Crane Inspection

LETOURNEAU, INC. QUALIFIED CRANE INSPECTOR TRAINING MANUAL GENERAL TABLE OF CONTENTS

PREVENTIVE MAINTENANCE SCHEDULES AND CRANE INSPECTION

NOTE The contents of this Crane Inspector’s Training Manual include all publications or excerpts from publications referenced in the Preventive Maintenance Schedules. However, it is recommended that the inspector read, understand and follow all instructions contained within the crane’s OPERATING AND SERVICE and REPAIR AND OVERHAUL MANUALS prior to performing any inspections or service procedures to these cranes.

· · · ·

1

Module 1: Pre-Use or Daily Inspections and Service Module 2: Monthly Inspections and Service Module 3: Quarterly Inspections and Service Module 4: Annual Inspections and Service

PUBLICATION OSM-5 “WIRE ROPE USE, HANDLING AND MAINTENANCE”

2

PUBLICATION OSM-6 “BRAKES”

3

EXCERPTS FROM PUBLICATION OSM-4

4

·

Lubricating Oil Analysis

·

Power Loss Lowering System Inspection and Test Procedures

5

PUBLICATION ROM-1 “STRUCTURAL COMPONENTS” ·

PCM 120 SS

·

PCM 350 SS

PUBLICATION LET-1 “FIELD WELDING PROCEDURES”

6

EXCERPTS FROM PUBLICATION ROM-6

7

·

Automatic Overload Protection System Test and Calibration Procedures

8

EXCERPTS FROM PUBLICATION OSM-2 “SAFETY”

7-OSL, Crane TOC (MSWord) Training Manual 06-26-02

·

Identification and Safety Label Group

·

Load Charts – PCM 120/350 SS

·

Wire Rope Reeving Diagrams

COPYRIGHT 2002

LeTourneau, Inc.

1

Return to Main Page

PRE-USE OR DAILY WALK AROUND INSPECTIONS AND SERVICES TO BE PERFORMED BY QUALIFIED OPERATOR

Okay n

1.

Check hourmeter (located in Machinery House) for proper operation. Record reading in space provided. Hourmeter reading:___________________

2.

Check overall condition of crane and support structure. Look for damage.

3.

Check safety and instructional signs. Replace any that are illegible, deteriorated or missing.

4.

Visually check column, boom and swing components for cracked welds and broken or missing bolts.

5.

SLOWLY operate all powered components to their travel limits to check for propĆ er limit switch operation.

6.

Check wire rope for attachment, damage, deterioration and proper lubrication.

7.

Check all controls for proper operation.

8.

Check load moment indicator for proper operation.

9.

Check personnel warning horn for proper operation.

10.

Check all lighting for proper operation. (Include helicopter warning light if appliĆ cable).

11.

Check all brakes for proper stopping action.

12.

Check hydraulic lines to brakes for damage and leaks (where applicable).

13.

Check hydraulic brake unit high pressure filters service indicator (located in MaĆ chinery House). Service when required.

14.

Check hydraulic brake power unit (located in Machinery House) breather filter service indicator. Service when required.

15.

Check all drive motors for proper operation.

16.

Check swing gearbox and drivers for overheating and leaks.

17.

Check hook and block for proper attachment and condition of safety latch.

18.

Check all sheave pins and retainers.

19.

Check Machinery House ventilation system.

20.

Check fire extinguisher for proper charge, seal, and certification interval.

21.

Check the swing gear lubricant for shavings.

22.

Check for proper CW and CCW rotation and REPORT any unusual noises and vibrations.

23.

Check load rating chart at operator's controls. It must be correct and visible.

24.

Check hoist driver for visible oil leaks.

25.

Visibly check loose gear to be used, such as slings, sling hooks and shackles.

26.

Lubricate components and correct deficiencies as required based on these inĆ spections.

9ĆOSMĆ4.2.1b(M1), Gorilla 06/24/02

COPYRIGHT 2002

LeTourneau, Inc.

Needs Attention n

1

MONTHLY TO BE PERFORMED BY QUALIFIED OPERATOR OR QUALIFIED INSPECTOR

Okay n

1.


2.


3.


4.


5.


6.


7.


8.


9.


10.


11.


12.


13.


14.


15.


16.


17.


18.


19.


20.


21.


22.


23.


24.


25.


26.

Further check all control mechanisms for proper adjustment, excessive wear of components, and contamination by foreign matter.


COPYRIGHT 2002

LeTourneau, Inc.

Needs Attention n

1

PREVENTIVE MAINTENANCE REQUIREMENTS AND RECOMMENDATIONS

PUBLICATION OSMĆ4

Okay n

27.

Check boom hoist limit and anti-two block devices for proper operation. Care should be exercised to prevent damage to crane components.

28.

Check all electrically operated functions for proper operation.

29.

Correct deficiencies as required based on these inspections.

Needs Attention n

MONTHLY INSPECTION AND LUBRICATION REQUIREMENTS NOTE: Numbers in parentheses refer to lubrication points indicated on Figure 1. STOW BOOM FOR SAFE ACCESS TO LUBE POINTS.

2

1.

Thoroughly inspect wire rope per the instructions in Publication OSM 5, located in the Operating and Service Manual.

2.

Lubricate main hook sheaves. (1)

3.

Lubricate main hook swivel bearing. (1)

4.

Lubricate auxiliary hook bearings (optional). (2)

5.

Lubricate auxiliary sheaves (optional). (3)

6.

Lubricate boom sheaves (optional). (4)

7.

Lubricate floating block and equalizer sheave. (5)

8.

Lubricate boom selfĆaligning bushing (until new grease appears). (6)

9.

Lubricate swing roller bearings. (7)

10.

Lubricate swing gear and gearbox pinion. (8)

11.

Lubricate gantry sheave. (9)

12.

Lubricate swing bearing (PCM 350SS). (10)

13.

Lubricate spherical and thrust bearing (PCM 120SS). (10)

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


9

5

3

4

6 4 7

8 1 2

10

PCM 350SS

9

5

10 4 3

6 4 7

8

1 2

PCM 120SS

CAUTION: PROPERLY STOW BOOM BEFORE LUBRICATING CRANE. tag: lube points FIGURE 1. LUBRICATING POINTS PCM 350 AND PCM 120 TAĆ8997ĆCG

1ĆCGĆNGOĆ1600, P10Ć31


COPYRIGHT 2002

LeTourneau, Inc.

3


PUBLICATION OSMĆ4

NOTES

4

COPYRIGHT 2002

LeTourneau, Inc.


QUARTERLY TO BE PERFORMED BY QUALIFIED INSPECTOR

Okay n

Needs Attention n

NOTE: The quarterly inspections includes an inspection of electric motors, servicĆ ing drivers and swing gearbox and hydraulic brake system, structural inspection, and operational tests of the crane. These inspections should only be conducted by qualified and experienced inspectors. 1.


2.


3.


4.


5.


6.


7.


8.


9.


10.


11.


12.


13.


14.


15.


16.


17.


18.


19.


20.


21.


22.


23.


24.



COPYRIGHT 2002

LeTourneau, Inc.

1


PUBLICATION OSMĆ4

Okay n

25.


26.


27.


28.


29.


Needs Attention n

QUARTERLY INSPECTION AND LUBRICATION REQUIREMENTS NOTE: Numbers in parentheses refer to lubrication points indicated on Figure 2. STOW BOOM FOR SAFE ACCESS TO LUBE POINTS.

2

1.

Thoroughly inspect and lubricate wire rope per the instructions in Publication OSM 5, located in the Operating and Service Manual.

2.


3.


4.


5.


6.


7.


8.


9.


10.


11.


12.


13.


COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


9

5

3

4

6 4 7

8 1 2

10

PCM 350SS

9

5

10 4 3

6 4 7

8

1 2

PCM 120SS




COPYRIGHT 2002

LeTourneau, Inc.

3


PUBLICATION OSMĆ4

Okay n

Needs Attention n

DRIVERS MAIN HOOK, BOOM, AUXILIARY HOOK (OPTIONAL): 1.

Take samples for lubricating oil analysis and refill. Service if iron content is 100 ppm or greater. Refer to LUBRICATING OIL ANALYSIS, Publication OSMĆ4, for additional information. CRANE SWING COMPONENTS

SWING GEARBOX: 1.

Take sample for lubricating oil analysis and refill. Service if iron content is 100 ppm or greater. Refer to LUBRICATING OIL ANALYSIS, Publication OSMĆ4, for additional information. HYDRAULIC BRAKE SYSTEM

1.

Take oil sample for analysis. Flush system and refill if water or solid particle conĆ tamination is 60 ppm or greater. WIRE ROPE

WIRE ROPE - INSPECTION AND LUBRICATION REQUIREMENTS: 1.


2.

Inspect sheaves for wear, cracks, rope path alignment and bearing condition.

CABLE DRUM DEAD END INSPECTION: 1.

Check torque on wire rope dead end setscrews (140Ć150 lbs. lubricated with 30W motor oil). OPERATIONAL INDICATORS

1.

Check boom angle/radius indicators over full range for accuracy. DC MOTOR BRAKES

SWING, BOOM, MAIN HOOK AND AUXILIARY HOOK (OPTIONAL):

4

1.

Check the condition of all motor brakes. Refer to Publication OSMĆ6 in the OPĆ ERATING AND SERVICE MANUAL.

2.

Check all motor brakes for proper operation. Refer to Publication OSMĆ6 in the OPERATING AND SERVICE MANUAL.

3.

Check swing motor brake for proper adjustment. Refer to Publication OSMĆ6 in the OPERATING AND SERVICE MANUAL.

4.

Check for damage or leakage in hydraulic brake systems.

5.

Check speed sensors mounting, tightness and condition of leads. COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


Okay n

Needs Attention n

Okay n

Needs Attention n

POWER LOSS LOWERING SYSTEM 1.

Inspect and test the power loss lowering system. Refer to POWER LOSS LOWĆ ERING SYSTEM, located in Publication OSMĆ4 in the OPERATING AND SERĆ VICE MANUAL.

QUARTERLY ELECTRICAL P.M.

!

CAUTION

Be sure all electrical power is turned off and locked out before touching any electrical connection or terminal. Due to the potential for injury, only qualified experienced persons should enter the Machinery House. ELECTRICAL CONTROLS GROUP: 1.

Check hook Controller condition. Insure card cover is secure and harness conĆ nections are tight.

2.

Check Boom Controller condition. Insure card cover is secure and harness conĆ nections are tight.

3.

Check Swing Controller condition. Insure card cover is secure and harness connections are tight.

4.

Check all converter panels for tight connections and condition of components. Remove any accumulated dust.

5.

Check circuit breakers.

6.

Blow out the cabinet with clean, dry compressed air.

7.

Check backĆup batteries for clean, tight terminal connections (located on top of machinery house).


COPYRIGHT 2002

LeTourneau, Inc.

5


PUBLICATION OSMĆ4

QUARTERLY DC MOTOR BRUSH INSPECTION VERNIER GAUGE

POSITION BRUSH IN GAUGE SAME WAY FOR ALL MEASUREMENTS.

BRUSH

NOT ALL LEADS SHOWN

HIGH POINT ON BRUSH 1ĆCGĆ1088, P01Ć112

TA8010CG

MOTOR

BRUSH #

DIM.

REPLACED?

ANY SPECIAL CONDITIONS

1. 1.

SWING SĆ1A MOTOR

2. 3. 4. 1.

2.

MAIN HOOK N 9 MOTOR NĆ9

2. 3. 4. 1.

2.

BOOM NĆ9 MOTOR

2. 3. 4. 1.

4.

AUXILIARY HOOK NĆ9 MOTOR

2. 3. 4.

NOTES!ă 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE. 2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS. 3. SEE CHAPTER 4.0 OF TAKING CARE OF YOUR DC MOTOR" LOCATED IN SECTION 2, DC MOTORS, OF THE REPAIR AND OVERHAUL MANUAL FOR CONDITIONS TO LOOK FOR.

6

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


1

2

A

3

B

4

C

5

D

SIMPLIFIED AND EXAGGERATED ILLUSTRATION OF ARMATURE AND COMMUTATOR TA8009CG

1ĆCGĆ1083, P01Ć112

MOTOR

TRACK #

TIR

MAX. BARĆTOĆBAR

SURFACE CONDITION - SEE NOTE

1. 1.

SWING SĆ1A MOTOR

2. 3. 4. 1.

2 2.

MAIN HOOK NĆ9 MOTOR

2. 3. 4. 1.

3 3.

BOOM NĆ9 MOTOR

2. 3. 4. 1.

4.


2. 3. 4.

NOTES!ă 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE. 2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS. 3. IN THE SURFACE CONDITIONS" COLUMN INDICATE OBSERVED CONDITION OF COMMUTATOR SURFACE CONĆ CERNING THE FOLLOWING: (a) CONDITION OF FILM, (b) SIGNS OF ARCING, (c) GROOVING, (d) OTHER CHARACTERĆ ISTICS. REFER TO TAKING CARE OF YOUR DC MOTOR" FOR AN INTERPRETATION OF THE OBSERVATIONS. 9ĆOSMĆ4.2.1b(M3), Gorilla 06/24/02

COPYRIGHT 2002

LeTourneau, Inc.

7


PUBLICATION OSMĆ4

QUARTERLY STRUCTURAL INSPECTIONS Okay n

!

Needs Attention n

CAUTION

Dye penetrant and magnetic particle tests shall be conducted on any welds suspected of being cracked. Structural repairs MUST be made in accordance with the guidelines in STRUCTURAL REPAIRS, Publication ROMĆ1, in the REPAIR AND OVERHAUL MANUAL and LeTourneau, Inc., Publication LeTĆ1, FIELD WELDING PROCEDURES, located in the back of Section 1 of the REPAIR AND OVERHAUL MANUAL. Before ANY structural repairs are made to the crane, the certifying authority shall be notified and his surveyor present when the repairs are performed. Any inspections and tests required by the certifying authority after structural repairs are made shall be completed and a new certificate issued BEFORE the crane is returned to service. AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS): 1.

Test the AOPS, Refer to AOPS TEST AND CALIBRATION PROCEDURE, loĆ cated in Publication ROMĆ6 in the REPAIR AND OVERHAUL MANUAL.

COLUMN GROUP - BASE: 1.

Closely inspect welds holding bolt plate to column.

2.

Closely inspect circumferential and vertical welds of column structure.

3.

Closely inspect welds at all gusset plates.

4.

Closely inspect welds on ladder assembly and holding ladder to column.

5.

Closely inspect for missing, loose or broken bolts.

COLUMN GROUP - UPPER: 1.


2.


3.

Closely inspect welds on platform assembly and holding platform to column.

4.


5.


6.

Closely inspect all bearings, wear bands and king pin condition.

BOOM:

8

1.

Closely inspect main boom hinge pins and attachment point welds.

2.

Closely inspect splice joints in top chords for cracks.

3.

Closely inspect welds at bridle cable ears and plates.

4.

Closely inspect for excessive wear at pins and ears. COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


Okay n

5.

Closely inspect welds in joints on bottom chords.

6.

Closely inspect welds at all diagonal pipes.

7.

Closely inspect condition and attachment of luffing ropes.

8.

Closely inspect boom sections attachment points for loose, broken or missing bolts.

9.

Closely inspect boom light assemblies for proper attachment, broken lenses, lose wiring and proper operation.

10.

Closely inspect limit switches for proper mounting and adjustment.

11.

Closely inspect catwalks and handrails for cracked welds and loose, broken or missing bolts.

Needs Attention n

JIB BOOM (OPTIONAL): 1.


2.

Closely inspect for excessive wear at pins and ears.

3.


4.


5.

Closely inspect sheaves, pins and retainers.

SWING TABLE ROLLER ASSEMBLY: 1.

Closely inspect welds at boom and gantry attachment points.

2.

Closely inspect welds around the entire structure.

3.

Closely inspect welds at Machinery House mounting points.

4.

Closely inspect swing gearbox mounting.

5.

Closely inspect all pins and retainers.

6.

Closely inspect structure for loose, missing or broken bolts.

7.

Closely inspect swing bearing and gear for loose, broken or missing bolts.

LOWER BEARING AND SOCKET ASSEMBLY: 1.

Closely inspect for loose, missing or broken bolts or nuts.

2.

Closely inspect all welds on assembly.

3.

Closely inspect all bearings, bushings and oil seals.

SWING GEAR UNIT ASSEMBLY: 1.

Closely inspect gearbox mounting.


COPYRIGHT 2002

LeTourneau, Inc.

9


PUBLICATION OSMĆ4

Okay n

2.

Closely inspect gearbox pinion for cracks.

3.

