the glow plugs must be energized to warmthe cylinders. A “Wait To Start” indicator light will illumi‐nate to alert the operator not to crank the engine be‐cause the combustion chamber is too cold for fuel igni‐tion. Refer to Figure 1-37 for location of indicator light.When the cylinders are warm enough to ignite the firstcharges of fuel, the indicator light will go out and the en‐gine can be started.

DANGERDo not use starting fluids to aid in engine startup. This engine is equipped with a glow plugtype cold starting aid and use of a startingfluid can cause an explosion resulting insevere personal injury or death.

Figure 1-89Starting Fluid Warning Label

WARNING

Operator's Manual


Figure 1-90Electric Engine Block Preheater

1. Preheater Cord

1

Electric Engine BlockPreheaterThe electric engine block preheater uses electricalpower to heat the coolant and circulate it through theengine during cold ambient conditions. The electricengine block preheater power cord is located on theright side of the engine. Refer to Figure 1-90.

To Start The Electric Engine Block Preheater1. Park crane in suitable area for storage, engage the

park brake, shift the transmission to neutral, andshutdown the engine.

2. Plug preheater cord into 110V to120V electricalsource.

WARNINGAreas adjacent to the preheater must be cleanand free of oil and debris to avoid possible firehazard.

Note: Unplug the engine block preheater beforestarting the engine.

To Stop Electric Engine Block Heater1. Unplug preheater cord from electrical source.

Operator's Manual


Figure 1-91Battery Cable Connections

1. Negative Terminal2. Positive Terminal

1

2

- +-

+

Jump Starting The CraneThe crane has two (2) 12V batteries located in the bat‐tery box at the rear of the crane.

WARNINGTo avoid serious personal injury and/orequipment damage, follow these proceduresin the order they are given.

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

Wear protective clothing and shield your faceand eyes when working around batteries.Batteries contain sulfuric acid which burnsskin, eyes, and clothing.

Do not jump start a damaged battery. Be surevent caps are tight and level. If anothervehicle is used, be sure booster vehicle andcrane are not touching.

The gases around the battery can explode ifexposed to open flames or sparks. Anexplosion could result in serious personalinjury and/or equipment damage.

1. Check all battery terminals and remove any corro‐sion before attaching jumper cables.

2. Connect one end of the first jumper cable to the12V positive (+) terminal of the discharged battery.

3. Connect the other end of the first cable to the 12Vpositive (+) terminal of the 12V power source orbooster battery.

4. Connect one end of the second jumper cable to thenegative (-) terminal of the 12V power source orbooster battery.

5. Connect the other end of the second cable to aground location on the carrier frame as far awayfrom crane batteries as possible.

6. If another vehicle is used to jump start the crane,start the booster vehicle. Make sure booster ve‐hicle and crane are not touching. Run the boostervehicle's engine at a moderate speed.

7. Start the disabled crane. After the crane is started,remove jumper cables in reverse order.

8. Let the crane's engine run for a few minutes tocharge the discharged batteries.

9. Check the battery gauge in the operator's cab.The gauge reading should be increasing toward14 volts.

Note: If the batteries are at very low charge,voltage may increase slowly. If voltage doesnot increase, replace the batteries and/or checkthe electrical system.

Operator's Manual


Crane OperationCranes are used primarily for making heavy lifts. In or‐der to do this properly, certain procedures must be fol‐lowed. The following is a suggested procedure formaking typical lifts:

Note: Before operating the crane near airports, radioand microwave towers, power lines, etc., always con‐sult and comply with all local, state, and federal laws.

1. Determine the weight to be lifted. Be sure to addthe weight of the hook block and/or hook ball,slings, rigging, fly, etc. Determine height to whichthe load must be lifted.

2. Consult the capacity chart, Working Areas andWorking Range charts in the Crane Rating Manualin the operator's cab. Find the shortest boomlength and load radius that will accomplish the job.

3. Position the crane so a minimum swing is neces‐sary. Do not swing the upper over areas not cov‐ered on the capacity chart in the Crane RatingManual, as the crane could tip, even without a loadon the hook in these areas.

