a. Carrier Cab Assembly. The carrier cab contains all the controls and indicators necessary for traveling and parking functions. The cab is all-steel, acoustically treated, fully enclosed with tinted safety glass windows throughout. Access to the cab is via a hinged left side door which features a latch handle and keyed lock. A grab handrail is provided to aid the operator in getting in and out of the cab. A suspension seat installed in the cab is adjustable both vertically and horizontally.
The seat is also equipped with a seat belt.
A 1-A:10-B:C rated 2.50 lb (1.13 kg) dry-type fire extinguisher is mounted inside the cab, between the door and the operator's seat.
A single-blade windshield wiper is installed to remove moisture from the windshield.
The wiper is driven by an electric motor that is controlled by a lever on the steering column. A windshield washer system is installed to spray a cleaning solution onto the windshield. It consists of two nozzles (one on each side of the wiper arm), a canister, and pump. The electric pump draws the solution from the canister and forces it through a hose to the two nozzles that spray it onto the windshield.
The carrier cab also features a hot-water heater and a roof-mounted air conditioning unit. The cab heater circulates hot engine coolant through a heat exchanger. Hot air is blown out of the heater into the cab by a variable speed blower motor. The air conditioning unit is comprised of a self-contained evaporator and condenser coil unit, a remote engine-mounted compressor, and a control panel which allows the operator to control temperature and fan speed.
b. Superstructure Cab Assembly. The superstructure cab contains all controls and indicators for craning operations and traveling on the job site. The cab is all-steel, acoustically-treated, and fully enclosed with tinted safety glass windows throughout.
Access to the cab is via a sliding door which features a latch handle and keyed lock. Grab handrails are provided beside the door opening to aid the operator in getting in and out of the cab.
The superstructure cab has a skylight with a tinted safety glass window. A manually-operated skylight wiper is provided to remove moisture from the skylight.
The cab seat is mounted on a track assembly, allowing it to be adjusted to a comfortable distance from the steering wheel and front console. The seat has a lever at the front of the bottom cushion to adjust the tilt of the seat back. An armrest on each side of the seat houses the hydraulic remote controls used to control the crane functions. The armrests swing up beside the seat and latch in place to make it easier for traveling and entering and exiting the cab. A safety device in the armrests disables the controllers when the armrests are in the latched position. In addition to the safety device in the armrests, a tape switch incorporated in the cab seat, deactivates the controllers when the operator leaves the seat.
A 1-A:10-B:C rated, 2.5 lb (1.13 kg) dry-type fire extinguisher is mounted in the cab, under the operator's seat.
A single-blade windshield wiper is installed to remove moisture from the windshield.
The wiper arm is driven by an electric motor which is controlled by a two-speed switch located on the front console panel. A windshield washer system is installed to spray a cleaning solution on to the windshield. It consists of two nozzles (one on each side of the wiper arm), a canister which is located beneath the cab, and a pump assembly.
Located beneath the cab, is a diesel fuel burning heater which provides heat to the cab. The heater fuel tank is located on the right side of the turntable. All heater controls are located within the cab. Windshield defroster controls and tubing are provided with the heater.
The superstructure cab also features an air conditioning unit. The air compressor and condenser unit is housed behind a cover on the left side of the boom on the forward side of the counterweight. The air conditioner controls including the air handler and blower fan are located in the cab.
c. Engine. The diesel engine is housed in the engine compartment behind the carrier cab and is used to provide crane mobility. The engine is also used to charge the air system, drive the steering pumps, and supply electrical power for carrier control circuits, accessories, and lighting. In addition, the engine drives the hydraulic pumps though the pump drive. All controls for the engine are located in both cabs.
d. Fuel Tank. A single 44-gal. (166.6 L) capacity fuel tank is mounted on the right side of the carrier frame. The filler cap is located on the top of the tank.
e. Drive Train. The drive train consists of the transmission, drive shafts, and the associated linkages. The transmission is electrically shifted and has six forward and three reverse speeds from the carrier cab and three forward and three reverse speeds from the superstructure cab.
f. Axles. The axles are drive steer axles and have inter-axle differential locks to lock the differentials together for traveling in adverse road conditions.
g. Steering Systems. The crane is equipped with a front axle steering system and a rear axle steering system. The two separate systems can be activated from either cab.
h. Brakes. The brakes, which are drum and shoe-type, are air operated. The rear axle is equipped with spring applied brakes to hold the carrier stationary when parking and to provide auxiliary braking in case of emergency.
i. Air System. The air system provides the air supply to operate the service brakes, the parking brakes, trailer service connections, air inflation system, and the engine air throttle. The engine driven air compressor supplies the air to charge the air reservoirs. An air dryer removes moisture from the air before it reaches the reservoirs.
j. Hydraulic System and Components. The hydraulic system is designed to provide adequate pressure and flow for simultaneous operation of various crane functions.