Closely inspect gearbox pinion adjustment. Should be .020" gap. Refer to the REPAIR AND OVERHAUL MANUAL, Section 1, SWING GEAR UNIT, for informaĆ tion on Swing Gearbox adjustment.

4.

Closely inspect the gearbox lube level.

Needs Attention n

WINCH HOUSING ASSEMBLY: 1.

Closely inspect the mounting structure welds.

2.

Closely inspect for proper attachment of drivers and drive motors.

3.

Closely inspect cable drum structures for cracks, wear and proper attachment.

GANTRY ASSEMBLY: 1.


2.

Closely inspect for wear at attachment points.

3.

Closely inspect welds at attachment points.

4.

Closely inspect welds at main pipes and support pipes.

5.

Closely inspect boom stops.

GANTRY SHEAVE HOUSING ASSEMBLY: 1.

Closely inspect pins, retainers and capscrews.

2.

Closely inspect sheaves for wear.

3.

Closely inspect housing assembly welds.

4.


FLOATING SHEAVE HOUSING ASSEMBLY: 1.


2.


3.


4.


5.

Closely inspect wire rope for proper attachment.

HOOK AND BLOCK ASSEMBLY:

10

1.


2.


3.

Closely inspect housing assembly welds. COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


Okay n

4.


5.

Closely inspect hook assembly for bends, cracks and overall condition.

Needs Attention n

AUXILIARY HOIST ASSEMBLY: 1.


2.


3.


4.


5.



COPYRIGHT 2002

LeTourneau, Inc.

11

ANNUAL TO BE PERFORMED BY QUALIFIED INSPECTOR

Okay n

Needs Attention n

NOTE: The annual inspections includes an inspection of electric motors, servicing drivers and swing gearbox and hydraulic brake system, structural inspection, and operational tests of the crane. These inspections should only be conducted by qualified and experienced inspectors. 1.


2.


3.


4.


5.


6.


7.


8.


9.


10.


11.


12.


13.


14.


15.


16.


17.


18.


19.


20.


21.


22.


23.


24.



COPYRIGHT 2002

LeTourneau, Inc.

1


PUBLICATION OSMĆ4

Okay n

25.


26.


27.


28.


29.


Needs Attention n

ANNUAL INSPECTION AND LUBRICATION REQUIREMENTS NOTE: Numbers in parentheses refer to lubrication points indicated on Figure 3. STOW BOOM FOR SAFE ACCESS TO LUBE POINTS.

2

1.


2.


3.


4.


5.


6.


7.


8.


9.


10.


11.


12.


13.


COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


9

5

3

4

6 4 7

8 1 2

10

PCM 350SS

9

5

10 4 3

6 4 7

8

1 2

PCM 120SS




COPYRIGHT 2002

LeTourneau, Inc.

3


PUBLICATION OSMĆ4

Okay n

Needs Attention n

DRIVERS - SERVICE REQUIREMENTS MAIN HOOK, BOOM, AUXILIARY HOOK (OPTIONAL): S Main Hook 1.

S Boom

Drain,, flush and refill drivers for:

S Auxiliary Hook CRANE SWING COMPONENTS - SERVICE REQUIREMENTS SWING GEARBOX: 1.

Drain, flush and refill swing gearbox. HYDRAULIC BRAKE SYSTEM - SERVICE REQUIREMENTS

1.

Flush and refill hydraulic brake system. WIRE ROPE - INSPECTION AND LUBRICATION REQUIREMENTS

1.


2.

Inspect sheaves for wear, cracks, rope path alignment and bearing condition. CABLE DRUM DEAD END INSPECTION

1.

Check torque on wire rope dead end setscrews (140Ć150 lbs. lubricated with 30W motor oil). OPERATIONAL INDICATORS

1.

Check boom angle/radius indicators over full range for accuracy. DC MOTOR BRAKES

SWING, BOOM, MAIN HOOK AND AUXILIARY HOOK (OPTIONAL):

4

1.

Check the condition of all motor brakes. Refer to Publication OSMĆ6 in the OPĆ ERATING AND SERVICE MANUAL.

2.

Check all motor brakes for proper operation. Refer to Publication OSMĆ6 in the OPERATING AND SERVICE MANUAL.

3.

Check swing motor brake for proper adjustment. Refer to Publication OSMĆ6 in the OPERATING AND SERVICE MANUAL.

4.

Check for damage or leakage in hydraulic brake systems.

5.

Check speed sensors mounting, tightness and condition of leads.

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


ANNUAL ELECTRICAL P.M. Okay n

!

Needs Attention n

CAUTION

Be sure all electrical power is turned off and locked out before touching any electrical connection or terminal. Due to the potential for injury, only qualified experienced persons should enter the Machinery House. ELECTRICAL CONTROLS GROUP: 1.

Check hook Controller condition. Insure card cover is secure and harness conĆ nections are tight.

2.

Check Boom Controller condition. Insure card cover is secure and harness conĆ nections are tight.

3.

Check Swing Controller condition. Insure card cover is secure and harness connections are tight.

4.

Check all converter panels for tight connections and condition of components. Remove any accumulated dust.

5.

Check circuit breakers.

6.

Blow out the cabinet with clean, dry compressed air.

7.

Check backĆup batteries for clean, tight terminal connections (located on top of machinery house).

CORROSION INHIBITORS: 1.

Replace corrosion inhibitors inside controller panel.


COPYRIGHT 2002

LeTourneau, Inc.

5


PUBLICATION OSMĆ4

ANNUAL DC MOTOR BRUSH INSPECTION VERNIER GAUGE

POSITION BRUSH IN GAUGE SAME WAY FOR ALL MEASUREMENTS.

BRUSH

NOT ALL LEADS SHOWN

HIGH POINT ON BRUSH 1ĆCGĆ1088, P01Ć112

TA8010CG

MOTOR

BRUSH #

DIM.

REPLACED?

ANY SPECIAL CONDITIONS

1. 1.

SWING SĆ1A MOTOR

2. 3. 4. 1.

2.

MAIN HOOK N 9 MOTOR NĆ9

2. 3. 4. 1.

2.

BOOM NĆ9 MOTOR

2. 3. 4. 1.

4.


2. 3. 4.

NOTES!ă 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE. 2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS. 3. SEE CHAPTER 4.0 OF TAKING CARE OF YOUR DC MOTOR" LOCATED IN SECTION 2, DC MOTORS, OF THE REPAIR AND OVERHAUL MANUAL FOR CONDITIONS TO LOOK FOR.

6

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


1

2

A

3

B

4

C

5

D

SIMPLIFIED AND EXAGGERATED ILLUSTRATION OF ARMATURE AND COMMUTATOR TA8009CG

1ĆCGĆ1083, P01Ć112

MOTOR

TRACK #

TIR

MAX. BARĆTOĆBAR

SURFACE CONDITION - SEE NOTE

1. 1.

SWING SĆ1A MOTOR

2. 3. 4. 1.

2 2.

MAIN HOOK NĆ9 MOTOR

2. 3. 4. 1.

3 3.

BOOM NĆ9 MOTOR

2. 3. 4. 1.

4.


2. 3. 4.

NOTES!ă 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE. 2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS. 3. IN THE SURFACE CONDITIONS" COLUMN INDICATE OBSERVED CONDITION OF COMMUTATOR SURFACE CONĆ CERNING THE FOLLOWING: (a) CONDITION OF FILM, (b) SIGNS OF ARCING, (c) GROOVING, (d) OTHER CHARACTERĆ ISTICS. REFER TO TAKING CARE OF YOUR DC MOTOR" FOR AN INTERPRETATION OF THE OBSERVATIONS. 9ĆOSMĆ4.2.1b(M4), Gorilla 06/24/02

COPYRIGHT 2002

LeTourneau, Inc.

7


PUBLICATION OSMĆ4

ANNUAL STRUCTURAL INSPECTIONS Okay n

!

Needs Attention n

CAUTION

Dye penetrant and magnetic particle tests shall be conducted on any welds suspected of being cracked. Structural repairs MUST be made in accordance with the guidelines in STRUCTURAL REPAIRS, Publication ROMĆ1, in the REPAIR AND OVERHAUL MANUAL and LeTourneau, Inc., Publication LeTĆ1, FIELD WELDING PROCEDURES, located in the back of Section 1 of the REPAIR AND OVERHAUL MANUAL. Before ANY structural repairs are made to the crane, the certifying authority shall be notified and his surveyor present when the repairs are performed. Any inspections and tests required by the certifying authority after structural repairs are made shall be completed and a new certificate issued BEFORE the crane is returned to service. COLUMN GROUP - BASE: 1.


2.

Closely inspect circumferential and vertical welds of column structure.

3.


4.


5.


COLUMN GROUP - UPPER: 1.


2.


3.

Closely inspect welds on platform assembly and holding platform to column.

4.


5.


6.

Closely inspect all bearings, wear bands and king pin condition.

BOOM:

8

1.

Closely inspect main boom hinge pins and attachment point welds.

2.


3.

Closely inspect welds at bridle cable ears and plates.

4.


5.


6.


7.

Closely inspect condition and attachment of luffing ropes. COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


Okay n

8.

Closely inspect boom sections attachment points for loose, broken or missing bolts.

9.

Closely inspect boom light assemblies for proper attachment, broken lenses, lose wiring and proper operation.

10.

Closely inspect limit switches for proper mounting and adjustment.

11.

Closely inspect catwalks and handrails for cracked welds and loose, broken or missing bolts.

Needs Attention n

JIB BOOM (OPTIONAL): 1.


2.


3.


4.


5.

Closely inspect sheaves, pins and retainers.

SWING TABLE ROLLER ASSEMBLY: 1.

Closely inspect welds at boom and gantry attachment points.

2.

Closely inspect welds around the entire structure.

3.

Closely inspect welds at Machinery House mounting points.

4.

Closely inspect swing gearbox mounting.

5.


6.

Closely inspect structure for loose, missing or broken bolts.

7.

Closely inspect swing bearing and gear for loose, broken or missing bolts.

LOWER BEARING AND SOCKET ASSEMBLY: 1.

Closely inspect for loose, missing or broken bolts or nuts.

2.

Closely inspect all welds on assembly.

3.

Closely inspect all bearings, bushings and oil seals.

SWING GEAR UNIT ASSEMBLY: 1.

Closely inspect gearbox mounting.

2.

Closely inspect gearbox pinion for cracks.

3.

Closely inspect gearbox pinion adjustment. Should be .020" gap. Refer to the REPAIR AND OVERHAUL MANUAL, Section 1, SWING GEAR UNIT, for informaĆ tion on Swing Gearbox adjustment.


COPYRIGHT 2002

LeTourneau, Inc.

9


PUBLICATION OSMĆ4

Okay n

4.

Needs Attention n

Closely inspect the gearbox lube level.

WINCH HOUSING ASSEMBLY: 1.

Closely inspect the mounting structure welds.

2.

Closely inspect for proper attachment of drivers and drive motors.

3.

Closely inspect cable drum structures for cracks, wear and proper attachment.

GANTRY ASSEMBLY: 1.


2.


3.

Closely inspect welds at attachment points.

4.

Closely inspect welds at main pipes and support pipes.

5.

Closely inspect boom stops.

GANTRY SHEAVE HOUSING ASSEMBLY: 1.


2.


3.


4.


FLOATING SHEAVE HOUSING ASSEMBLY: 1.


2.


3.


4.


5.

Closely inspect wire rope for proper attachment.

HOOK AND BLOCK ASSEMBLY:

10

1.


2.


3.


4.


5.

Closely inspect hook assembly for bends, cracks and overall condition. COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


Okay n

Needs Attention n

AUXILIARY HOIST ASSEMBLY: 1.


2.


3.


4.


5.



COPYRIGHT 2002

LeTourneau, Inc.

11


PUBLICATION OSMĆ4

ANNUAL CRITICAL COMPONENT TESTING AND INSPECTION Okay n

Needs Attention n

NOTE: Testing and inspection of critical crane components shall be conducted in acĆ cordance with the requirements of the certifying authority under which the crane is operating. Refer to API RP 2D 8/1999. HYDRAULIC BRAKE SYSTEM: 1.

Inspect and test the backĆup AC pump motor. Refer to Publication OSMĆ6 in the OPERATING AND SERVICE MANUAL.

POWER LOSS LOWERING SYSTEM: 1.

Inspect and test the power loss lowering system. Refer to POWER LOSS LOWĆ ERING SYSTEM located in Publication OSMĆ4 in the OPERATING AND SERĆ VICE MANUAL.

AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS): 1.

Test the AOPS, Refer to AOPS TEST AND CALIBRATION PROCEDURE, located in Publication ROMĆ6 in the REPAIR AND OVERHAUL MANUAL.

LOAD AND SPEED TESTING: The following weight will be needed during the test procedure. NOTE: SWL is Safe Working Load on the hook in pounds, which is the crane rating minus hook and block weight per API 2C. PCM 120SS

PCM 350SS

RADIUS

SWL

RADIUS

SWL

Main Hook - Boom Up

22 ft.

98,400

30 ft.

146,800

Aux Hook - Boom Up

30 ft.

20,000

35 ft.

20,000

Okay n

Needs Attention n

The following inspection or tests must be performed before doing any load testing.

12

1.

Verify that all controls are working properly.

2.

Verify that regenerative braking systems are functioning properly.

3.

Verify that all brake systems are functioning properly.

4.

Verify that all limit switches are adjusted and functioning properly.

5.

Inspect cable to verify proper reeving and that no rubbing or looseness of cable is occurring.

6.

Verify boom raise and lower electrical stop limits.

7.

Replace brake system pressure filter. COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4

PREVENTIVE MAINTENANCE REQUIREMENTS AND RECOMMENDATIONS Time

Test boom luffing and swing speeds with no load load.

Start

1.

Record time required to raise boom from horizontal to maximum boom up posiĆ tion.

2.

Record time required to lower boom from maximum up position to horizontal position.

3 3.

Test swing speed with no load through 180 180° and compare to specification.

4.

Verify that acceleration to full speed and regenerative braking to 0 speed is smooth.

5.

Verify that brake sets are smooth at the stopped position.

End

LEFT RIGHT

Evaluate hook speeds:

!

CAUTION

Always use a minimum load of 2000 lbs. on the hook when running the hook at full speed to prevent slack in cable spooling off of the drum. Distance

1 1.

Boom Up, Main Hook with 2,000 lb. load

2 2.

Boom Up, Main Hook with 75,000 lb. load

3 3.

Boom Up, Aux Hook with 2,000 lb. load

4 4.

Boom Up, Aux Hook with 10,000 lb. load

Time

Speed FPM

Motor Volts

UP DOWN UP DOWN UP DOWN UP DOWN

Okay n

5 5.

Motor Current

Evaluate smoothness of acceleration, deceleration, and stopĆ ping.

Needs Attention n

MAIN AUX

Rated load testing: 1 1.

With boom full up, lift rated load. During this test it is recomĆ mended that the load not be raised over two feet from the deck surface.

2 2.

Evaluate electrical and disc braking systems to assure that they control and hold the load properly. Hold the load for five minutes.


COPYRIGHT 2002

LeTourneau, Inc.

MAIN AUX MAIN AUX 13

PUBLICATION OSMĆ5

OPERATING AND SERVICE MANUAL LeTOURNEAU, INC. PCM CRANE WIRE ROPE USE, HANDLING & MAINTENANCE TABLE OF CONTENTS

TABLE OF CONTENTS

Page

LIST OF ILLUSTRATIONS (Con'd.)

SCOPE OF THIS PUBLICATION . . . . . . . . . . . . . . . 1

FIGURE

COMPONENTS OF WIRE ROPE . . . . . . . . . . . . . . . 2

Page

8.

WEDGE SOCKET ASSEMBLY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .

15

9.

CORRECT INSTALLATION OF WEDGE SOCKET ASSEMBLY . . . . . . . . . . . . . . . . . . .

15

10.

GO" - NOĆGO" METHOD OF DETERĆ MINING CORRECT WIRE ROPE SIZE . . . . .

16

11.

TIGHTENING TORQUE VALUES . . . . . . . . .

16

WIRE ROPE REPLACEMENT CRITERIA AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 WIRE ROPE REPLACEMENT CRITERIA . . . . . . . . 9

12.

INCORRECT INSTALLATION METHODS OF WEDGE SOCKET . . . . . . . . . . . . . . . . . .

16

13.

WIRE ROPE MAINTENANCE . . . . . . . . . . . .

17

REPLACEMENT ROPE SELECTION CRITERIA . . 10

14.

WIRE ROPE SEIZING . . . . . . . . . . . . . . . . . .

20

WIRE ROPE REPLACEMENT PROCEDURES . . . . 10

15.

METHOD OF CLEANING WIRE ROPE . . . .

22

WIRE ROPE SLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SLING REPLACEMENT CRITERIA . . . . . . . . . . . . . 14

16.