4. The crane must be supported by a firm, solid levelsurface before starting to lift. All capacities in theCrane Rating Manual are based on the crane beinglevel in all directions. If the crane is not level, outswing or side swing of the load will greatly reducelifting capacities and could cause crane damage oran accident. If the ground is soft, use mats.

5. If outriggers are used, the following points must beobserved:a. The outrigger beams must all be equally ex‐

tended (all fully retracted, intermediate ex‐tended, or fully extended) to lift the loadsshown in the Crane Rating Manual. Major re‐ductions in lifting capacity will result if beamsare not in the same position and this could leadto serious crane damage or an accident.

b. Outrigger pontoons must be on solid, smoothfooting, flush with the ground (no hills, or val‐leys under pontoons), otherwise pontoonsmay be damaged or destroyed. If there is anydoubt, use mats.

c. All capacities listed for the crane on outriggersare based on the outrigger jacks being used toraise the crane so that all tires are clear of theground and the crane is level. A bubble level isprovided in the operator's cab to assist the op‐erator in leveling the crane.

6. When making lifts on tires, the following pointsmust be observed:

a. All tires must be inflated to pressures as listed onthe Tire Inflation Label located on the hydraulicreservoir or in the Crane Rating Manual.

b. On tire lifts are to be made from the main boomonly. Do not use the auxiliary lifting sheave or fly.

c. Lifts while on tires must be from firm level sur‐face. Use mats and/or grade the supportingsurface as required to ensure safe lift.

7. Raise the boom and swing over the load. Extendthe boom to the desired length.

8. Lower the hook block and/or hook ball and fasten itonto the load. The following points must be observed:a. The boom peak must be directly above the

load. Booms are made to lift, and must neverbe used to drag a load sideways.

b. Always use chains, wire ropes, or slings of amplesize and make periodic checks of their condition.

c. Always use sufficient parts of line. ConsultWire Rope Capacity chart in the Crane RatingManual in the operator's cab for the number ofparts of line needed for a given lift.

d. When lifting loads, care should be taken to pre‐vent sudden loading or unloading of the winchwire rope. Ease into the load. Lift the load afew inches (centimeters) off the ground andhold to check the winch brakes.

9. Lift the load to the desired height. Boom to the de‐sired angle. Be careful when booming down or ex‐tending the boom, as these increase the load ra‐dius and result in a decrease in capacity. Makesure the load being lifted remains within the liftingcapacity of the crane at the boom length and ra‐dius being used.

10. Control the load at all times. Use hand lines toguide the load. Do not guide loads into place withyour hands. Swing slowly and smoothly. Avoidjerks when starting or stopping swings.

11. If the crane is to travel with a suspended load, referto “Pick And Carry Operation” in this Section of thisOperator's Manual for further instructions.

During OperationThe operator must remain alert to possible malfunc‐tioning of the crane while operating. If the crane doesmalfunction, lower the load and shutdown the craneuntil the problem is found and corrected. During op‐eration, the operator must:1. Remain alert to any noise, loss of power, or bad re‐

sponse to control of the crane. Watch the engineoil pressure and coolant temperature gauges forproper operating ranges.

Operator's Manual


Figure 1-92Hand Signals

permission of the Publisher the American Society of Mechanical Engineers, 345 E. 47th Street, New York, New York 10017.

USE WHIP LINE

MOVE SLOWLY

TRAVEL

RAISE BOOM

LOWER THE LOAD

DOG EVERYTHING

LOWER

LOWER BOOM

RAISE THE LOAD

EMERGENCY STOP

USE MAIN HOIST

SWING

(Telescoping booms)

(One track)

STOP

(Both tracks)TRAVEL TRAVEL

EXTEND BOOM

(Telescoping booms)EXTEND BOOM

(Telescoping booms)RETRACT BOOM

(Telescoping booms)RETRACT BOOMRAISE THE BOOM AND LOWER THE BOOM AND

HOIST

Extracted from the American National Standard, Crawler, Locomotive and Truck Cranes, ANSI B30.5b-1985, with the

2. Watch the hydraulic system oil temperaturegauge. If the temperature exceeds maximum tem‐perature, shutdown the crane until the problem iscorrected. (Refer to Section 2 of this Operator'sManual for the maximum temperature for each vis‐cosity of hydraulic oil.)