(1) Reservoir. The hydraulic reservoir is a 64 gal. (242 L) steel tank located on the left side of the carrier. A full flow return-type 10 micron filter is installed in the reservoir.
(2) Hydraulic Oil Cooler. An air cooled hydraulic oil cooler is mounted on the right side of the superstructure. The oil cooler consists of a hydraulic radiator, a by-pass valve, a fan, and an electric fan motor. The fan draws cool air through the cooling fins of the oil cooler. All return oil from the superstructure is routed through the oil cooler.
(3) Pump and Disconnect. The hydraulic pump and disconnect are mounted on a drive pad of the torque converter. With the disconnect engaged and the engine and torque converter operating, the pump provides oil to the hydraulic components.
The hydraulic pump is a gear-type pump and consists of three sections. The first section of the pump, the one on the mounting flange end, provides an output of 39 gpm (147 lpm). The second section provides 39 gpm (147 lpm) and the third section supplies 16 gpm (61 lpm).
The disconnect assembly is provided for cold weather starting and consists of a housing, lever, movable collar, and a sliding splined sleeve. The disconnect housing is connected to the torque converter drive pad and the pump is bolted to the disconnect housing.
(4) Directional Control Valves. The directional control valves are four way, three position valves with either an open or closed spool. The valves are grouped into valve banks permitting simultaneous independent control of crane functions. The closed spool-type valves are equipped with integral check valves to ensure components will remain stationary when the valves are closed. Each valve bank contains a main relief valve. In addition, certain crane functions are further protected by a circuit relief valve.
(5) Emergency Steer Pump. The emergency steer pump will provide oil flow for the steering system in the event of an oil flow loss in the main steering system caused by an engine or steering pump failure. The pump is ground-driven off of the transmission. This function is automatic, being activated by a flow switch.
k. Turntable Assembly and Swing Mechanism. An anti-friction roller bearing supports the superstructure and attaches it to the carrier allowing 360º of continuous rotation (swing) in either direction. The swing function is accomplished through use of a hydraulically driven motor driving a gearbox which in turn drives the roller bearing via an external gear. A spring and hydraulically actuated and hydraulically released brake is provided to stop swing and hold the superstructure in a desired position, two mechanical swing locks are also provided.
(1) Swing Motor. The hydraulic swing motor is a low speed, high torque motor.
The motor provides indirect drive power for turntable swing through the swing gearbox.
(2) Swing Gearbox. The swing gearbox is a sun and planetary gear-type, driven mechanically by the swing motor. The swing gearbox rotates the turntable at a reduced operational speed.
(3) Swing Brake. The swing brake assembly consists of a brake assembly mounted on the swing gearbox. The swing brake is hydraulically controlled by the operator from the superstructure cab through use of the SWING BRAKE ON/OFF selector switch which electrically positions the swing brake control valve, and by the swing brake foot pedal when the SWING BRAKE ON/OFF selector switch is in the OFF position.
(4) Mechanical Swing Locks.
(a) Swing Lock Pin. A pin-type swing lock that consists of a rounded pin which engages a welded retainer to lock the turntable with the boom straight over the front or rear of the carrier. The swing lock pin is operated using the SWING LOCK Pin Control Lever (49, Figure 5-2).
(b) Positive Swing Lock. A gear-type swing lock that consists of a lock assembly with teeth that meshes with the swing gear teeth to lock the turntable with the boom at any point along the 360º of rotation of the swing gear. The positive swing lock is operated using the Positive Swing Lock Handle (6, Figure 5-2).
l. Boom Assembly. The boom is a three section, 27 to 70 ft (8.2 to 21.3 m) cable extended boom.
The boom is trapezoidal in design and utilizes one 5.5 in. (13.9 cm) telescope cylinder. The telescoping sections are supported on graphite impregnated nylatron wear pads. Adjustable side wear pads prevent metal to metal contact between the sections. The boom nose consists of three sheaves mounted on heavy duty, tapered roller bearings and utilizes pin-type guards to allow easy reeving. The boom features a mechanical boom angle indicator mounted on the left-rear side of the boom.
m. Main Hoist, Superstructure. The main hoist provides power and speed for load raising and lowering operations utilizing the main hook block. A vane-type hydraulic motor drives the hoist drum by means of a planetary gear reduction system. A metallic disc brake is also an integral part of the hoist assembly. An indication of hoist drum rotation is provided by an electronic pulse generator attached to the hoist with a pulsating indicator in the boom LIFT/MAIN hoist control lever (8, Figure 5-2) in the cab. The pulsation rate felt by the operator is proportional to the hoist speed.