METHOD OF LUBRICATING WIRE ROPE .

22

17.

WIRE ROPE LUBRICATION . . . . . . . . . . . . .

24

GENERAL PROCEDURES AND PRECAUTIONS . 2 TEST REPORTS AND WIRE ROPE INSPECTION RECORDS . . . . . . . . . . . . . . . . . . . . . 3 WIRE ROPE INSPECTION PROCEDURES . . . . . . . . 5 WIRE ROPE INSPECTION TOOLS . . . . . . . . . . . . . 5

PROOF LOADING AND LABELING . . . . . . . . . . . . . 14 WIRE ROPE ATTACHMENT PROCEDURE . . . . . . . . 15 INSTALLATION SAFETY ADVISORIES . . . . . . . . . . 15 WEDGE SOCKET ASSEMBLY INSTALLATION . . . 15 OPERATIONAL SAFETY ADVISORIES . . . . . . . . . . 16 SHEAVES, ROLLERS AND DRUMS . . . . . . . . . . . . . . 17 SHEAVES, ROLLERS AND DRUM INSPECTION . 17 SEIZING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . 19 LUBRICATING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . 21 THE IMPORTANCE OF REGULAR WIRE ROPE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 21 CHOOSING THE PROPER LUBRICANT . . . . . . . . 21 WIRE ROPE LUBRICATING PROCEDURES . . . . . 21

SCOPE OF THIS PUBLICATION Publication OSMĆ5, WIRE ROPE USE, HANDLING, AND MAINTENANCE, is to assist maintenance personnel and operators with the basics of inspection, mainteĆ nance and replacement of the wire rope on the crane. As wire rope is a load bearing member of the crane, it is ESSENTIAL to properly maintain it to ensure safe operation.

NOTE

PCMĆ350SS ELECTRIC DECK CRANE WIRE ROPE SPECIFICATIONS . . . . . . . . . . . . . . . . . 25

In several places in this publication, the terms qualified" or competent" person are used with regards to inspection, repair and certification of the crane and its components. A qualified" or competent" person is defined as follows: A person who, by possession of a professional degree, certificate of professionĆ al standing or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

LIST OF ILLUSTRATIONS FIGURE

Page

1.

THE THREE BASIC COMPONENTS OF WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . .

2.

ROPE MEASUREMENT . . . . . . . . . . . . . . . . .

5

3.

WIRE ROPE INSPECTION PROCEDURES .

7

2

4.

ROPE LAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

5.

WIRE ROPE TRANSFER PROCESS . . . . . .

10

6.

RATED CAPACITY SINGLEĆLEG WIRE ROPE SLINGS . . . . . . . . . . . . . . . . . . .

13

7.

RATED CAPACITY - BRIDLE SLINGS . . . .

13

1ĆOSMĆ5.1, 350SS 5/8/00

COPYRIGHT 2002

LeTourneau, Inc.

1

WIRE ROPE USE, HANDLING & MAINTENANCE

PUBLICATION OSMĆ5

NOTE Mandatory rules of this publication per ANSI/ASME are characterized by the word SHALL." If a provision is of an advisory nature, it is indicated by the word SHOULD" and is recommended to be considered, the advisability of which depends on the facts in each situation.

D

Inspect regularly, following the PREVENTIVE MAINĆ TENANCE SCHEDULES in the back of Publication OSMĆ4.

D

Never overload.

D

Minimize shock loading as overstressing of the rope will occur.

NOTE In order to ensure that there is no slack in the rope at the start of loading, start the load carefully and apply the power smoothly and steadily.

COMPONENTS OF WIRE ROPE Wire rope, also referred to as rope, consists of three basic components, the core, the individual wires that form the strands and the multiĆwire strands that are helically laid around the core. Refer to Figure 1 for an illustration of the components of wire rope.

D

Do not operate the machine if the ropes are frozen.

!

Take special precautions under the following conditions: 1.

3.ąthe conditions are abnormal or severe,

WIRE (2)

4.ąthere is a hazard to personnel.

CENTER WIRE (3) STRAND

WIRE ROPE

tag: 3 basic comp FIGURE 1. THE THREE BASIC COMPONENTS OF WIRE ROPE 1ĆCGĆ1227, P08Ć15 TA8021CG

D

Protect rope from sharp corners or edges with padĆ ding.

D

Avoid dragging the rope from under loads or over obstacles.

D

Avoid dropping the rope from heights.

D

Avoid rolling loads with ropes.

D

Store all unused rope in a clean, dry place.

D

Never use wire rope which has been cut, badly kinked or crushed.

D

Prevent loops in slack lines from being pulled tight and kinking.

NOTE

GENERAL PROCEDURES AND PRECAUĆ TIONS Wire ropes, like the machines and hoists on which they are used, require careful use, handling and mainteĆ nance for satisfactory performance, long life and adequate safety. The following general precautions and procedures should be observed to meet these requirements:

!

CAUTION

ALWAYS wear gloves when handling wire rope to prevent hand injury.

2

the exact load is unknown,

2.ąthere is a possibility of shock loading,

CORE (1)

D

CAUTION

If wire rope is replaced ensure that the correct replaĆ cement rope is used. Refer to the PARTS CATALOG for the correct rope for your machine.

Once a kink has been made in a wire rope the damage is permanent. A weak spot will always remain no matter how well the kink seems to have been straightened out. If a loop forms, do not pull it out; unfold it. D

Avoid reverse bends.

D

Repair or replace faulty guides and rollers.

D

Ensure the sheaves are aligned properly.

D

Replace sheaves having deeply worn or scored grooves, cracked or broken rims, and worn or damĆ aged bearings.

D

Repair faulty clutches.

D

Check for abnormal line whip and vibration.

D

Ensure that the rope is installed properly on the drums.

COPYRIGHT 2002

LeTourneau, Inc.

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


D

Never wind more than the proper amount of rope on a drum.

D

Never allow the rope to crossĆwind.

D

Ensure that the rope ends are properly seized.

D

Ensure that the ropes do not bind in sheaves.

apply a lubricant coating to the outside layer of rope on the reel. 3. On a crane that is out of service for long period of time, apply a lubricant to the outside layer of the rope on the drum. Apply additional lubricant to the accessible exposed rope in the hoist system.

NOTE

4. Care should be taken during shipping and handling of the reel and rope to prevent damage to the rope. The loose end of the rope on the reel should be secured properly to the reel.

New wire rope requires a runĆin period before operating at full load and full speed. D a.

Use thimbles in eye fittings at all times. LUBRICATION INSTRUCTIONS:

Lubricate regularly according to the PREVENTIVE MAINTENANCE SCHEDULES in the back of Publication OSCĆ4 and the instructions in LUBRICATING WIRE ROPE, this publication, page 21. Modify these recomĆ mendations for extreme conditions. Also, refer to wire rope manufacturer's recommendations. b.

TEST REPORTS AND WIRE ROPE INĆ SPECTION RECORDS Written, dated and signed operational test and inspecĆ tion reports should be kept and readily available for a period of two years.

STORAGE PROCEDURES:

Wire rope placed in storage whether mounted on a machine or not should be properly maintained. The following procedures should be performed to prevent rope damage and deterioration: 1. Stored ropes should be covered in a well ventilated area and away from excessive heat. 2. Where covered storage is not available, the rope and reel should be covered with waterĆ proof material. For long periods of storage

1ĆOSMĆ5.1, 350SS 5/8/00

COPYRIGHT 2002

NOTE Wire rope removed from service should be identified and marked as unfit for use on cranes, slings or other load carrying devices.

NOTE UNDER NO CIRCUMSTANCES shall any machine be reĆrated in excess of the original load ratings unless rating changes are approved by LeTourneau, Inc. and a new load chart is available.

LeTourneau, Inc.

3


PUBLICATION OSMĆ5

NOTES

4

COPYRIGHT 2002

LeTourneau, Inc.

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


WIRE ROPE INSPECTION PROCEDURES Wire Rope is a structural component of the crane requiring periodic replacement. Possible loss of strength can result from wear, abuse and other forms of deterioration. The wire rope must be carefully selected, inspected and maintained. The qualified person who determines whether replacement is necessary should be knowledgeable in the inspection and maintenance of wire rope. No precise rules can be given for determination of the exact time for replacement of rope, since many variable factors are involved. Continued use depends largely upon good judgement by the qualified person in evaluating the strength remaining in the rope after allowance for deterioration disclosed by inspection. Continued rope operation depends upon this remaining strength.

NOTE Wire rope removed from service should be identified and marked as unfit for use on cranes, slings or other load carrying devices. b.

Wire ropes on the machine shall be inspected daily or prior to use if the machine is not used daily. This visual inspection should include moving and standing ropes, end fittings and pins. The daily visual inspections should be concerned with discovering gross damage, such as listed below, which may be an immediate hazard:

WIRE ROPE INSPECTION TOOLS Tools for the inspection of wire rope should include but are not limited to the following:

1. Distortion of the rope such as crushing, unĆstranding, birdcaging, main strand disĆ placement, or core protrusion; loss of rope diameter in a short rope length or unevenness of outer strands provide evidence that rope replacement should be considered. Refer to Figure 2 for an illustration of the wire rope measuring process.

D Awl

2. General corrosion

D Marlin spike

3. Number, distribution, and type of visible broken (Refer to WIRE ROPE REPLACEMENT CRITERIA AND PROCEDURES, this publicaĆ tion page 9.)

D Steel tape D Sheave groove gauges

4. Core failure in rotation resistant ropes. ParticĆ ular care shall be taken when inspecting rotation resistant ropes because of their susceptibility to damage from handling and misuse and potential for deterioration when used on equipment with limited design paĆ rameters. Internal deterioration of rotation resistant ropes may not be readily observable.

D Calipers D Chalk D Wiping cloth D Gloves a.

DAILY VISUAL INSPECTION

INSPECTION PROCEDURES: ACTUAL DIAMETER

B. CORRECT

A.

C. INCORRECT

tag: rope measuremt FIGURE 2. ROPE MEASUREMENT 1ĆCGĆ1229, P08Ć15

1ĆOSMĆ5.1, 350SS 5/8/00

TA8023CG COPYRIGHT 2002

LeTourneau, Inc.

5


PUBLICATION OSMĆ5

NOTE

machine. Care should be exercised in inspecting the rope at these points. Refer to Figure 3. Inspection should include but not be limited to the following areas:

Rotation resistant wire rope is rope consisting of an inner layer of strand laid in one direction covered by a layer of strand laid in the opposite direction. This has the effect of counteracting torque by reducing the tendenĆ cy of the finished rope to rotate.

1. Equalizer sheaves or saddles, also referred to as fixed guides, or other sheaves where wire rope travel is limited. 2. End connections including socket or end attachments to running ropes, boom penĆ dants and other standing wire ropes. Refer to Figure 2.

c. Particular care should be taken when inspecting section of rope subject to rapid deterioration such as flange points, crossover points, and repetitive pickup points on drums. d.

3. Sections of wire rope where the rope is continually running over sheaves within the various hoist systems. This inspection is of particular importance where boom angle and load block changes are frequent and limited to short distances.

PERIODIC INSPECTION

A qualified person should inspect the wire rope at a frequency based on such factors as: expected rope life as determined by experience on the particular installaĆ tion or similar installations, severity of environment, percentage or lifts at maximum rating, frequency rates of operation, and exposure to shock loads. Inspections need not be at equal calendar intervals and should be more frequent as the rope approaches the end of its useful life. However, this inspection shall be made at least annually. A written, signed and dated inspection report should be kept and readily available for two years or until the wire rope is retired. The periodic inspection shall cover the entire length of the rope. Any deterioraĆ tion resulting in appreciable loss of original strength, such as described below, shall be noted and determinaĆ tion made as to whether further use of the rope would constitute a hazard:

4. At crossover and flange points of the wire rope on hoist drums. 5. Special care should be taken in the inspection of rotation resistant wire rope (see above). j.

Wire ropes which have been idle for one month or more should be inspected by a qualified person before being placed into service. A written, signed and dated inspection report should be kept and readily available for two years or until the wire rope is retired.

NOTE A long range inspection program should be established to include records on examination or ropes removed from service to establish a relationship between visual observation and actual condition of the internal structure.

e. The points listed in the daily visual inspections above f. Reduction of rope diameter below nominal diameĆ ter due to loss of core support, internal or external corrosion, or wear of outside wires g. Severely corroded or broken wires at end connecĆ tions h. Care shall be taken when inspecting rope sections subject to rapid deterioration, such as the following: 1. Sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited; 2. Sections of the rope at or near terminal ends where corroded or broken wires may proĆ trude; 3. Sections subject to reverse bends; 4. Sections of rope which are normally hidden during routine visual examination, such a parts passing over sheaves. i.

ROPE INSPECTION AT CONTACT POINTS

Heavy wear and /or broken wires occur in wire rope sections in contact with certain components of the 6

WIRE ROPES NOT IN REGULAR USE

k.

INSPECT FOR LOCALIZED WEAR

Premature wear at one spot is common and can be prevented if the cause is detected. Uneven wear can be minimized by moving the rope at regular intervals so that different stretches of it are at the critical wear points. Changing layer and crossover points is merely a matter of cutting a few feet of rope from the drum end and refastening it. The cut should be long enough to move the change of layer at least one full coil from its former position and to move the crossover points oneĆquarter turn around the drum. Move the static section on an equalizer sheave three sheave diameter lengths away by cutting off the section on the drum end of the rope. To distribute wear due to vibration, cut off a section next to the dead end and refasten the rope. l.

INSPECT FOR SLACK IN THE ROPE

Even with the utmost care during installation, it is quite common to find that the dead turns on the drum become somewhat slack in operation. This slackness

COPYRIGHT 2002

LeTourneau, Inc.

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


THE WIRES BREAK IN THE VALLEY WHERE STRAND TO STRAND CONTACT OCCURS

VALLEY BREAKS CHECK FOR INTERNAL DAMAGE AFTER DISCOVERING BROKEN WIRES BETWEEN STRANDS.

BROKEN WIRES IN THE INDEPENDENT WIRE ROPE CORE ARE NOT DISCERNIBLE FROM EXTERIOR EXAMINATION OF THE ROPE.

tag: wir rop inspect

1ĆCGĆ1231, P08Ć15

1ĆOSMĆ5.1, 350SS 5/8/00

FIGURE 3. WIRE ROPE INSPECTION PROCEDURES COPYRIGHT 2002

LeTourneau, Inc.

TA8002CG

7


PUBLICATION OSMĆ5

arises from a certain amount of stretch which occurs in a new rope under tension and periodically throughout the life of the rope from release of the load. When this slackness is noted, these turns should be rewound to tighten them. If left uncorrected, a wedging action, causing abrasion from the second layer, will occur and broken wires in the dead turns will appear.

NOTE Localized abrasion and fatigue can be dealt with, without the necessity of discarding the whole rope, by installing a longer rope than necessary, initially, and cutting one end or the other to expose a new section of rope to the place where the deterioration occurs.

NOTES

8

COPYRIGHT 2002

LeTourneau, Inc.

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


WIRE ROPE REPLACEMENT CRITERIA AND PROCEDURES Wire rope is an expendable item and is routinely replaced in accordance with criteria set out in American Petroleum Institute API RP 2D Recommended Practices for Maintenance and Operation of Offshore Cranes. It also has a variable load life characteristics which significantly differ from the more or less permanent components of the crane. Because of this and the many other inherent properties peculiar to wire rope, it was decided to set singular design factors taking into consideration each type rope and rope service. The design factors have been increased and based on experience, are sufficiently large to account for minor strength effects such as specified sheave sizes, tackle dynamics and nominal versus minimum rope strength.

WIRE ROPE REPLACEMENT CRITERIA The following general instructions should be used in the inspection process for determination of the replaceĆ ment interval of wire rope on the machine.

NOTE

When inspection indicates suspected loss of original strength, the qualified person shall make a determinaĆ tion relative to further use of the wire rope. Conditions such as the following shall be reasons for questioning continued use of the rope or for increasing the frequency of inspection: b. In running ropes, 12 randomly distributed broken wires in 1 lay, or 4 broken wires in 1 strand in 1 lay. c. In rotation resistant wire ropes, 4 randomly distributed broken wires in one lay or 2 broken wires in 1 strand in 1 lay. d. One (1) outer wire broken at the contact point with the core of the rope indicated by an externally protrudĆ ing wire or loop of loose wires. e. Wear of oneĆthird the original diameter of outside individual wires.

Wire rope removed from service should be identified and marked as unfit for use on cranes, slings or other load carrying devices. a.

The various rope conditions noted upon inspection should be used to determine continued use or retireĆ ment of the rope in question. The following replacement criteria examples are a list of wire rope applications for a crane.

f. Kinking, crushing, birdcaging, or any other damĆ age resulting in distortion of the rope structure. g.