3. Listen for any unusual noises in the hydraulic system,power train, gear boxes. If any, correct problem.

4. Watch for oil leaks or any loss of control. If any de‐velop, correct before continuing operation.

5. Make sure all controls work freely and easily, with nosticking or binding. Lubricate or adjust as necessary.

6. If working on outriggers, periodically check theoutriggers to make sure the crane is level and sta‐ble. If working on tires, make sure the tires are in‐flated to the proper pressure. (Refer to the Tire

Inflation Label or the Crane Rating Manual forproper tire pressure.)

7. Heed all DANGER, WARNING, and CAUTION la‐bels. Observe good safety practices at all times.

Hand SignalsHand Signals are important for communications be‐tween the designated signalman and the operator. Ahand signal chart, Figure 1-92, is included in this Sec‐tion of this Operator's Manual. A copy is also locatedon the right side window in the operator's cab.

These signals should be used at all times unless voiceinstructions with a radio or telephone are being used.One person should be designated as a signalman andtheir signals obeyed by the operator. Obey a stop sig‐nal from anyone.

Operator's Manual


Pick And Carry OperationTravel during pick and carry operations is restricted tospeeds of 2.5 mph (4km/h) or less, and creep, on afirm, level surface. Creep is defined as crane move‐ment limited to 200 ft (61m) in a 30 minute period andnot to exceed 1mph (1.6km/h) maximum speed. Liftsare to be made off the main boom only, with the craneprepared as follows:1. Ensure that the suspension has been adjusted to

the proper travel height. Refer to “SuspensionHeight Adjustment” in this Section of this Operat‐or's Manual.

2. Inflate the tires to the required pressure listed onthe Tire Inflation Label or the Tire Inflation chart inthe Crane Rating Manual.

3. Do not exceed On Tires, Pick And Carry capacities.Refer to Creep or 2.5 mph (4km/h) capacity chartsin the Crane Rating Manual.

4. Level the crane on fully extended outriggers withthe tires clear of the ground.

5. Position upper over front of the carrier and engagethe travel swing lock. Release the swing parkbrake and the 360° swing lock if equipped.

CAUTIONDo not leave the swing park brake or 360°swing lock, if equipped, in the engagedposition during pick and carry operations.Failure to release these devices during thisoperation may result in damage to the swingspeed reducer.

6. Boom must be extended in accordance with boommode EM1.

7. Properly store the fly base and tip, if equipped.8. Retract all outrigger jacks just clear of the ground

but leave the outrigger beams fully extended.9. Attach as many hand lines as necessary to prevent

the load from swinging during travel.10. Carefully attach the load to the winch wire rope and

lift it only as high as necessary.11. Carefully travel at no more than 2.5 mph (4km/h)

depending on chart selection. Take extra care dueto the increased overall width caused by the ex‐tended outrigger beams. The outriggers or pon‐toons must not be allowed to hit any obstructions.Maintain a safe distance from all personnel and ob‐structions. Travel only on a firm, level surface.

12. Once the desired destination is reached, shift thetransmission to neutral and apply the park brake.

Operator's Manual


Jobsite Travel, No LoadUpper Over the Front, Boom Retracted

2.5 MPH (4.0km/h) Maximum

Counterweight (lb)

Installed on Upper

Maximum Boom Angle (°)

35-58 Ft FlyStored

35 Ft Fly Erected(2° Offset)

58 Ft Fly Erected(2° Offset)

74-90 Ft Fly Erected(2° Offset)

0 45 45 45 PROHIBITED

9,600 45 45 45 PROHIBITED

19,200 45 45 45 PROHIBITED

28,800 40 40 40 PROHIBITED

Traveling The CraneCertain conditions must be met for safe travel. Refer tothe following procedures before traveling the crane.