n. Auxiliary Hoist, Superstructure. The auxiliary hoist provides power and speed for all operations requiring an auxiliary hook such as when the pile driver is attached to the crane. Since the hoist is identical to the main hoist, it can perform all main hoist operations. A vane-type hydraulic motor drives the hoist drum by means of a planetary gear reduction system. A metallic disc brake is also an integral part of the hoist assembly. The auxiliary hoist indicator also provides hoist drum rotation information to the operator via a pulsating indicator in the boom SWING/AUXiliary hoist control lever (20, Figure 5-2) in the cab.
o. Outrigger System. The outriggers are integral with the carrier frame but are controlled and operated from the superstructure. The outriggers are full hydraulic, double box-type. They are positioned to provide a rigid four point platform (outriggers fully extended and set) capable of supporting the machine and its maximum load capacity. Integral holding valves and floats are standard equipment.
A sight level bubble indicator is located in the superstructure cab to ensure crane leveling.
p. Swivels. Electrical and air/hydraulic swivels are used to route the air, electrical, and hydraulic circuits to the superstructure from the carrier frame. These swivels are mounted as a single assembly, and are installed at the center of rotation.
q. Electrical System. The electrical system operates on 24 VDC and consists of an alternator and four 12-volt, lead acid batteries which are series-parallel connected.
The system is single wire ground return-type, utilizing the crane's chassis as ground.
The system also features a battery disconnect switch designed to protect operators and maintenance personnel while performing inspections and maintenance.
There is a standard NATO slave receptacle mounted below the battery box located on the right side of the crane. The receptacle can be used to start the crane or power the auxiliary power unit in the event the vehicle's onboard batteries cannot provide the power for either function.
A backup alarm is an audio system used to warn personnel outside the crane when the vehicle is backing up. The alarm system is electrical and consists of the backup alarm and associated wiring. The alarm is tied into the backup light electrical wiring, and is activated when the backup light is activated. Two backup alarms are installed. One is installed on the rear of the turntable and one is installed on the rear of the chassis.
A boom swing alarm can also be sounded by the crane operator in the superstructure cab. The alarm is activated by a pushbutton on the right side arm rest.
r. Related Crane Functions. The crane is equipped with interface components and attachment points for connecting and operating the following attachments:
(1) Clamshell. When attached to the main hoist cable, a hydraulically-operated general purpose bucket with teeth can be operated from the superstructure cab. Hydraulic control and actuation power is supplied by the crane via a hose reel/tagline mounted on the boom.
(2) Grapple. When attached to the main hoist cable, a hydraulically-operated, four-tine grapple with heavy-duty cylinders can be operated from the superstructure cab. A hydraulic tagline mounted on the boom provides power for operating the grapple.
(3) Concrete Bucket. A concrete bucket can be attached to the main hoist cable. The material release lever is operated by personnel on the ground.
This is a Government-furnished attachment.
(4) Pile Driver. The Linkbelt drop hammer, diesel engine-driven, and Berminghammer pile driver systems can be attached to the shafts on the boom nose using parallel adapter plates mounted on the lead tower.
Mounting lugs, located on brackets on the front of the crane superstructure, allow attachment of the catwalk for the Linkbelt pile driver system and the spotter for the Berminghammer pile driver system. The pile drivers, which are Government-furnished attachments, are operated by controls that are part of the respective pile driver systems.
The spotter for the Berminghammer pile driver system is controlled by controls in the superstructure cab and hydraulic power is provided by the boom hose reel on the crane.
A catwalk bracket, for the Linkbelt pile driver system, may be fabricated to raise the catwalk platform above the spare tire when swinging the boom from the 12 o'clock through the 10 o'clock positions. See Appendix L, Installation/Operation of Pile Driver (Linkbelt), for fabrication information.
s. Auxiliary Power Unit for Emergency Crane Stowage. An auxiliary power unit (APU) has been provided on the left side of the crane, just forward of the main hydraulic tank. The unit provides hydraulic power for returning the crane to the travel mode after a catastrophic failure of the crane's hydraulic system. It uses the onboard 24 VDC power supply to operate a small hydraulic pump. The hydraulic pump supplies the power for swinging/retracting/lowering the boom, lowering the hook block, lifting and retracting the outriggers, and steering/straightening the wheels. The APU can also be powered from an external 24 VDC power source via the NATO slave receptacle coupled to an intervehicular cable.
The auxiliary power unit consists of an electrically-driven hydraulic motor and starter relay, a two-way diverter ball valve, an on/off switch, and associated hydraulic piping and check valves.
There are two user interface controls for the APU. First, an on/off toggle switch turns on and shuts off the electric motor driving the APU hydraulic pump. Second, a two-way diverter valve determines which crane hydraulic circuit is powered by the APU hydraulic pump. Refer to Section 5 of this manual for detailed procedures covering the use of the APU for vehicle recovery operations.
SECTION 5
OPERATING INSTRUCTIONS