BROKEN WIRE REPLACEMENT CRITERIA

Broken wire replacement criteria were developed by testing with hardened steel sheaves. When broken wires begin to appear, additional broken wires can be anticipated in a short period. Once broken wires are observed, inspections should be made at more freĆ quent intervals.

NOTE The term ROPE LAY or LAY LENGTH will be used in later paragraphs of this publication. A ROPE LAY or LAY LENGTH is the distance measured parallel to the axis of the rope in which a strand makes one complete helical revolution about the core. Refer to Figure 4 for an illustration of a ROPE LAY.

Evidence of heat damage from any cause.

h. Reductions from nominal wear diameter greater than those shown below: Maximum Allowable ReducĆ tion from Nominal Diameter

Rope Diameter Up to 5/16" (8 mm)

1/64" (.04 mm)

Over 5/16" to 1/2" (13 mm)

1/32" (0.8 mm)

Over 1/2" to 3/4" (19 mm)

3/63" (1.2 mm)

Over 3/4" to 1Ć1/8" (29 mm)

1/16" (1.6 mm)

Over 1Ć1/8" to 1Ć1/2" (38 mm)

3/32" (2.4 mm)

Refer to Figure 2 for an illustration of the wire rope measuring process. i. Attention shall be given to end connections. Upon development of more than 2 broken wires adjacent to a socketed end connection, the rope shall be reĆsocketed or replaced. ReĆsocketing shall not be attempted if the resulting rope length will be insufficient for proper operation.

NOTE ONE ROPE LAY

FIGURE 4. ROPE LAY 1ĆCGĆ1228, P08Ć15

1ĆOSMĆ5.1, 350SS 5/8/00

TA8001CG

COPYRIGHT 2002

These replacement criteria were developed on steel sheaves. When sheaves of other materials are used, the manufacturer of the sheave should be consulted.

LeTourneau, Inc.

9


PUBLICATION OSMĆ5

NOTE

WIRE ROPE REPLACEMENT PROCEĆ DURES

Inspection records should be maintained to determine the time interval for retirement of the wire rope. Records should be readily available until the specific wire rope is retired. All observed rope deterioration as listed above should be recorded on these inspection records.

These general instructions should be followed in the replacement of the wire rope on the machine to prevent damage: a. Unreeling or uncoiling of wire rope should be done as recommended by the rope manufacturer. Care should be taken to avoid kinking or introduction of twist into the rope. Use additional care when unreeling or uncoiling rotationĆresistant rope.

REPLACEMENT ROPE SELECTION CRITERIA Replacement wire rope should be selected by using the following criteria:

NOTE Wire rope on the machine MUST be replaced with same diameter, length, construction and grade rope as the machine was originally equipped. The replacement rope MUST not be different unless approved by LeTourneau, Inc. and all furnished load rating charts MUST be reviewed and changed as required. ReplaceĆ ment wire rope shall be certified to original specifications and the certificate kept on file in the Control Book.

b. To avoid introduction of twist into the rope while reeving, remove the rope from the same side of the reel as it will operate on the drum, top to top or bottom to bottom. When transferring wire rope from a storage reel to a drum, the rope should travel from the top of the reel to the top of the drum; or from the bottom of the drum. This will avoid a reverse bend in the rope as it is being installed. Installing a rope so that a reverse bend is put into it causes the rope to become twisty," difficult to handle and spool smoothly on the drum. This is especially true of large diameter wire ropes. A braking action should be applied to the reel at all times (use a block of timber against the reel flange) in order to get a good smooth wrap on the drum. Refer to Figure 5 for an illustration of the transferring process.

WRONG

WRONG

(THIS REVERSES THE NATURAL CURVE IN THE WIRE.)

REEL

REEL DRUM

DRUM

BRAKE

BRAKE

Never reel from top to bottom or from bottom to top.

RIGHT

RIGHT

(THIS RETAINS THE NATURAL CURVE IN THE WIRE.)

REEL

REEL DRUM

DRUM BRAKE

BRAKE

tag: wir rop transf 1ĆCGĆ1232, P08Ć15, 1/28/98

10

Always reel from top to top or from bottom to bottom.

FIGURE 5. WIRE ROPE TRANSFER PROCESS COPYRIGHT 2002

LeTourneau, Inc.

TA8000CG

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


c. For crane applications, care must be taken to assure that the boom hoist system is reeved for the specific crane configuration in use. d. When reeving through the sheave system avoid kinks or looping which could damage the rope. e. Cut off all welded ends of the rope before installing in a wedge socket or wedge in the drum. f. New rope, when first installed, should be broken in by slowly lifting and lowering a light load several cycles through the entire hoist mode.

bending the rope about small pipe or crane compoĆ nents which might induce kinks or curling. i. Wire rope clips should be installed in accordance with wire rope or clip manufacturer's recommendations. The saddle portion of the clip shall be applied to the live rope segment and the UĆbolt to the dead or shortened end segment. The wire rope clip nuts should be tightened after initial use of the wire rope and periodicalĆ ly checked. This instruction does not apply to the use of wire rope clips with wedge sockets.

g. Before cutting a rope, seize the rope at either side of the cut location to prevent unĆlaying of the strands. Seizing of the wire rope should be performed by or supervised by a qualified person. Refer to SEIZING WIRE ROPE, page 19, this publication. h. Care should be taken during installation to avoid contaminating, scraping or nicking the wire rope. Avoid

NOTE The wire rope is retained to the cable drum dead end with 3/4 UNC setscrews. These setscrews tighten to 140Ć150 lbs. torque with the threads lubricated with 30W motor oil. Torque should be checked every six months.

NOTES

1ĆOSMĆ5.1, 350SS 5/8/00

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LeTourneau, Inc.

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PUBLICATION OSMĆ5

NOTES

12

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PUBLICATION OSMĆ5


WIRE ROPE SLINGS This instruction applies to singleĆpart wire rope slings. Consult sling manufacturer's recommendations for multiĆpart rope slings.

!

CAUTION

RATED CAPACITY FOR SINGLEĆLEG SLING IN U.S. TONS (2,000 Lb.) ROPE DIAM. (INCH)

MS(1)

HT(2)

S(3)

1/2

2.2

2.0

2.3

5/8

3.4

3.0

3.6

3/4

4.9

4.2

5.1

7/8

6.6

5.5

6.9

1

8.5

7.2

9.0

1Ć1/8

10.0

9.0

11.0

1Ć1/4

13.0

11.0

14.0

1Ć3/8

15.0

13.0

17.0

1Ć1/2

18.0

16.0

20.0

1Ć3/4

25.0

21.0

27.0

2

32.0

28.0

34.0

Wire rope slings should not be field fabricated except where necessary under special cirĆ cumstances. If circumstances require field fabrication, proper equipment should be available and qualified persons should perform this function using accepted standard practices. Zinc or resin poured sockets should be fabricated in accordance with API RP 9B. a.

SINGLEĆLEG WIRE ROPE SLINGS

The data in Figure 6 shall be used to determine the rated capacity of the various size singleĆleg wire rope slings of improved plow steel (IPS), independent wire rope core (IWRC) constructed with the terminals as noted. Increase these values by 15 percent if extra plow steel (EIPS) independent wire rope core (IWRC) rope is used in the sling fabrication. Consult the wire rope manufacĆ turer for ratings of wire rope slings of construction and grades other than those listed in this section.

!

MS(1) HT(2) MS(1)

FIGURE 6. RATED CAPACITY SINGLEĆLEG WIRE ROPE SLINGS

CAUTION

No singleĆleg hitch should be used on slings with a load that cannot be controlled. Always rig the sling and load so as not to allow the load or lifting device to rotate and unĆlay the sling rope. Rotation or twisting of the load can cause excessive stress on the attachment connection and reduce the slings capacity or pull out.

Mechanical sleeve attachment Hand tucked splice attachment Zinc or resin poured

A

A

ANGLE A 15° 30° 45° 60°

COSINE OF ANGLE A 0.966 0.866 0.707 0.500

Example: TwoĆlegged bridle of 1 inch IPS, IWRC wire rope with zinc poured socket attachments, at 45°. Rated Capacity = 9.0 tons x 2 x 0.707

b.

CHOKER SLINGS

Cosine of Angle A

Slings used in choker configurations have a rated capacity of 70 percent or S(3) if the choke angle is 120° or greater. c.

BRIDLE SLINGS

For bridle slings and basket hitches where both legs are not vertical use the following computation of the sling arrangement rated capacity. Rated Capacity equals Single leg capacity (refer to Figure 7) times the number of legs times the cosine of angle A. 1ĆOSMĆ5.1, 350SS 5/8/00

Number of Legs Capacity from FigĆ ure 6 Rated Capacity = 12.73 tons

tag: bridle slings FIGURE 7. RATED CAPACITY - BRIDLE SLINGS

d.

SLING INSPECTION:

All loose slings should be visually inspected daily and a detailed periodic inspection should be performed on a

COPYRIGHT 2002

LeTourneau, Inc.

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PUBLICATION OSMĆ5

regular basis with the frequency of inspection based on the following: Slings should not be made using wire rope clips. 1. Frequency of sling use 2. Severity of service conditions 3. Nature or type of lifts being made 4. Experience based on service life of slings used in similar applications

NOTE

d.

Evidence of heat damage or exposure.

e.

Cracked, deformed or worn end attachments.

f. Hooks that have been opened more than 15 percent of their normal throat opening or twist more than 10 degrees from the plane of the unbent hook. g.

Severe corrosion of the rope or end attachments.

PROOF LOADING AND LABELING Slings of all rope grades and construction terminated by mechanical, hand tucked or poured attachments shall be proof loaded by the sling manufacturer when specified by the purchaser.

Inspections should be made by qualified persons only. Deterioration which could contribute to loss of the original strength shall be noted and the sling retired if such loss is considered excessive.

SLING REPLACEMENT CRITERIA Reasons for replacing the wire rope sling include but are not limited to the conditions below. If there is any question relative to the integrity of the sling, it should be retired. a. In singleĆpart slings, ten (10) randomly distributed broken wires in one lay length or five (5) broken wires in one strand in one lay length. b.

c. Kinking, crushing, birdcaging or any other damĆ age resulting in distortion of the rope strand and core configuration.

Severe localized abrasion or scraping.

The proof load for singleĆleg slings with mechanical or poured attachments shall be twice the vertical rated capacity. Slings with handĆtucked splice attachments shall be proof loaded to the vertical rated capacity. The proof load for multipleĆleg bridle slings shall be applied to each of the individual legs. Slings of all types, grade and construction should be labeled showing sling manufacturer and the vertical rated capacity when specified by the purchaser. Slings of other than wire rope construction should be used, inspected and tested in accordance with the sling manufacturer's recommendations.

NOTES

14

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PUBLICATION OSMĆ5


WIRE ROPE ATTACHMENT PROCEDURE The PCM Electric Deck Cranes use a Wedge Socket Assembly with a cable clamp for attachment of the wire rope to components other than the cable drums. It is CRITICALLY IMPORTANT that the Wedge socket Assembly be correctly installed. Incorrect installation can result in bodily injury and/or damage to equipment.

D Repair minor cracks or gouges to socket or pin by lightly grinding until surfaces are smooth. Do not reduce original dimension more than 10%. D Inspect permanent assemblies annually, or more often in severe operating conditions. D Use only with standard 6 to 8 strand wire rope of designated size. For intermediate size rope, use next larger size socket. For example, when using 9/16" diameter wire rope, use a 5/8" size Wedge Socket Assembly. Welding of the tail on standard wire rope is not recommended. The tail length of the dead end should be a minimum of 6 rope diameters but not less than 6". Refer to Figure 9.

INSTALLATION SAFETY ADVISORIES

D Loads may slip or fall if the wedge socket is not properly installed. D A falling load can seriously injure or result in the loss of life. D Read and understand these instructions before installing the wedge socket.

TAIL LENGTH*

D Do not side load the wedge socket. D Apply first load to fully seat the wedge and wire rope in the socket. This load should be of equal or greater weight than loads expected in use.

RIGHT CORRECT INSTALLATION OF WEDGE SOCKET ASSEMBLY

WEDGE SOCKET ASSEMBLY INSTALLAĆ TION

*TAIL LENGTH Standard 6 to 8 strand wire rope

Components of the Wedge Socket Assembly are shown in Figure 8. PIN SOCKET

A minimum of 6 rope diameters, but not less than 6"

FIGURE 9. CORRECT INSTALLATION OF WEDGE SOCKET ASSEMBLY

COTTER KEY

1ĆCGĆ1959, P10Ć73

WEDGE

FIGURE 8. WEDGE SOCKET ASSEMBLY COMPONENTS

NOTE

TAĆ9257ĆCG

The general guidelines listed below should be followed in the installation and maintenance of the Wedge Socket Assembly: D Always inspect socket, wedge and pin before installing. D Do not use any part showing cracks. 1ĆOSMĆ5.1, 350SS 5/8/00

TAĆ9259ĆCG

D To use rotation resistant wire rope (special wire rope constructions with 8 or more outer strands), ensure that the dead end is welded, brazed or seized before inserting the wire rope into the wedge socket to prevent core slippage or loss of rope lay. The tail length of the dead end should be a minimum of 20 rope diameters but not less than 6". Refer to Figure 9.

CABLE CLAMP

1ĆCGĆ1958, P10Ć73

Rotation Resistant Wire Rope A minimum of 20 rope diameters, but not less than 6"

COPYRIGHT 2002

The wedge has GO" and NOĆGO" features to determine correct wire rope size cast into the wedge. Refer to Figure 10. The proper size wire rope is determined when the following criteria are met: 1. The wire rope shall pass through the GO" hole in the wedge.

LeTourneau, Inc.

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PUBLICATION OSMĆ5

WRONG ROPE BACKWARD

FIGURE 10. GO" - NOĆGO" METHOD OF DETERMINING CORRECT WIRE ROPE SIZE 1ĆCGĆ1960ĆP10Ć73

WRONG WEDGE BACKWARD

FIGURE 12. INCORRECT INSTALLATION METHODS OF WEDGE SOCKET

TAĆ9258ĆCG

1ĆCGĆ1961, P10Ć73

2. The wire rope shall NOT pass through the NOĆGO" hole in the wedge. Rope Size

3/8

7/16

1/2

9/16

5/8

3/4

Clip Size

3/8

7/16

1/2

9/16

5/8

3/4

*Torque Ft./Lbs.

45

65

65

95

95

130

7/8

1

1Ć1/8 1Ć1/4

7/8

1

1Ć1/8 1Ć1/4

225

225

225

TAĆ9256ĆCG

D Do not attach dead end to live end or install wedge backwards. Refer to Figure 12. D Use a hammer to seat wedge and rope as deep into socket as possible before applying first load.

360

*The tightening torque values shown are based upon the threads being clean, dry and free of lubrication.

OPERATIONAL SAFETY ADVISORIES D Apply first load to fully seat the wedge and wire rope in the socket. This load should be of equal or greater weight that loads expected in use.

FIGURE 11. TIGHTENING TORQUE VALUES D Properly match socket, wedge and clip to wire rope size. Refer to Figure 11. D Align live end of rope with center line of pin. Refer to Figure 9. D Secure dead end section of rope. Refer to FigĆ ure 9. D Tighten nuts on clip to recommended torque. Refer to Figure 11.

16

WRONG TAIL CLIPPED TO LIVE LINE

COPYRIGHT 2002

D During use, do not strike the dead end section with any other elements of the rigging (two blocking).

NOTE Efficiency rating of the wedge socket terminaĆ tion is based upon the catalog breaking strength of wire rope. The efficiency of a properly assembled wedge socket is 80%.

LeTourneau, Inc.

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PUBLICATION OSMĆ5


SHEAVES, ROLLERS AND DRUMS During regular inspections and when ropes are changed on a crane a number or areas effecting performance and rope life should be checked and corrected. This inspection or check should include but not be limited to the following:

SHEAVES, ROLLERS AND DRUM INSPECĆ TION

g. Rope end attachment checked for compatibility of rope size. h. Rope spooling on drum checked for correct spacing and cross over and winding. i. Grooved drums checked for condition, size and alignment of grooves.

a. Sheaves should be checked with a groove gauge for wear and checked for corrugation, the rope imprint in the groove surface. Refer to Figure 13 for and illustration of the sheave inspection process. b. Sheaves should be checked for broken or chipped flanges. c.

f. Drum flange should be checked for cracks, chips or other deterioration.

Sheaves should be checked for cracks in the hub.

d. Sheaves should be checked for freedom of rotation without drag. e. Sheaves and shafts should be checked for bearing or shaft wear.