WARNINGDo not use 4‐wheel, crab, or rear wheel steermode for extended or high speed travel assteering behavior may be unfamiliar and aloss of crane control could occur.

Do not travel with upper over the side. Posi‐tion upper over the front and engage the travelswing lock. Crane may tip over causing per‐sonal injury and/or crane damage.

Job Site TravelJob site travel is limited to speeds less than 2.5 mph(4km/h). The crane may be traveled on the job site withno load per the following procedure:1. Ensure that the suspension has been adjusted to


2. Inflate the tires to pressure listed on the Tire Infla‐tion Label or the Tire Inflation chart in Crane RatingManual for 2.5 mph (4km/h) maximum speed.

3. Level the crane on fully extended outriggers.4. If traveling on a firm, smooth, and level surface,

position the upper and attachments according tothe “Job Site Travel” chart in this Section of this Op‐erator's Manual Do not move the boom duringtravel.

5. If traveling on a slope, travel directly up or down theslope. Position the upper over the front of the carri‐er with the boom fully retracted and at 0°. The flybase and tip stored.

6. Engage the travel swing lock. Release the swingpark brake and the 360° swing lock if equipped.

CAUTIONDo not leave the swing park brake or 360°swing lock, if equipped, in the engagedposition during pick and carry operations.Failure to release these devices during thisoperation may result in damage to the swingspeed reducer.

7. Fully retract all outrigger jacks and beams.

CAUTIONWhen the hoist line is tied off to the crane orany solid object, do not extend the boom,raise or lower the boom, or raise the crane onoutriggers. The winch system could beoverloaded causing major winch or cranedamage.

8. Secure hook block and/or hook ball to prevent ex‐cessive swinging.

9. Carefully travel at no more than 2.5 mph (4km/h).Maintain a safe distance from all obstructions,structures, and power lines.

10. Once the desired destination is reached, shift thetransmission to neutral and apply the park brake.

Operator's Manual


Figure 1-93Travel Speed Limitation Label

TRAVEL SPEEDSMAX

SPEED(MPH)

GEAR

1.42.97.6

123

CAUTION

4.08.119.8

2-WHEEL DRIVE

4-WHEEL DRIVE123

Do not exceed 5 mph travel speed withcounterweight configurations of 0 lb. &28,800 lb. Failure to comply with thislimitation may result in crane damage.

Highway TravelHighway travel is considered to be any travel of thecrane over 2.5 mph (4km/h). The following conditionsand precautions must be met for any highway travel.1. If equipped, the fly base and tip must be secured in

the stored position on boom.2. The boom must be over the front of the crane with

the travel swing lock engaged. Release the swingpark brake and the 360° swing lock if equipped.

CAUTIONDo not leave the swing park brake or 360°swing lock, if equipped, in the engaged posi‐tion during pick and carry operations. Failureto release these devices during this operationmay result in damage to the swing speed re‐ducer.

3. All boom sections must be fully retracted with theboom at 0°. Secure the hook block and/or hookball to prevent excessive swinging.


4. All outriggers must be fully retracted (jacks andbeams) with all pontoons removed from jacks andstored properly.

5. The drive train must be set to 2‐Wheel drive and thesteering selection switch in the conventional steermode.

6. Disengage the main hydraulic pump if equipped.7. Ensure that the suspension has been adjusted to


8. Check all tires for correct pressure, adjust if re‐quired. Refer to the Tire Inflation label located onthe hydraulic reservoir or Tire Inflation Chart in theCrane Rating Manual.

9. During highway travel there must be at least a 30minute rest period for every 50 miles (80km) of driv‐ing or 2 hours of sustained operation whichever oc‐curs first and a 60 minute rest period after 4 hoursof operation.