CHECK FLANGES FOR WEAR, CHIPS AND CRACKS

j. Smooth drums checked for surface conditions to ensure that there are no cracks or corrugation from the rope. MAINTENANCE OF SHEAVES, ROLLERS AND DRUMS Proper maintenance of the equipment over which the ropes operate has an important bearing on rope life. Worn grooves, poor alignment of sheaves and worn parts resulting in shock loads and excessive vibration will have a deteriorating effect. Sheaves and grooved rollers should be checked periodically for wear in the grooves, which may cause pinching and abrasion of the ropes. If the

ÎÎÎ ÎÎÎ ÎÎÎ ÎÎÎ ÎÎÎ ÎÎÎ ÎÎÎ ÎÎÎ

CHECK SHEAVE GROOVES FOR WEAR.

CHECK BEARINGS FOR WOBBLE, LUBRICATION & EASE OF ROTATION A SHEAVE BADLY CORRUGATED BY THE ROPE'S "PRINT", A CONDITION WHICH COULD SERIOUSLY DAMAGE THE WIRE ROPE. IMPROPER

A PROPER FITTING SHEAVE GROOVE SHOULD SUPPORT THE ROPE OVER 135150 DEGREES OF ROPE CIRCUMFERENCE.

CHECK GROOVES FOR PROPER SIZE OBSERVE THE GROOVE SO THAT IT MAY BE CLEARLY SEEN WHETHER THE CONTOUR OF THE RADIUS GAUGE MATCHES THE CONTOUR OF THE BOTTOM OF THE RADIUS GAUGE.

tag: wire rope maint

FIGURE 13. WIRE ROPE MAINTENANCE 1ĆCGĆ701, P01Ć50

1ĆOSMĆ5.1, 350SS 5/8/00

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PUBLICATION OSMĆ5

groove bears the imprint of the rope, it should be machined clean or replaced. The same should be done with drums showing similar effects. Sheaves with oversized grooves do not properly support the rope and must be replaced. A radius gauge should be used to check the alignment of the rope in the grooves ( Refer to Figure 13). Poor alignment of sheaves will result in wear on the

rope and wear on the sheave flange. This should be corrected immediately as a distorted groove will also result. Sheave and roller bearings should be checked for free operation. Sticking will cause unnecessary wear. Excessive wear in the sheave bearings can cause rope fatigue from the vibration.

NOTES

18

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LeTourneau, Inc.

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


SEIZING WIRE ROPE Seizing is as process in which wire ropes are bound and secured prior to a cut being made. While there are numerous ways to cut wire rope, in every case certain precautions must be observed. For one thing, proper seizings are always applied on both sides of the place where the cut is to be made. In a wire rope, carelessly or inadequately seized ends may become distorted and flattened, and the strands may loosen. Subsequently, when the rope is put to work, there may be an uneven distribution of loads to the strands, a condition that will significantly shorten the life of the rope. There are two widely accepted methods of applying seizing (Refer to Figure 14 for Method A" and Method B"). The seizing itself should be a soft, or annealed, wire or strand. The seizing wire diameter and the length of the seize will depend on the diameter of the wire rope. But the length of the seizing should never be less than the diameter of the rope being seized. For preĆformed ropes, one seizing on each side of the cut is normally

sufficient. But for those that are not preĆformed, a minimum of two seizings is recommended (Method B"). Seizings should be spaced six rope diameters apart.

SEIZING THE ROPE Figure 14 lists seizing lengths and seizing wire diameĆ ters suggested for use with some commonly used wire ropes. METHOD A": Lay one end of the seizing wire in the groove between two strands and wrap the other end tightly in a close helix over a position of the groove, using a seizing iron (a round bar 1/2" to 5/8" diameter x 18" long) as shown in Figure 14. Seizing widths should not be less than the rope diameter. METHOD B": The procedure illustrated in Figure 14 is the second of the two (A and B) accepted methods for placing seizing on wire rope.

NOTES

1ĆOSMĆ5.1, 350SS 5/8/00

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PUBLICATION OSMĆ5

2

3 6 1

4

METHOD A"

5

METHOD B"

SEIZING - SUGGESTED DIAMETERS AND LENGTHS Rope Diameters

Seizing Wire Diameters*

Seizing Lengths

inches

mm

inches

mm

inches

mm

1/8–5/16

3.5–8.0

.032

0.813

1/4

6.0

3/8–9/16

9.5–14.5

.048

1.21

1/2

13.0

5/8–15/16

16.0–24.0

.063

1.60

3/4

19.0

1–1-15/16

26.0–33.0

.080

2.03

1-1/4

32.0

1-3/8–1-11/16

35.0–43.0

.104

2.64

1-3/4

44.0

1-3/4–2-1/2

45.0–64.0

.124

3.15

2-1/2

64.0

2-9/16–3-1/2

65.0–89.0

.124

3.15

3-1/2

89.0

*The wire rope manufacturer should be consulted for seizing wire diameters of rope not included in this chart. tag: wir rop seiz 1ĆCGĆ1240, P08Ć15

20

FIGURE 14. WIRE ROPE SEIZING COPYRIGHT 2002

LeTourneau, Inc.

TAĆ6029

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


LUBRICATING WIRE ROPE The lubrication new ropes receive during manufacture is adequate for initial storage and early stages of the rope's working life, but a regular lubrication program is essential to gain the maximum service life from the rope. The following instructions provide guidelines for the proper lubricating of the wire rope on the machine.

!

Used crankcase oil should NEVER be used to lubricate a wire rope. It contains tiny metal chips which abrade the rope, it is acidic, and it has few of the characteristics that a good rope lubricant should have.

THE IMPORTANCE OF REGULAR WIRE ROPE LUBRICATION

NOTE Lubricants recommended by LeTourneau, Inc. are listed in Publication OSMĆ4, PCM CRANE LUBRICATION SPECIFICATIONS, this manuĆ al. Lubricate the wire rope at regular intervals in accordance with the PREVENTIVE MAINTEĆ NANCE SCHEDULES in the back of publicaĆ tion OSMĆ4. For off shore cranes, a rust preventive lubricant such as Mobil MobilarĆ ma 798" or Texaco Crater X" or equivalent is recommended.

Lubricating a rope is as important as greasing any other piece of machinery. If a planned program of regular lubrication is not carried out, then the rope will deteriorate as follows: D

Corrosion and pitting will occur, causing a loss of steel area and, therefore, a loss in strength of the rope.

D

The wires will become brittle from excessive corroĆ sion and will break easily.

D

Since each wire in the rope moves relative to the others during operation, they are subject to fricĆ tional wear. Lack of lubrication will increase the wear rate, causing a marked reduction in strength from loss of steel area.

D

Pits also cause internal nicking of the wires, which results in loss of strength.

D

Ropes not in regular service or those not considĆ ered as operating ropes are vulnerable to weatherĆ ing out of the lubrication. Moisture seeps in, and both core and wires deteriorate.

CHOOSING THE PROPER LUBRICANT Wire rope should be lubricated with a lubricant which provides excellent protective covering properties proĆ ducing a nonĆtacky but firm and flexible coating. This lubricant should also be water repellent, have excellent resistance to very high and very low temperatures, good lubricating properties and free of mineral acids.

WIRE ROPE LUBRICATING PROCEDURES a.

Corrosion resistance.

D

Water repellent.

D

Penetrating ability.

D

Chemically neutral.

D

High pressure flow characteristics.

D

Adhesiveness and an affinity for steel.

D

Temperature stability.

1ĆOSMĆ5.1, 350SS 5/8/00

ROPE CLEANING TECHNIQUES

The rope must be clean and dry before the lubricant is applied because effective lubrication occurs only when the dressing comes in contact with bare metal. If this is not done, the lubricant will fall off, allowing moisture to work into the rope to cause corrosion. Excessive moisture gradually leaches out the internal lubricant.

!

CAUTION

ALWAYS wear gloves when handling wire rope to prevent hand injury. The old lubricant can be removed by stationary or powerĆdriven wire brushes or by compressed air jets (Figure 15). It is advisable to use a light penetrating cleaner to soften the builtĆup material before removing it. The lubricant supplier should be contacted regarding the proper cleaning oil to use.

!

CAUTION

Do not use gasoline or kerosene to clean wire rope as too much of it will remove the internal lubricant.

Good wire rope lubricants have the following characterĆ istics: D

CAUTION

b.

LUBRICANT APPLICATION TECHNIQUES

In view of the small space existing between wires in the strand and strands in the rope, do not expect externally applied lubricant to completely penetrate the rope. The main object in external lubrication is to fill the gaps between the strands and rope so that a complete seal is provided. The lubrication should be carried out periodiĆ cally to maintain this seal. The frequency required will depend upon the particular installation. COPYRIGHT 2002

LeTourneau, Inc.

21


PUBLICATION OSMĆ5

COMPRESSED AIR

WIRE BRUSHES

AIR BLAST DRYING

BATH OF PENETRATING CLEANER

tag: clean wire rope FIGURE 15. METHOD OF CLEANING WIRE ROPE

TEMPORARY WINDING DRUM

PREFERRED METHOD SINCE ROPE OPENS UP OVER SHEAVE ALLOWING OIL TO PENETRATE.

AIR BLAST APPLICATION

AIR OIL

OIL BATH APPLICATION

BRUSH APPLICATION

DIP AND SWAB APPLICATION

OIL BATH APPLICATION

tag: lub wire rope

USING SPLIT WOODEN OR METAL BOXES ROPE PASSES THROUGH BURLAP OR SIMILAR WIPER AT OUTLET END OF BOX

1ĆCGĆ705, P01Ć51

22

FIGURE 16. METHOD OF LUBRICATING WIRE ROPE COPYRIGHT 2002

LeTourneau, Inc.

TA7654CG

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


Application of the lubricant may be accomplished by several methods. These should be considered with due regard to the viscosity of the compound in its state for application, length of rope involved and limitation of facilities. Light oils may be applied by brushing or running the rope through an oil bath, by spraying, drip method and mechanical force feed (Figure 16). For maximum penetration, the lubricant should be applied to the rope where it opens up" as it travels around a sheave or winds on a drum. It is also advisable to apply the lubricant in a warm area. If the lubricant must be applied manually in an extremely cold area, however, rope lubricants are available with pour points as low as -50° F to -60° F.

blast may also be used provided that dry air is used as any moisture would promote corrosion. Where long lengths of rope are involved, brushing or hand application is tedious. However, a thorough examination can be carried on at the same time so that two important jobs can be accomplished in one operation. General recommendations regarding the time interval that should elapse between lubrications are found in the PREVENTIVE MAINTENANCE SCHEDULES located in the back of Publication OSMĆ4, in the OPERATING AND SERVICE MANUAL. The rope should be properly lubricated at all times, and thorough periodic inspecĆ tions will indicate when it must be done.

Medium weight lubricant or heavy lubricant applied hot can be brushed on, applied by hand or by running the rope through a funnel containing the lubricant. The air

NOTE If a wire rope is taken out of service for an appreciable length of time, it should be cleaned, lubricated and stored in a dry place where it will be protected from the elements.

NOTES

1ĆOSMĆ5.1, 350SS 5/8/00

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LeTourneau, Inc.

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PUBLICATION OSMĆ5

WIRE ROPE LUBRICATION LUBRICATION OF WIRE ROPES IN SERVICE (1)

(2)

(3)

(4)

(5)

Operating CondiĆ tions

Ropes working in inĆ dustrial or marine enĆ vironments.

Ropes subject to heavy wear.

Ropes working over sheaves where (1) and (2) are not critical.

As (3) but for friction drive applications.

Standing ropes not subject to bending.

Predominant cause of rope deterioration

Corrosion.

Abrasion.

Fatigue.

Fatigue-corrosion.

Corrosion.

Typical applications

Cranes and derricks working on ships, on docksides, or in polĆ luted atmospheres.

Mine haulage, excaĆ vator draglines, scrapĆ ers and slushers.

Cranes and grabs, jib suspension ropes, pilĆ ing, percussion and drilling.

Lift suspension, comĆ pensating and goverĆ nor ropes, mine hoist ropes on friction windĆ ers.

Pendant ropes for cranes and excavaĆ tors. Guys for masts and chimneys.

Dressing requireĆ ments

Good penetration to rope interior. Ability to displace moisture. InĆ ternal and external corrosion protection. Resistance to wash off". Resistance to emulsification.

Good antiĆwear propĆ erties. Good adhesion to rope. Resistance to removal by mechaniĆ cal forces.

Good penetration to rope interior. Good luĆ brication properties. Resistance to fling off".

NonĆslip property. Good penetration to rope interior. Ability to displace moisture. InĆ ternal and external corrosion protection.

Good corrosion protection. Resistance to wash off". ResistĆ ance to surface crackĆ ing.

Type of lubricant

Usually a formulation containing solvent leaving a thick (0.1 mm) soft grease film.

Usually a very viscous oil or soft grease conĆ taining M0S2 or graphite. Tackiness additives can be of advantage.

Usually a good generĆ al purpose lubricating oil of about SAE 30 viscosity.

Usually a solventĆdisĆ persed temporary corĆ rosion preventative leaving a thin, semiĆ hard film.

Usually a relatively thick, bituminous compound with solĆ vent added to assist application.

Application techĆ nique. Refer to FigĆ ure 16.

Manual or mechaniĆ cal.

Manual or mechaniĆ cal.

Mechanical.

Normally by hand.

Normally by hand.

Frequency of apĆ plications*

Monthly.

Weekly.

10/20 cycles per day.

Monthly.

Six months/2 years.

*The periods indicated are for the general case. The frequency of operation, the environmental conditions and the economics of service dressing will more correctly dictate the period required.

Opening of rope sections during passage over sheave or drum. Arrows indicate the access points for lubricant. 1ĆCGĆ1241, P08Ć15

FIGURE 17. WIRE ROPE LUBRICATION

24

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LeTourneau, Inc.

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


PCMĆ350SS ELECTRIC DECK CRANE WIRE ROPE SPECIFICATIONS The crane is equipped with wire rope of the specificaĆ tions listed below. The wire rope on the crane shall be replaced with rope of the same specifications only. a.

c.

BRIDLE LINE ASSEMBLY 1. 2Ć3/8 inch x 68 ft. wire rope (412Ć1305) āĂĂĂĂĂ(123.5 ft. boom) 2Ć3/8 inch x 93 ft. wire rope (423Ć5450) āĂĂĂĂĂ(149.5 ft. boom)

MAIN HOOK LINE ASSEMBLY 1. 1 inch wire rope x 2225 ft. (423Ć5088) 2. Rotation resistant

2. 6 x 26 Warrington Seale Ć IWRC Ć EIPS

3. DYFORM 34LR GR2160

3. 274 tons breaking strength

NOTE

4. 70.03 tons breaking strength

NOTE Must have written certification of 70.03 tons breaking strength. b.

Must have written certification of 274 tons breaking strength. d.

AUXILIARY HOOK LINE ASSEMBLY

BOOM LINE ASSEMBLY

1. 1 inch wire rope x 550 ft. (P/N 422Ć9660)


2. Rotation resistant.

2. Constructex

3. DYFORM 18 HSLR



NOTE

NOTE

Must have written certification of 62.5 tons breaking strength.


NOTES

1ĆOSMĆ5.1, 350SS 5/8/00

COPYRIGHT 2002

LeTourneau, Inc.

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PUBLICATION OSMĆ5

BOOM POINT SHEAVE WHEELS

1" WIRE ROPE 2225' LONG 70.3 TONS B.S.

HOOK SHEAVE WHEELS

HOOK CABLE DRUM

PCM 350SS CRANE MAIN HOOK CABLE REEVING SCHEMATIC 1ĆCGĆ1581, P10Ć29

26

TAĆ8664ĆCG COPYRIGHT 2002

LeTourneau, Inc.

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


GUIDE SHEAVE WHEEL AUX. BOOM TIP SHEAVE WHEEL

1" WIRE ROPE 550' LONG, 57.5 TONS B.S.

10 TON HOOK

AUX. HOOK CABLE DRUM

PCM 350SS CRANE AUX. HOOK CABLE REEVING SCHEMATIC

1ĆCGĆ1583, P10Ć29

1ĆOSMĆ5.1, 350SS 5/8/00


LeTourneau, Inc.

27


PUBLICATION OSMĆ5

2

4

FLOATING SHEAVE WHEELS

6 8 10

1

12

3 5

7 GANTRY SHEAVE WHEELS

9

D.E. 11 1” WIRE ROPE (9 X 40 CONSTRUCTEX) 1075’ LONG, 62.5 TONS B.S.

CABLE DRUM

PCM-350SS CRANE BOOM UP CABLE REEVING SCHEMATIC 1ĆCGĆ1582, P10Ć29

28


LeTourneau, Inc.