10. Obey all “Rules of the Road” and travel carefully.

Operator's Manual


Counterweight Removal AndInstallation (If Equipped)Access to certain job sites may require the crane to betransported on roads with strict vehicle load limitations.In order to meet such limitations, the counterweightcan be removed and transported separately. If thecranne is equipped with maximun counterweight, re‐moving the counterweight can reduce the weight of thecrane by as much as 28,800 lb (13 064kg).

WARNINGWhen operating the crane with nocounterweight, always refer to the CraneRating Manual to ensure lifting capacities arenot exceeded.

Counterweight Removal1. Park the crane on a firm level surface, engage the

park brake, and shift the transmission to neutral.2. Properly level the crane on fully extended outrig‐

gers with all tires clear of the ground.3. Fully retract all boom sections. If equipped, prop‐

erly store the fly on the boom.4. Swing the upper over the front of the carrier. En‐

gage the travel swing lock and boom up to 63°.5. Attach the remote control box to the electrical con‐

nector on the left rear of the upper frame. Refer toFigure 1-94.

Note: If only one counterweight slab is installedon the upper, place the single counterweight re‐moval bracket in the “Up” position.

WARNINGTo avoid personal injury, do not place anybody part under counterweight during lower‐ing or raising of the counterweights.

6. Remove the lock pins and pins which secure thecounterweight to the upper frame.

Note: Counterweight cylinders may have to beraised (retracted) to relieve pressure on thepins to ease removal.

CAUTIONDo not fully extend the counterweight removalcylinders allowing them to push down on thecounterweights. Damage to the engine hoodmay occur. Extend the cylinder just enough toallow the counterweights to rest on theremoval brackets.

7. Push the DOWN button on the remote control boxto lower (extend) the counterweight to the counter‐weight removal brackets.

8. Remove the lock pins and pins which secure thecounterweight to the counterweight removal cylin‐ders.

Note: If all counterweights are not to be re‐moved, remove only the two counterweightconnecting pins above the counterweight(s) tobe removed.

9. Push the UP button on the remote control box toraise (retract) the cylinders away from counter‐weight.

Note: The counterweight slabs weigh 9,600 lb(4 355kg) each.

10. Swing the upper over the rear of the carrier. Attacha sling to the counterweight using the lifting bars inthe counterweight.

11. Attach other end of sling to the crane's hook block.


Do not travel or transport the crane with thecounterweight positioned on the removalbrackets. Counterweight may fall causingsevere personal injury and/or crane damage.

12. Lift counterweight off removal brackets and ontotransport vehicle.

Operator's Manual


Figure 1-94Counterweight Removal And Installation

1. Lock Pins With Keepers - Counterweights to Upper Frame2. Counterweight Connecting Pin With Keepers - Counterweight to Counterweight3. Lifting Bars4. Counterweight Removal Brackets5. Single Counterweight Removal Brackets - Up Position for Single Counterweight Slab Removal/Installation6. Single Counterweight Removal Brackets - Down Position for Two or Three Counterweight Slab Removal/Installation7. Counterweight Removal Remote Control Box8. Counterweight Leveling Bolts

1

2

3

4

KEEP CLEAR OFMOVING PARTSTO PREVENTSERIOUS BODILYINJURY.

WARNING

8

ÏÏÏÏÏ

ÏÏÏÏÏ

ÏÏ

ÏÏÏ

ÏÏ ÏÏÏÏÏ

ÏÏÏÏÏÏÏ

ÏÏÏÏ

ÏÏÏÏ

A

A

7

View A-A

B

B

5

6

Operator's Manual


Counterweight Installation1. Park the crane on a firm level surface, engage the

park brake, shift the transmission to neutral.2. Properly level the crane on fully extended outrig‐

gers with all tires clear of the ground.3. Attach a sling to the counterweight using the lifting

bars on the counterweight. Refer to Figure 1-94.

Note: If only one counterweight slab is to beinstalled on the upper, place the single counter‐weight removal bracket in the “Up” position. Iftwo or more slabs are to be installed, ensure thebrackets are in the “Down” position.