1ĆOSMĆ5.1, 350SS 5/8/00

PUBLICATION OSMĆ5


PCMĆ120SS ELECTRIC DECK CRANE WIRE ROPE SPECIFICATIONS The crane is equipped with wire rope of the specificaĆ tions listed below. The wire rope on the crane shall be replaced with rope of the same specifications only. a.

c.

BRIDLE PENDANTS 1. 1Ć3/4 inch x 50 ft. (P/N 422Ć9572)

MAIN HOOK LINE ASSEMBLY

2. 6 x 26 Warrington Seale - IWRC - EIPS

1. 1Ćinch swaged wire rope x 1375 ft. (423Ć5086)

3. 168 tons breaking strength


NOTE

3. DYFORM 34LR GR2160

Must have written certification of 168 tons breaking strength.

4. Rotation resistant

NOTE Must have written certification of 70.03 tons breaking strength. b.

d.

AUXILIARY HOOK LINE ASSEMBLY 1. 1 inch wire rope x 550 ft. (P/N 422Ć9660)

LUFFING



3. DYFORM 18 HSLR


4. Rotation resistant.

3. CONSTRUCTEX

NOTE

NOTE



NOTES

1ĆOSMĆ5.2, 120SS 5/8/00

COPYRIGHT 2002

LeTourneau, Inc.

25


PUBLICATION OSMĆ5



HOOK SHEAVE WHEELS

HOOK CABLE DRUM

PCM 120SS CRANE MAIN HOOK CABLE REEVING SCHEMATIC TAĆ8926ĆCG

1ĆCGĆ1586, P10Ć30

26

COPYRIGHT 2002

LeTourneau, Inc.

1ĆOSMĆ5.2, 120SS 5/8/00

PUBLICATION OSMĆ5


6

FLOATING SHEAVE HOUSING

4

2

5

DEAD END 3

1” WIRE ROPE 460” LONG 62.5 TONS B.S.

1

GANTRY SHEAVE HOUSING

BOOM UP CABLE DRUM

TAĆ8928ĆCG

1ĆNGOĆ1588, P10Ć30, 5/3/00

1ĆOSMĆ5.2, 120SS 5/8/00

COPYRIGHT 2002

LeTourneau, Inc.

27


28

PUBLICATION OSMĆ5

COPYRIGHT 2002

LeTourneau, Inc.

1ĆOSMĆ5.2, 120SS 5/8/00

PUBLICATION OSMĆ6

LeTOURNEAU, INC. ELECTRIC DECK CRANE BRAKES

TABLE OF CONTENTS

TABLE OF CONTENTS

Page

LIST OF ILLUSTRATIONS (Cont'd.) FIGURE

SCOPE OF THIS PUBLICATION . . . . . . . . . . . . . . . . . 1 GENERAL WARNINGS AND CAUTIONS . . . . . . . . . . 1 SWING MOTOR ELECTROĆMECHANICAL BRAKE 2 WORKING AIR GAP ADJUSTMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BENCH (MAXIMUM) AIR GAP ADJUSTMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DISASSEMBLY OF SWING MOTOR ELECTROĆMECHANICAL BRAKE HEAD . . . . . . . . . 3 BRAKE DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . 3 ASSEMBLY OF THE SWING MOTOR ELECTROĆMECHANICAL BRAKE HEAD . . . . . . . . . 3

Page

4

SWING MOTOR DISC BRAKE STACKING .

5

5

480 VAC BACKĆUP PUMP INSTALLATION .

9

6

HYDRAULIC POWER UNIT . . . . . . . . . . . . . .

10

7

HYDRAULIC BRAKE ASSEMBLY . . . . . . . . .

13

8

BRAKE CALIPER GROUP . . . . . . . . . . . . . . .

14

9

MANUALLY RELEASING HYDRAULIC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

10

SERVICING BRAKE ACTUATOR . . . . . . . . .

19

11

HYDRAULIC BRAKE SCHEMATIC, PCM 120SS/350SS . . . . . . . . . . . . . . . . . . . .

21

12

BRAKE CONTROL DIAGRAM . . . . . . . . . . . .

22

HOIST BOOM AND AUXILIARY HOOK ASSEMBLY DC MOTOR HYDRAULIC BRAKES . . . . 7 GENERAL WARNINGS AND CAUTIONS . . . . . . . . 7 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 7 SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . 8 DC MOTOR HYDRAULIC BRAKE - SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSPECT HYDRAULIC OIL RESERVOIR EVERY 50 HOURS OR WEEKLY . . . . . . . . . . . . . . . 8 SYSTEM PRESSURE CHECKS . . . . . . . . . . . . . . . . 11 OPERATION AND INSPECTION OF DC MOTOR HYDRAULIC BRAKE CALIPER ASSEMBLIES . . . . 11 DISC PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . 12 MANUALLY RELEASING THE HYDRAULIC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SERVICING THE HYDRAULIC BRAKE ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSPECTIONS UPON DISASSEMBLY . . . . . . . . . . 17 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 BRAKE SYSTEM LEAKAGE CHECK . . . . . . . . . . . . 18

SCOPE OF THIS PUBLICATION Publication OSMĆ6, BRAKES, is to assist maintenance personnel with the inspection, adjustment, replacement of discs, and repair or the electric swing motor brake and the hydraulic brakes found on the main hook, boom, and auxiliary hook DC motors. In routine operation of the crane it is ESSENTIAL to pay close attention to the stopping action of all of these compoĆ nents. Brakes are wear items whose service life is affected by production, scheduling of the machine, load, speed, and the operator's skill in stopping the crane's movements properly to minimize wear.

GENERAL WARNINGS AND CAUTIONS The following general warnings and cautions apply to both the swing motor electroĆmechanical brake and the hydraulic brakes or the hoists and boom:

LIST OF ILLUSTRATIONS FIGURE

Page

1

SWING MOTOR ELECTROĆMECHANICAL BRAKE SPECIFICATIONS . . . . . . . . . . . . . . .

3

2

MOTOR BRAKE ADJUSTMENT . . . . . . . . . .

3

3

BRAKE WIRING . . . . . . . . . . . . . . . . . . . . . . .

4

1ĆOSMĆ6.2a, 120SS & 350SS, Gorilla 6/6/00

When performing service or repair operations on elevated structures of the crane, NEVER proceed beyond the safety of hand railed platforms. Serious injury or loss of life from falling is possible outside these areas. COPYRIGHT 2002

LeTourneau, Inc.

1

BRAKES

PUBLICATION OSMĆ6

the maximum air gap. Maximum air gap for the brake is 0.125 inch (refer to Figure 1). When the working air gap reaches the Reset gap (refer to Figure 1), perform the following procedure:

The boom must be in the stowed position and the drum safety lock pin installed before inspecting, servicing or repairing any part of the crane's hydraulic brake system. Also, place a DO NOT OPERATE sign on the controls and lock the operators control panel before performing maintenance or inspecting the hydraulic brake system. Serious injury or death is possible if the crane is started or moved while maintenance or repairs are being conducted.

!

a. Back off the three locking capscrews just enough to free the brake adjusting screws. b. Turn the adjusting screws to change the air gap. Turn clockwise to increase air gap; counterclockwise to decrease air gap. c. Check gap in at least three equally spaced locations around brake ring. d. When desired air gap of 0.080 inch is obtained, tighten the three locking capscrews to lock the adjustĆ ing screws and recheck air gap. Tightening the locking capscrews may cause a slight change in brake adjustment. Torque capscrew to value listed on torque tag affixed to brake head.

CAUTION

Swing movement WILL NOT stop immediately when the SWING joystick potentiometer is returned to the neutral position. Swing speed, load, brake adjustment and wind will effect the distance the boom will travel before regeneraĆ tive braking will bring it to a full stop. The operator should be aware that there are variable factors involved and start and stop swing movements with caution.

!

BENCH (MAXIMUM) AIR GAP ADJUSTMENT PROCEDURES If the brake has been removed from the motor for any reason, the following procedure should be performed to adjust the Bench (maximum) air gap (refer to Figure 1): a. When reassembling the brake, assemble the coil ring and inner magnet ring and set the maximum air gap, refer to Figure 1 for the correct bench air gap.

CAUTION

b. This air gap is measured between the bottom of the maximum air gap adjusting nut and the outer magnet plate with the brake head completely comĆ pressed.

DO NOT attempt to stop the crane's rotation by moving the BRAKE switch to the SET position, except in an emergency. Doing so may damage the swing gear and swing motor pinion.

c. Tighten the jamnut against the adjusting nut, once the correct air gap has been obtained.

SWING MOTOR ELECTROĆMECHANICAL BRAKE WORKING AIR GAP ADJUSTMENT PROCEDURES The electroĆmechanical swing motor brake is properly adjusted when the working air gap between the two magnet rings is 0.080 of an inch. The inner magnet ring structure is secured to the outer magnet ring and coil assembly by three studs, nuts and jamnuts. The setting of these three nut and jamnut combinations determines

2

d. Attach the coil and magnet assembly to the endbell or continuous brake ring. e. After attaching the coil and magnet assembly to the endbell, the air gap can be adjusted with the three adjusting screws. This will not affect maximum air gap which is limited to the settings prescribed in Figure 1 by the three hex nut and jamnut combination.

COPYRIGHT 2002

NOTE If brake air gap is allowed to open to 0.150 inch, the brake will start to slip.

LeTourneau, Inc.


PUBLICATION OSMĆ6

AIR GAP SETTINGS

BRAKES Working Air Gap

.080"

Maximum Air Gap

0.125"

Air Gap Gauge

STATIONARY DISC ENDBELL

Compressed to 65 lbs., P/N 078Ć2389 (6 ea.) at 2.8125"

COILS

600 VAC, Resistance between phases 8.92 ohms at 20°C, P/N 403Ć6237 (6 ea.)

MAGNET RINGS BRAKE HEAD ASSEMBLY

BRAKE ADJUSTING SCREW

P/N 095Ć5056

SPRINGS

BRAKE DISCS*

ROTATING DISC

LOCKING CAPSCREW MAXIMUM AIR GAP ADJUSTING NUT

Rotating P/N 401Ć5420 (3 ea.) JAMNUT

Stationary P/N 403Ć9598 (4 ea.) Inner P/N 078-8338 Outer P/N 081Ć4667

MAXIMUM AIR GAP

P/N 403Ć6240

*Refer to Figure 4 for brake disc stacking procedure.

FIGURE 1. SWING MOTOR ELECTROĆ MECHANICAL BRAKE SPECIFICATIONS

WORKING AIR GAP

DISASSEMBLY OF SWING MOTOR ELECĆ TROĆMECHANICAL BRAKE HEAD

BRAKE SPRING

The motor brake head consists of two major compoĆ nents: Inner Magnet Ring and Outer Magnet Ring and Coil Assembly.

INNER MAGNET RING

FIGURE 2. MOTOR BRAKE ADJUSTMENT

NOTE

1ĆCGĆ700, P06Ć02

If a safety or instructional sign is on a part that is replaced, make sure a new sign is installed on the replaced part.

TAĆ7661CG

NOTE

a. Separate the inner magnet ring from the outer magnet ring and coil assembly by removing six (6) nuts from the studs. Lift the outer magnet ring and coil assembly off the inner magnet ring. b. Remove the brake springs from the spring reĆ cesses of the inner magnet ring. Note the number of and location of the springs on the inner magnet ring. c. Check for broken or weak brake springs. Check brake spring tension in accordance with Figure 1. d. If the three studs mounted in the inner magnet ring are worn, they should be replaced.

NOTE

Do not mix coils on the same outer magnet ring. f.

Inspect inner magnet ring for physical damage.

g. Inspect outer magnet ring and coil assembly for physical damage, especially in the area of the brake adjusting screws. Replace any broken coil anchor bolts.

BRAKE DISC REPLACEMENT When installing brake discs, care should be made to assure that discs (both stationary and rotating) be flat. Warped discs should not be used. Air gaps should be set up and maintained in accordance with air gap adjustment procedures as outlined in this publication. The discs should be stacked as shown in Figure 4.

ASSEMBLY OF THE SWING MOTOR ELECTROĆMECHANICAL BRAKE HEAD

The stud threads in the inner magnet ring are 3/ " NPT. 8 e. Check for continuity of the coils in the inner magnet ring assembly with an ohmmeter. Replace any defective coil. Refer to Figure 1 for the brake coil resistance. 1ĆOSMĆ6.2a, 120SS & 350SS, Gorilla 6/6/00

OUTER MAGNET PLATE

a. Place the inner magnet ring on a bench and torque the three studs to 110-120 ft. lbs. The studs must not protrude above the flat surface of the inner magnet ring.

COPYRIGHT 2002

LeTourneau, Inc.

3

BRAKES

PUBLICATION OSMĆ6

L1

L1

1

1

9

4

6

1 5

1 L2

10 11

11

2

4

5

3 6

8

12

5 8 5

2

12

2

4 7

9

3

L3

6

7

6 10

3

2

3 4

L3

L2

SWING BRAKE FIGURE 3. BRAKE WIRING

1ĆCGĆ1577, P10Ć37

If necessary, grind the end of the studs flush with the surface of the inner magnet ring. b. Install the brake springs in the spring recesses of the inner magnet ring with the number of springs required (by the PARTS CATALOG) to meet the specifiĆ cations for the particular motor on which the brake head assembly will be used. c. If the coils have been removed from the outer magnet ring, they must be installed with the pigtail facing inward. Refer to Figure 3 for the wiring diagram of the coil connections. d.

f. With three (3) 1/2" UNF nuts, pull the outer magnet ring and coil assembly down until the proper air gap is met (refer to WORKING AIR GAP ADJUSTMENT PROCEDURES, page 2, to adjust the maximum air gap). Use the other three (3) 1/2" UNF nuts to lock this adjustment.

NOTE There must not be interference or dragging of the inner magnet ring with the coil boxes. If necessary, loosen the anchors of the offendĆ ing coil and readjust.

CAUTION

Tighten the capscrews just enough to prevent coil movement. Safety lock the capscrews with 1/4" UNC nuts.

4

e. Position the outer magnet ring and coil assembly into the inner magnet ring so that the studs do not line up with the adjusting screws in the outer magnet ring and coil assembly.

Lock the coils in position with the coil anchors.

!

TAĆ8985ĆCG

g. Install the brake adjusting screws in the outer magnet ring and coil assembly.

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ6

BRAKES

ROTATING DISCS

STATIONARY DISCS FIGURE 4. SWING MOTOR DISC BRAKE STACKING TAĆ8980ĆS

1ĆCGĆ1564, P10Ć32

NOTES


COPYRIGHT 2002

LeTourneau, Inc.

5

BRAKES

PUBLICATION OSMĆ6

NOTES

6

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ6

BRAKES

HOIST, BOOM, AND AUXILIARY HOIST ASSEMBLY DC MOTOR HYDRAULIC BRAKES The Hoist, Boom, and Auxiliary Hoist Assembly DC Motors are equipped with a dual caliper, spring applied, hydraulically released disc brake. Hydraulic power is provided by a hydraulic power unit. System operation and maintenance procedures are provided below.

!

Handling and disposal of used oils may be subject to federal, state and local laws and regulations. Use authorized waste disposal facilities; for example, local collection sites and garages providing authorized facilities for receipt of used oil. If in doubt, contact your state and local environmental authorities or the Environmental Protection Agency for direction on proper handling and disposal of used oil.

GENERAL WARNINGS AND CAUTIONS

!

The boom must be in the stowed position before inspecting, servicing or repairing any part of the crane's hydraulic brake system. Also, place a DO NOT OPERATE sign on the controls and lock the operators control panel before performing maintenance or inspecting the hydraulic brake system. Serious injury or death is possible if the crane is started or moved while maintenance or repairs are being conducted.

Hydraulic fluid under pressure can penetrate the skin and cause serious personal injury, blindness, or death. If any fluid is injected into the skin it must be removed within a few hours by a doctor familiar with treating this type of injury. Fluid leaks under pressure may not be visible. When searching for leaks, NEVER use your hand, use a piece of cardboard or wood. Wear work gloves and keep your hand well away from the possible source of leakage. Do not tighten or loosen hydraulic lines without first relieving the pressure. Wear safety goggles for eye protection.

The hydraulic brake canisters are under spring pressure. Do not attempt to disasĆ semble them without the special tools required. Refer to SERVICING THE HYĆ DRAULIC BRAKE ACTUATORS, page 17. 1ĆOSMĆ6.2a, 120SS & 350SS, Gorilla 6/6/00

CAUTION

CAUTION

To prevent injury, wear hard hat, protective glasses and other protective equipment as required by job conditions.

!

CAUTION

To ensure future safety, if a safety or instructional sign is on a part that is replaced, make sure a new sign is installed on the replaced part. Replace immediately any safety or instructional sign that is not legible. Refer to the PARTS CATALOG to order replacement signs.