Note: The counterweight slabs weigh 9,600 lb(4 355kg) each.

4. Using the crane, pick the counterweight off thetransport vehicle.


5. Swing the upper over the rear of the carrier. En‐gage the travel swing lock. Set the counterweighton the removal brackets. Make sure counter‐weight is balanced on the removal brackets.

WARNINGCounterweight must be balanced on theremoval brackets. Counterweight may fallcausing personal injury and/or cranedamage.

6. Swing the upper over the front of the carrier and en‐gage the travel swing lock.

CAUTIONDo not fully extend the counterweight removalcylinders allowing them to push down on thecounterweights. Damage to the engine hoodmay occur. Extend the cylinder just enough toalign with the counterweights connectinglugs.

7. Push the DOWN button on the remote control boxto lower (extend) the counterweight removal cylin‐ders to align connecting lugs on the counter‐weight.

8. Install the pins and lock pins to secure the counter‐weight to the counterweight removal cylinders.

9. Push the UP button on the remote control box toraise (retract) the cylinders and lift the counter‐weight.

WARNINGTo avoid personal injury, do not place anybody part under counterweight during lower‐ing or raising of the counterweights.

10. Continue to lift counterweight until the lugs on thecounterweight align with the lugs on the upperframe.

11. Install the pins and lock pins which secure thecounterweight to the upper frame.

12. Lower (extend) cylinders slightly to transfer theweight of the counterweight from the cylinders tothe upper frame.

13. Adjust the counterweight leveling bolts so that thecounterweights hang level and do not sway. Donot tighten the leveling bolt to the point that thecounterweight pins cannot be easily removed.

Operator's Manual


Figure 1-95Lifting The Crane

Lifting The CraneThe entire crane (except the fly) can be lifted or thecomponents may be removed from the crane and liftedindividually. Refer to Figure 1-95 for the center ofgravity (CG) and weights for the entire crane and theindividual components. The following conditions andprecautions must be met before lifting the crane or re‐moving any component.1. The crane must be parked on a firm level surface

with the travel swing lock engaged. The swingpark brake and 360° swing lock, if equipped, mustbe released.

2. Use lifting equipment, shackles, slings, chains,etc. of suitable size and strength. All lifting equip‐ment must be inspected before lifting the crane.The inspection must be recorded and dated in ac‐cordance with current OSHA regulations.

3. Do not lift crane with fly attached to boom. Dam‐age to the fly may result. Remove the fly from thecrane before lifting. Refer to Section 4 of this Oper‐ator's Manual for the correct procedures for remov‐ing the fly.

4. When lifting the entire crane (without fly), extendthe outrigger beams to the intermediate positionand install slings around the beams. Protect slingsfrom any sharp edges.

Operator's Manual


5. The weights and locations of all CG's include allpossible options (heaviest crane) except the flybase and fly tip. Use the CG's as a starting point.Center hoist line on the CG, lift a few inches (centi‐meters) and adjust the hoist line to keep the crane/component(s) level at all times.

6. Removal of any component(s) from the crane willshift the CG of the entire crane. Adjust hoist line toaccount for the removal of any component(s).

7. Use only properly attached nylon straps to lift flybase or fly tip to prevent damage to the compo‐nent. Refer to Figure 1-12. Protect the strapsfrom sharp edges.

8. Do not allow the hoist lines to contact boom whilelifting crane. Damage to the boom may result.

Towing The CraneAlways use good judgment and reliable equipmentwhen towing the crane. Use extra caution when towingthe crane on the highway and in traffic. When makingconnections between the crane and towing vehicle, besure none of the connections will cause damage toeither vehicle. Pay particular attention to tie rods, brakelines, power steering cylinders, and power steeringlines. The tow lugs are the recommended connectionpoints on the crane.

Note: Due to difficulty in steering the crane, towingshould be limited to short distances.

Always exercise safety and follow all local codes whentowing the crane. Prepare the crane as follows beforetowing it.1. If equipped, store the fly base and tip on the boom.2. The boom must be over the front of the crane with

the travel swing lock engaged. Release the swingpark brake and the 360° swing lock if equipped.