SYSTEM DESCRIPTION

NOTE The hydraulic power unit owner's manual is provided at the end of this publication. Refer to Figure 6 for an illustration of the hydraulic power unit. a. Hydraulic System: The primary hydraulic power source is a low pressure gear pump. A secondary 480 VAC pump (see Figure 5) is available as a backup to the primary pump (see BACKUP AC PUMP MOTOR section in Publication OSMĆ4 of this manual). In the event of crane power loss, a Power Loss Lowering System (PLLS) exists to allow for the constant speed lowering of a load from the operator's console (see PCM Crane Power Loss Lowering System, located in Section 5, SOLID STATE CONVERSION SYSTEM, in the REPAIR AND OVERHAUL manual). This system uses a 24 VDC motorĆdriven pump mounted on the hydraulic power unit and powered by four 12 VDC batteries. A manual release method also exists (see page 15 OF THIS PUBLICATION) as a backup to the PLLS. b. Primary Hydraulic Power Source: The primary hydraulic power source is mounted on a 20Ćgallon reservoir with the pump inside the reservoir and the COPYRIGHT 2002

LeTourneau, Inc.

7

BRAKES

PUBLICATION OSMĆ6

primary motor protruding from the top. This motor is a IEEE 45 Class in a 3 HP size with 3Ćphase 480Ćvolt power required. The pump produces 5 gpm at the 130 psi requirement. c. Power Loss Lowering System Power Source: The PLLS hydraulic pump and 24 VDC motor are mounted to the top of the reservoir. At full pressure, the 24 VDC motor will consume 30 to 35 amps from a battery power pack. The pump produces 3 gpm at 130 psi and has a maximum rating of 3000 psi. This system is only used for partially releasing the hoist brake and allowing a load to slip through the brakes to the deck (POWER LOSS HOIST LOWERING Ċ see Section 5, SOLID STATE CONVERSION SYSTEM, in the REPAIR AND OVERHAUL MANUAL). d. Valving: The valving is solenoid operated by 24 VDC and is rated at 4000 psi. It is sized to handle up to 20 gpm. and is being utilized at 5 gpm except during spring brake apply when the flow will approach 15 gpm. The solenoids for these valves are equipped with a manual override feature which allows for manual operation if control voltage is lost or if a coil should fail. The coil connector is also equipped with an LED to indicate it is being energized. e. Reservoir: The reservoir is of steel construction and is coated to withstand marine environment. It holds 20 gallons of hydraulic fluid. The suction strainers for each pump are inside the reservoir and the pressure filter is mounted on top of the reservoir. A visual level and temperature gauge is used in conjunction with a low level switch and a temperature switch. A screw type fill port is incorporated into the top of the reservoir and a combination filterĆdesiccant breather is used to control atmospheric air ingestion quality. f. Hydraulic Fluid: Use only nonĆflammable hydrauĆ lic fluid LeTourneau, Inc. P/N 423Ć5122.

bronze, suitable for use in the corrosive marine environment. A thermocouple mounted in proximity to the disc monitors temperature during the power loss hoist lowering function.

!

Refer to the REPAIR AND OVERHAUL MANUAL, Section 5, SOLID STATE CONVERĆ SION SYSTEM, for information on the power loss lowering card and thermocouple before any adjustments, disassembly, or assembly of the thermocouple is attempted.

SYSTEM OPERATION a. The hydraulic pump becomes operational when the MASTER switch is turned to the ON position. System pressure is regulated to 130 psi when the BRAKE switch is turned to the ENABLE position. b. The brakes do not release until the appropriate joystick (hoist or boom) is moved off of the neutral position. The appropriate electronic controller enerĆ gizes relay CR2 (hoist) or CR3 (boom) which applies system pressure through solenoids to the appropriate springĆapplied brake canisters and releases the brakes. Various external conditions, however, can prevent the controller from releasing the brakes or automatically set the brakes once they have been released (low hydraulic fluid pressure, low hydraulic fluid level, high hydraulic fluid temperature, various limit switches, etc.).

DC MOTOR HYDRAULIC BRAKE - SYSĆ TEM MAINTENANCE Routine maintenance is required to keep the Hydraulic Brake System functioning properly. Refer to Figure 6 for an illustration of the hydraulic power unit. Also, refer to the hydraulic power unit owner's manual at the end of this publication.

g. Hose and Fittings: The hosing and fittings in the system are rated at 2000 psi minimum which yields an extremely conservative safety factor at 130 psi working pressure. the elastomers are rated for usage from Ć50° F to +300° F. h. Brake Caliper Assembly (refer to Figures 7 and 8): The caliper CĆclamp and base mount is a steel casting machined by LeTourneau, Inc. The pads are metallic filled, organic material containing no asbestos. The actuating cylinder is a device with the outer chamber containing a high force spring that applies the brake when pressure is removed. The cylinder end closest to the attachment bolts allows a pressure to be applied to release or modulate the torque of the brake. Stored externally on the cylinder is a release bolt that screws into the spring end of the cylinder to allow release or modulation of the brake using common hand tools (refer to Figure 9). The disc is made of aluminum 8

CAUTION

NOTE Refer to SERVICE UPON RECEIPT, located in Publication OSMĆ1, in the OPERATING AND SERVICE MANUAL for service and inspecĆ tions required during startĆup and the initial 50 and 100 hours of operation. It is essential that these services be performed to achieve proper operation and efficient service from the hydraulic brake system.

INSPECT HYDRAULIC OIL RESERVOIR EVERY 50 HOURS OR WEEKLY Inspect the hydraulic oil reservoir weekly for proper level and condition of the fluid. The hydraulic power unit is equipped with an Electrical Fluid Level Indicator. This device provides a sight gauge for quickly checking the fluid level. If the system is low, the leak should be

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ6

BRAKES

3

4

5

2

6

1 7

6

8

12

9

10

11

13

13

1 2 3 4 5 6 7 8 9 10 11 12 13 14

FITTING FITTING HOSE FITTING CHECK VALVE BUSHING PUMP MOTOR FITTING HOSE FITTING PIPE FITTING POWER UNIT NIPPLE DRAIN VALVE

14

FIGURE 5. 480 VAC BACKĆUP PUMP INSTALLATION TAĆ9278ĆCG

1ĆCGĆ2077, P10Ć41


COPYRIGHT 2002

LeTourneau, Inc.

9

BRAKES

1ĆCGĆ1601, P10Ć41

10

A

A 10

4

18

4

11

3

B

4

3

2

1

2

9 8 19 1 SOL 1

4 C

8

COPYRIGHT 2002

tag: hyd power unit

B

B

B

B

5

4

3

2

1

A

A

A

A

A

B

13

5

LeTourneau, Inc.

B

20 17

6

16

12

5

2

15 7

21

14 7

24 3

25 18

4

4

2

11 10

22 23

11 AB a

b

SOL 2

19

AB b

a

SOL 3

1 SOL 4

AB b

a

SOL 6

SOL 5

AB a

b PT

SECTION A-A

b

23

MOTOR CHECK VALVE BREATHER PRESSURE FILTER MANIFOLD OIL FILTER RESERVOIR SANDWICH BODY DIRECT. CONT. VALVE RELIEF VALVE 3 HP MOTOR OIL LEVEL GAUGE GEAR PUMP

14 15 16 17 18 19 20 21 22 23 24 25

SHUTTLE VALVE SUCTION STRAINER COUPLING RELIEF VALVE PRESSURE GAUGE GEAR PUMP ADAPTER SUCTION STRAINER PRESSURE SWITCH DIRECT. CONT. VALVE OIL LEVEL SWITCH TEMP. SWITCH

FIGURE 6. HYDRAULIC POWER UNIT

3

7

19

1

SECTION B-B

PUBLICATION OSMĆ6

10

9

AB a

6

TAĆ8982ĆCG


SOL 7

1 2 3 4 5 6 7 8 9 10 11 12 13

PUBLICATION OSMĆ6

BRAKES

repaired and the system filled to the proper level before operating the crane. Use a filter when filling the reservoir, with a mesh width of 0.002 in. (0.06 mm) or better. Fill via the 10 micron system filter. Refer to PCM CRANE LUBRICATION SPECIFICATIONS, Figure 1 in Publication OSMĆ4, located in the OPERATING AND SERVICE MANUAL, for the recommended hydraulic fluid.

!

CAUTION

Do not operate the hydraulic system with a low reservoir fluid level. Cavitation of the hydrauĆ lic pump can occur which will cause serious component damage and brake system failure.

SYSTEM PRESSURE CHECKS Check main system pressure weekly or every 50 hours of operation. The system should operate at 130 psi. Note any system pressure corrections in the crane's permanent file. Frequent reĆadjustment indicates wear in the pressure relief components. Pressure drops should be investigated to determine the cause.

OPERATION AND INSPECTION OF DC MOTOR HYDRAULIC BRAKE CALIPER ASSEMBLIES

a. DAILY AND MONTHLY FILTER INSPECTION AND SERVICE 1. High Pressure Filters: The high pressure filters are equipped with an indicator to determine when they should be replaced. The high pressure filters should be checked daily and replaced if required. 2. Suction Filters: The suction filters require inspection and cleaning yearly or every 2,500 hours of operation. The filters should be cleaned with solvent and blown through with air to remove any buildĆup of contaminants. 3. Breather Filter: The breather filter is deĆ signed to eliminate fluid contamination resultĆ ing from wet, dirty air. The breather filter has an indicator in its side to determine when the unit needs servicing. The breather should be inspected daily and serviced when required. Refer to the PARTS CATALOG for ordering replacement filters. b.

SERVICE MANUAL for the recommended hydraulic fluid.

The DC Motor Hydraulic Brake System has a caliper assembly and spring/hydraulic actuator. Operation of the spring/hydraulic actuator is as follows: a. NORMAL OPERATION The brake in a released position has hydraulic pressure applied to the piston opposite the spring chamber, which keeps the spring compressed (CAGED). The brake is in readiness for normal applicaĆ tion by releasing the hydraulic pressure from the spring chamber. b. SPRING BRAKE APPLICAĆ TION - The spring force, acting against the piston, forces the push rod against the push rod flange nut by the piston tube and sets the brake pads (The spring is now in an UNCAGED position). 1ĆCGĆ1576, P10Ć37 TAĆ8978ĆCG

HYDRAULIC FLUID REPLACEMENT

The hydraulic fluid should be replaced every five years under normal conditions. However, fluid contaminated with water or solid particle contaminants must be replaced more often. Fluid samples should be taken every 250 hours as part of a continuing lubricating analysis program. The type and size or particles should be analyzed to determine imminent component failure. Action should be taken before system failure results. Fluid that is contaminated with a water content of 60 ppm or greater should be replaced immediately. The system should be drained and refilled when in warm operating condition. All filters should be cleaned or replaced as is applicable. Use a filter when filling the reservoir, with a mesh width of 0.002 in. (0.06 mm) or better. Fill via the 10 micron system filter. Refer to PCM CRANE LUBRICATION SPECIFICATIONS, Figure 1 in Publication OSMĆ4, located in the OPERATING AND 1ĆOSMĆ6.2a, 120SS & 350SS, Gorilla 6/6/00

NORMAL OPERATION

c.

SPRING BRAKE APPLICATION

INSPECTION

The brakes should be checked at regular intervals for normal wear condition. Inspect the brakes as follows:

COPYRIGHT 2002

1. Land any load on the hook and properly stow the boom in the boom rest. Install cable drum lock pin. 2. Inspect brake for loose or missing bolts, nuts, retaining rings or other attachments. Secure or replace as required. 3. Inspect carrier and lining (pads) assemblies for wear, scars or breaks.

NOTE If adjustment is required, the brakes must be released.

LeTourneau, Inc.

11

BRAKES

d.

PUBLICATION OSMĆ6

ADJUSTMENT

!

!

CAUTION

Install cable drum lock pin before performing any service work to hydraulic brake system. Refer to CABLE DRUM LOCK PIN in Publication OSMĆ4.

Install cable drum lock pin before performing any service work to hydraulic brake system. Refer to CABLE DRUM LOCK PIN in Publication OSMĆ4.

!

!

CAUTION

Spring brake chambers are under comĆ pressed spring force. Releasing the tension on the brakes must be done with the use of the jackbolt and nut assembly (P/N 423Ć2980 & 423Ć2981) or shop air minimum 100 psi. If air is used to release the brake, ensure the supply is uninterrupted or the brake will set quickly and unexpectedly possibly causing injury. Refer to MANUALLY RELEASING THE HYDRAULIC BRAKES, page 15.

CAUTION

Spring brake chambers are under comĆ pressed spring force. Releasing the tension on the brakes must be done with the use of the jackbolt and nut assembly (P/N 423Ć2980 & 423Ć2981) or shop air minimum 100 psi. If air is used to release the brake, ensure the supply is uninterrupted or the brake will set quickly, possibly causing injury. Refer to MANUALLY RELEASING THE HYDRAULIC BRAKES, page 15. 1. Use the jackbolt assembly mounted externalĆ ly on the brake cylinder to release tension on the brake or 100 psi air pressure. Refer to Figure 9 for an illustration of the use of the jackbolt. Numbers in parentheses refer to Figure 8. 2. Loosen the locknut (20) and adjust the stop bolt (19) to achieve a .060" clearance between the floating brake pad (15, pad farthest from actuator) and the rotor (2), measured at the center of the pad's I.D. 3. Tighten the locknut (20). 4. Loosen the set screw (6) and screw the adjusting nut (8) to achieve a .060" clearance between the piston actuated pad (15, pad closest to actuator) and the rotor (2), again, measured at the center of the pad's I.D. 5. Tighten the set screw (6) to lock the adjustĆ ment.

NOTE Replace the brake pads if lining is less than 1/4" thick.

DISC PAD REPLACEMENT Numbers in parenthesis refer to Figure 8. If brake pads or other parts need replacement, remove the brake assemblies as follows: 12

CAUTION

a. Use the jackbolt assembly mounted externally on the brake cylinder or shop air of 100 psi minimum to release tension on the brake. Refer to Figure 9 for an illustration of the use of the jackbolt. b. Loosen the jamnut (17) and back the stop bolt (18) into the brake mount bracket (16) to release the tension on the springs (32). c. Unhook the springs (30) from the clamp structure (29). d. Remove the mount bolts (33) and caliper mounts (28) to allow the clamp structure (29) to be maneuvered clear of the rotor (2). e. Inspect the rotor. If it is badly grooved or scored, have it resurfaced or replace it. Minimum thickness is .68 inch. f. Remove the lining bolts (11 and 19) to release the worn pads (15) from the backing plates (13 and 29). g. Loosen the setscrew (6). Then back the adjusting nut (8) toward the actuator (5) to allow for the increased thickness of the new pads. h. Position the new pads (15) on the backing plates (13 and 29) and install the lining bolts (11 and 19). i. Position the assembled caliper structure to the rotor (2). Then position the caliper mount plates (14 and 28) on the brake mount bracket (14) and within the grooves along each side of the clamp structure (29). j. Install the mount bolts (31), and as they are tightened, continually check that the assembled caliper structure can move freely toward and away from the brake rotor. If any binding occurs, reposition the caliper mount plates (14 and 24) and retighten the mount bolts (31). Binding of the caliper may cause the pads to continually drag against the rotor, resulting in excessive wear.

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ6

BRAKES

k. Connect the springs (30) to the clamp structure (29). l. Screw the stop bolt (18) out until the clearance between the floating pad (15, pad farthest from actuator) and the rotor is .060 " measured at the center of the pad. Tighten the locknut (17). m. Turn the adjusting nut (8) until the piston actuated pad (15, pad closest to actuator) has clearance of .060" between it and the rotor (2). Then tighten the setĆ screw (6).

To check the run out tolerance while the brake head assembly is removed, place a dial indicator on the rotor assembly and rotate the rotor by hand one revolution. If run out should exceed .005 of an inch, it will be necessary to check rotor installation. n. Activate the brakes and check for proper moveĆ ment of the caliper and actuator rod.

NOTE If excessive wear is observed on the brake head carrier linings, the brake rotor run out should be checked. This should be done at the time new carrier linings are installed.

12

15

14

13

16

8

9 17

4

1

66

2 11

55

3

10 10

14

7

12

tag: air brake assy

LOCKNUT STOP BOLT FLOATING PAD ROTOR SETSCREW ADJUSTING NUT PISTON ACTUATED PAD ACTUATOR SPRING LINING BOLT LINING BOLT MOUNT BOLTS CALIPER CALIPER MOUNT BRAKE MOUNT BRACKET BACKING PLATE BACKING PLATE

FIGURE 7. HYDRAULIC BRAKE ASSEMBLY TAĆ8973ĆCG

1ĆNGOĆ1602, P10Ć41


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

COPYRIGHT 2002

LeTourneau, Inc.