CAUTIONDo not leave the swing park brake or 360°swing lock, if equipped, in the engagedposition during towing operations. Failure torelease these devices during this operationmay result in damage to the swing speedreducer.

3. All boom sections must be fully retracted with theboom at a 0° angle. Secure the hook block and/orhook ball to prevent excessive swinging.



5. All control levers in the operator's cab must be inthe neutral position.

6. Shift the transmission to neutral and engage the2‐Wheel Drive mode. Remove the drive tube be‐tween the transmission and axle or lift the rear driv‐ing wheels.

CAUTIONFailure to disconnect the drive tube, or lift thedriving wheels, before pushing or towing thecrane can cause major transmission damage.

7. Unlock the steering column by turning the ignitionswitch to the “On” position. Turn on the hazardflashers.

8. Release the park brake when the crane is attachedto the towing vehicle and ready to be towed.

Operator's Manual


Transporting The CraneWhen transporting the crane, precautions should betaken in securing the crane to the trailer, barge, or othermeans of conveyance. The tow lugs are the recom‐mended tie down points. If the tow lugs cannot beused to tie the crane down, chains may be loopedaround the outrigger boxes or the axle housings to se‐cure the crane down.

CAUTIONIf chains are wrapped around the axle hous‐ing, be certain the chains will not damage thetie rods, brake lines, power steering cylin‐ders, or power steering lines.

If chains are wrapped around the outriggerbox collar, be certain the chains will notdamage the hydraulic lines and fittings. Thechains should be wrapped around theoutrigger box, not the outrigger beam.

Always exercise safety and follow all local codes whenloading, unloading, or transporting the crane.

Prepare the crane as follows before transporting it:1. If equipped, store the fly base and tip on boom.2. The boom must be over the front of the carrier with

the travel swing lock engaged. Release the swingpark brake and 360° swing lock if equipped.

CAUTIONDo not leave the swing park brake or 360°swing lock, if equipped, in the engaged posi‐tion while transporting the crane. Failure to re‐lease these devices during this operation mayresult in damage to the swing speed reducer.

3. All boom sections must be fully retracted with theboom at a 0° angle. Secure the hook block and/orhook ball to prevent excessive swinging.



5. Engage the park brake and shift the transmissionto neutral.

6. If transport height adjustment is required, refer to“Suspension Height Adjustment” in this Section ofthis Operator's Manual.

7. All control levers in the operator's cab must be inthe neutral position.

8. Shutdown the engine and remove the keys fromthe crane. Lock all windows and doors.

9. Depending on the specific situations, furtherpreparations may be needed to protect the cranefrom the environment or vandalism. Refer to“Crane Storage” for further suggestions.

Operator's Manual


1. Control Box Quick Connect Location

Figure 1-96Suspension Height

1

SUSPENSION HEIGHT ADJUSTMENT

UP

DOWN

Suspension Height AdjustmentThe oscillation suspension cylinders can be retractedto reduce the overall height of the crane during trans‐port. A hand held electrical control box with 20 ft (6.1m)of cable is used to adjust the height of the crane. This isthe same electrical control box as used on the counter‐weight removal option. Quick connect electrical con‐nection is provided under the left fender.

Once the crane reaches the jobsite and is unloadedfrom the transport vehicle, the suspension must beproperly adjusted to the correct travel height before op‐erating the crane.

CAUTIONDo not travel the crane with the axle oscillationcylinders fully extended or fully retracted.Major damage to suspension componentscan occur if the crane's oscillationsuspension is not properly adjusted.Oscillation cylinders which are not properlyadjusted can leave suspension componentsunprotected from shock loads which can leadto major crane damage. Inspect the axleoscillation cylinders daily for the properadjustment as required.

Use the following procedures to adjust the travel height.1. Park the crane on a firm level surface.2. Position the upper directly over the front of the car‐

rier, fully retract the boom and lower to 0 degreeangle, and engage the travel swing lock.

3. Measure the non‐painted rod length for eachoscillation cylinder. The sum of the exposed rodsshould equal 4.0 in ± 0.125 in (10.16cm ±0.3cm). If suspension cylinders are not withinspecification proceed to the next step.

4. With the crane on a firm, level surface and on tires,push the UP button to extend the oscillation cylin‐ders until the measured sum of the exposed rodsequals 4.0 in (10.16cm).

Note: Do not retract suspension cylinders toobtain the measured sum of the exposed rods.

5. On cranes equipped with the Hydro‐gas option,press the DOWN button and hold for approximate‐ly 30 seconds. Then press the UP button until thenon‐painted rod length equals 4.0 in ± 0.125 in(10.16cm ± 0.3cm).

6. For transporting the crane, the suspension may be fullylowered exposing 0 in (0 cm) of rod length. If equippedwith hydro‐gas suspension, press the DOWN buttonand hold for approximately 30 seconds.

7. Disconnect the control box and store in the crane'stool box located under the operator's seat.

Operator's Manual


Crane StorageAnytime the crane is going to be left unattended itshould be prepared so that it will not be damaged bythe elements, be an attraction to vandals, or a playthingfor children.

Short Term Storage1. Do not leave crane where it will be a traffic hazard.2. Lower all loads to the ground.3. The travel swing lock must be engaged.4. Fully retract the boom. Boom down to 0°. The fly

may be erected if the crane is on outriggers.5. Tie off the hook block and/or hook ball to the tow

lugs. Winch lines should be snug.6. All control levers must be in the neutral position.7. Shift the transmission to neutral, engage the park

brake, and shutdown the engine. Block the wheelsto prevent the crane from rolling if on tires.

8. If the crane is on outriggers, the outriggers must beproperly set and supported so the crane will re‐main level.

9. In cold weather, locate the crane where it will notfreeze to the ground.

10. To preserve battery life, move the battery discon‐nect switches to the off position.

11. Remove the keys from the crane. Lock all windowsand doors.

Long Term Storage1. Store the crane inside a building if possible.2. Thoroughly clean the crane.3. Touch up any spots where paint has chipped. This

will prevent rusting.4. Lubricate the entire crane as per the Lubrication

Chart. Make sure all gear cases are filled to theirproper oil level.

5. Inflate tires to proper pressure as shown on the TireInflation Label or in the Crane Rating Manual.Check tire pressures periodically during storage tomake sure they do not go flat. If possible block thecrane up so the tires are clear of the ground. Makesure the blocking is placed so the crane cannot falloff it. If this is not possible, set the crane on planksso the tires will not sink in the ground. Block thetires to prevent the crane from rolling.

6. Fully retract all hydraulic cylinders if possible. Fullyretract the boom and store the fly, if equipped.Cover all cylinder rods, machined, and unpaintedsurfaces with a coat of grease.

7. Position all control levers in neutral.8. Engage the park brake, shift the transmission to

neutral, and shutdown the engine.9. Prepare the engine as per the engine manufactur‐

er's manual. Make sure antifreeze protection issufficient to prevent the engine from freezing.

10. After engine has cooled, cover all open areasaround engine, cab, etc. to prevent entry of water.Cover entire engine area with a tarp if possible.

11. To preserve battery life, move the battery discon‐nect switches to the off position.

12. Remove the keys and lock the cab doors if in a lo‐cation where vandalism may occur. Cover all cabglass with plywood or boards to prevent glassbreakage. Provide a means of locking the engineaccess doors, fuel tank, and hydraulic reservoir.

13. Store the crane so it does not provide a playthingfor children. Such a unit can be an “attractive nui‐sance” for children to play on. If they fall off it or getentangled, serious injury may result.

14. While in storage, crane should be “exercised” every60 days to ensure the working condition of the crane.Remove necessary tarps, start engine, and operateall switches, control cables, and hydraulic functionsseveral times to circulate lubricants and to keep allmechanisms and linkages operative.