13

BRAKES

PUBLICATION OSMĆ6

1

2

3 4 5

6 7 16 10

9

8 13 15 14 12

20

19

18

17

11

21

30

22

34

29

33

32

24 25 23

26

31 28

27

1 2 3 4 5 6 7

BRAKE HUB DISC LOCKWASHER BOLT BRAKE ACTUATOR SETSCREW INSERT

8 9 10 11 12 13 14

SLEEVE NUT RING BOSS CAPSCREW LOCKWASHER CLAMP PLATE STR. PLATE

15 16 17 18 19 20 21

PAD MOUNT STR. JAMNUT BOLT CAPSCREW LOCKWASHER NUT

22 23 24 25 26 27 28

LOCKWASHER BAR LOCKWASHER BOLT FLATWASHER SPACER PLATE

29 30 31 32 33 34

CLAMP STR. SPRING BOLT WASHER BOLT LOCKWASHER

FIGURE 8. BRAKE CALIPER GROUP TAĆ9275ĆCG

1ĆCGĆ2078, P10Ć41

14

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ6

BRAKES

MANUALLY RELEASING THE HYDRAULIC BRAKES For emergency situations requiring the release of the brakes, adjustment, replacement of the brake pads, or other repair requiring removal of the brake caliper assembly, the tension on the brakes can safely be released using a jackbolt and primary hand tools. A jackbolt and nut assembly (P/N 423Ć2980 & 423Ć2981) is mounted externally on the brake cylinder to allow release or modulation of the brake (refer to Figure 9). Refer to Figure 9 for an illustration of the jackbolt assembly installed on the brake actuator.

The boom must be in the stowed position and the cable drum lock pin installed before inspecting, servicing, or repairing any part of the crane's hydraulic brake system. Also, place a DO NOT OPERATE sign on the controls and lock the operator's control panel before performing maintenance or inspecting the hydraulic brake system. Serious injury or death is possible if the crane is started or moved while maintenance or repairs are being conducted.

Jackbolt must be bottomed into threaded recess in cylinder rod. Use flat on jack bolt to tighten and keep it from screwing out of cylinder rod when jacknut is turned CCW.

1

2

1 1

2

3

1 SPECIAL TOOL P/N 423Ć2980 & 423Ć2981 2 ACTUATOR TOP PLATE 3 CYLINDER ROD 4 JAMNUT 5 PISTON

4

5

1ĆCGĆ1593, P10Ć37


FIGURE 9. MANUALLY RELEASING HYDRAULIC BRAKES

COPYRIGHT 2002

LeTourneau, Inc.

TAĆ8932ĆCG

15

BRAKES

PUBLICATION OSMĆ6

NOTES

16

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ6

BRAKES

SERVICING THE HYDRAULIC BRAKE ACTUATORS The following instructions are provided to help techniĆ cians with the replacement of the hydraulic brake actuator seal kit.

e. Remove the mount bolts (33) and caliper mounts (16 & 30) to allow the clamp structure (31) to be maneuvered clear of the rotor (2). f. Unbolt the brake actuator (5) and take it to a suitable workbench.

DISASSEMBLY Numbers in parentheses refer to Figure 10. a. Do not remove pipe plug (24). Plug will act as guide for press stud. b. Position the brake actuator into brake actuator press (P/N 423Ć5028) with the 5/8Ć18 UNF studs protruding through the bottom of the press' base plate. Secure with mounting nuts. Refer to Figure 10.

NEVER attempt to disassemble the brake actuators while mounted on the motor. The brake actuators are under spring pressure and can cause serious injury if not disasĆ sembled and assembled in the proper manner. Disassemble and assemble the brake actuaĆ tors only with the proper tools and per the instructions in this document.

c. Power the press' ram down until it seats firmly against the top of the brake actuator. d. Remove the four 3/8" acorn nuts and washers (1) from the bolts (23) securing the top plate (3) of the actuator. e. Slowly release hydraulic pressure. The spring force against the inside of the cover will allow the cover and internal components of the actuator to be safely removed after the ram is backed off sufficiently.

REMOVAL Numbers in parenthesis refer to Figure 8.

f. Remove the springs (4 & 5) and piston (7) from the actuator.

CAUTION

g. Remove the seals and wear rings (6, 8, 9, 10 & 11) from the piston (7) and actuator housing (12 & 21).

Brake actuators are under compressed spring force. Releasing the tension on the brakes must be done with the use of the jackbolt and nut assembly (P/N 423Ć2980 & 423Ć2981) or shop air minimum 100 psi. If air is used to release the brake, ensure the supply is uninterrupted or the brake will set quickly and unexpectedly possibly causing injury. Refer to MANUALLY RELEASING THE HYDRAULIC BRAKES, page 15.

h. Remove cylinder rod (15) and OĆring (16), bushing (17), OĆring (18), and seals (19 & 20).

INSPECTIONS UPON DISASSEMBLY Numbers in parentheses refer to Figure 10. a. Check actuator cylinder bore (12) for scoring and dents.

a. Use the jackbolt assembly mounted externally on the brake cylinder or shop air of 100 psi minimum to release tension on the brake. Refer to Figure 9 for an illustration of the use of the jackbolt. Attach shop air to the inlet port of the actuator if that is your chosen method. 1ĆOSMĆ6.2a, 120SS & 350SS, Gorilla 6/6/00

c. Loosen the jamnut (19) and back the stop bolt (20) into the brake mount bracket (18) to release the tension on the springs (32). d. Unhook the springs (32) from the clamp structure (31).

The boom must be in the stowed position and the drum safety lock pins installed before inspecting, servicing, or repairing any part of the crane's hydraulic brake system. Also, place a DO NOT OPERATE sign on the controls and lock out the operator's control panel before performing maintenance or inspecting the hydraulic brake system. Serious injury or loss of life is possible if the crane is started or moved while maintenance or repairs are being conducted.

!

b. Disconnect hydraulic lines from the actuator (if not done to connect shop air for releasing spring tension).

b. Inspect the cylinder rod (15), bushing (17) and piston (7). Remove any nicks and scratches. If it is determined that the cylinder rod and piston are corroded, scored, or notched, they should be replaced. c. Thoroughly clean the springs (4 & 5) and coat with a light rust preventative lubricant.

COPYRIGHT 2002

LeTourneau, Inc.

17

BRAKES

PUBLICATION OSMĆ6

NOTE

f. Install the actuator onto the caliper. Tighten mount nuts to 200 ft. lbs.

If mounting studs are removed from housing, use Loctite threadĆlocking compound to reassemble. If piston is removed from cylinder rod, use Loctite threadĆlocking compound on retaining nut.

g.

Install assembly onto motor.

h.

Reconnect hydraulic lines.

BRAKE SYSTEM LEAKAGE CHECK a. Adjust brakes so push rod travel is as short as possible without brake shoes dragging.

ASSEMBLY Numbers in parentheses refer to Figure 10.

!

a. Install seal kit (P/N 423Ć2978) and lubricate with lubricant (P/N 151Ć0360). Refer to Figure 10. b. Install piston (7), bushing (17), and springs (4 & 5) into actuator housing (12 & 21).

CAUTION

Do not operate main hook, boom, or auxiliary hook motors until you are sure there are no leaks and the brakes are functioning properly.

c. Install actuator housing into press. Secure with nuts.

b. Turn MASTER switch to the ON position to activate hydraulic power unit.

d. Use pipe plug as centering guide. Use the hydraulic ram to press the cover structure (3) until it meets the case (12).

c.

d. Check pressure gauge. A drop is pressure indiĆ cates a leak in the plumbing.

e. Install the four 3/8" acorn nuts (1) and washers (2) onto the bolts (23) which the secure the cover structure. Torque to 25 ft. lbs.

e. Turn BRAKE switch to the ENABLE position (released). Check pressure gauge. A drop in pressure indicates a leak in the actuator.

Turn BRAKE switch to the SET position.

NOTES

18

COPYRIGHT 2002

LeTourneau, Inc.


WARNING

1

NEVER attempt to disassemble the brake actuators while mounted on the motor: The brake actuators are under spring pressure and can cause serious injury if not disassembled and assembled in the proper manner. Disassemble and assemble the brake actuators only with the proper tools and per the instructions in SERVICING THE HYDRAULIC BRAKE ACTUATORS, page 17.

IF PIPE PLUG REMOVED FOR USE OF MANUAL RELEASE TOOL, REINSTALL PRIOR TO USING PRESS FOR DISASSEMBLY

2 12

24

A 3 13

B 4

CYLINDER SHOWN IN RETRACTED POSITION – HAS 2” STROKE

14

25

15

5

PRESS P/N 423-5028 16

C

PIPE PLUG USED FOR CENTERING TOP WITH RAM

AFTER ACTUATOR IS SECURED IN PRESS WITH RAM SEATED AGAINST ACTUATOR, REMOVE 3/8” ACORN NUTS, BACK OFF STUD SLOWLY TO DISASSEMBLE ACTUATOR. REVERSE PROCEDURE FOR ASSEMBLY.

A

C

SECURE WITH MOUNTING NUTS

1ĆNGOĆ1594, Ldgr2Ć20, 2/12/98

1ĆOSMĆ6.2b, Gorilla 6/6/00

CYLINDER SHOWN IN RELEASED POSITION

FIGURE 10. SERVICING BRAKE ACTUATOR

COPYRIGHT 2002

LeTourneau, Inc.

SEAL KIT 423Ć2978 INSTALLATION

B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

3/8" ACORN NUTS LOCKWASHER TOP PLATE BOOST SPRING HEAVY SPRING OĆRING PISTON OĆRING WEAR RING OĆRING WEAR RING ACTUATOR HOUSING OĆRING JAMNUT CYLINDER ROD OĆRING BUSHING OĆRING SEAL SEAL BOTTOM PLATE WASHER 3/8" UNS X 7Ć1/2" BOLT 3/8" NPT PIPE PLUG WARNING DECAL MOUNT STUDS

6 17

18 7

19

20 8

9

21 26

10 22

11

23

TAĆ8931ĆCG

19

H T

H

P 6A

H

T

6B

P T

SOL. 8

7A

1A 1B

7B

P T

SOL. 3 B

H

P

H A

P T

BOOM HOIST BRAKE

H SOL. 5

SOL. 9 A

T

B

T

3A 3B SOL. 2

P T

PUBLICATION OSMĆ6

1ĆCGĆ1567, P10Ć32, 11/6/98


AUXILIARY HOIST BRAKE

HOIST BRAKE

5A 5B SOL. 4

P T

SOL. 7

COPYRIGHT 2002

LeTourneau, Inc.

130 PSI

SOL. 1

100 PSI

M

AC

5 GPM

M

DC

RESERVOIR

3 GPM

FUNCTIONAL DESCRIPTION: SOLENOID 1 - ENERGIZE REQUIRED FOR ALL FUNCTIONS. SOLENOID 2 - ENERGIZE FOR RELEASE OF HOIST BRAKE. SOLENOID 2, 3 & 8 - ENERGIZE FOR POWER LOSS LOWER AND EMERGENCY RELEASE TENSION ON HOIST BRAKE. SOLENOID 4 - ENERGIZE FOR RELEASE OF AUXILLIARY HOIST BRAKE. SOLENOID 4, 5 & 9 - ENERGIZE FOR POWER LOSS LOWER AND EMERGENCY RELEASE TENSION ON AUXILIARY HOIST BRAKE. SOLENOID 4, 5 & 9 - ENERGIZE FOR CONSTANT TENSION ON AUXILIARY HOIST BRAKE. SOLENOID 7 - ENERGIZE FOR RELEASE OF BOOM HOIST BRAKE.

NOTE: 1. THERE ARE 2 BRAKE CALIPERS ON EACH MOTOR. 2. HOLD IS SHOWN AS H, TENSION IS SHOWN AS T.

21

BRAKES

TAĆ8943ĆCG

FIGURE 11. HYDRAULIC BRAKE SCHEMATIC, PCM 120SS/350SS

22

1ĆNGOĆ2757, P03Ć27

LeTourneau, Inc.

COPYRIGHT 2002

E5

T3

E5

T3

UPPER CYLINDER

20

M1

20

LOWER CYLINDER

E1

HOIST BRAKE

UPPER CYLINDER

E1

LOWER CYLINDER

E1

AUXILIARY HOIST BRAKE

M1

E1

1

1

1

1

7

7

10

8

10

4

10

14

5

4

A3

14

8

A2

SOL 3

A3

5

10

A2

SOL 5

B

E4

A

P

T1

T

24

T

25

22

28

25

22

E4

A

23

B

P

T1

24

23

29

28 29

A

P

A2

T

P

E4

18

6

A2

T

9

6

A

E4

3 SOL 9

3

E3

SEE NOTE P1

P1

19

SEE NOTE

E3

SOL 8

B

B

12

12

a

a

a

AB

AB

b

b

b

21

21

SOL 1

VALVE DETAIL

SOL 7

SOL 4

SOL 2

AB

SEE NOTE

15

A4

26

E6

A4

1

11 UPPER CYLINDER

A1

T2

16

A4

17

M1

LOWER CYLINDER

1

BOOM HOIST BRAKE E1 20

T4

E5

T3

13

M2

E7

P2

5A

5B

E2

21

P2

4A

4B

P2

P2

3A

3B

E2

P2

2A

2B

P2

21

P2

1A

1B

E2

2

BRAKES PUBLICATION OSMĆ6

FIGURE 12. BRAKE CONTROL DIAGRAM

TAĆ10243Ć4


PUBLICATION OSMĆ6

BRAKES

BRAKE CONTROL DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29


BRAKE CONTROL UNIT HYDRAULIC POWER UNIT SOLENOID VALVE LOCKWASHER ANGLE MOUNT ANGLE MOUNT HOSE HOSE HOSE HOSE HOSE HOSE HOSE BOLT MANIFOLD HOSE HOSE HOSE HOSE HOSE KIT COVER VALVE SUBPLATE BOLT KIT SEAL KIT HOSE PLATE MOUNT SUBPLATE BOLT KIT

COPYRIGHT 2002

ADAPTERS: A1 HYDRAULIC A2 HYDRAULIC A3 HYDRAULIC A4 HYDRAULIC

FITTING FITTING FITTING FITTING

ELBOWS: E1 HYDRAULIC E2 HYDRAULIC E3 HYDRAULIC E4 HYDRAULIC E5 HYDRAULIC E6 HYDRAULIC E7 HYDRAULIC

FITTING FITTING FITTING FITTING FITTING FITTING FITTING

PLUGS: P1 JIG PLUG P2 PLUG W/#12 OĆRING TEES: T1 HYDRAULIC T2 HYDRAULIC T3 HYDRAULIC T4 HYDRAULIC

FITTING FITTING FITTING FITTING

MISCELLANEOUS FITTINGS: M1 PIPE REDUCER M2 CAP NUT

LeTourneau, Inc.

23

BRAKES

PUBLICATION OSMĆ6

NOTES

24

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION OSMĆ4


LUBRICATING OIL ANALYSIS An effective preventive maintenance program will give the owner or equipment manager the ability to predict and control downtime. An onĆgoing oil analysis program is very important in identifying components that are in need of replacement, overhaul or a change in their maintenance to prevent an unscheduled breakdown or premature failure.

THE ROLE OF LUBRICATING OIL ANALYĆ SIS IN A PREVENTIVE MAINTENANCE PROGRAM Service intervals for the drivers and gearboxes on the crane are included in PREVENTIVE MAINTENANCE SCHEDULES located in the back of this publication. These recommendations are based on normal conditions and a lubricating oil analysis program should be used to supplement these recommendaĆ tions. If the crane is used in extremes of temperatures, prolonged operation, sandy or dusty conditions or exposure to moisture, the lubrication intervals may have to be modified. An onĆgoing lubricating oil analysis program can help to identify problems resulting from the above mentioned conditions and others that may cause accelerated component failure which are unique to your operation. A preventive maintenance program custom tailored for a specific application is the most effective manner in which to maintain heavy equipment.

NOTE Lubricating oil analysis is designed to detect only that type of failure which characteristicalĆ ly begins with an increase in metal wear; that is, worn bearings, worn gears and slowly progressing fatigue failures. Component failures which are catastrophic and instantaĆ neous in nature are not caught by lubricating oil analysis.

oil (copper, iron, aluminum, silica, or chromium) indiĆ cates what part is wearing. Lubricating oil analysis is not effective unless it is done on a continual basis in order to establish a wear trend. At least two or three samples must be taken and recorded to establish this trend which reflects the conditions in which the crane is working. After the trend is established, records will readily show any accelerated increase in this pattern. Comparisons to other cranes with like components and working in similar conditions can also be made and used in forecasting downtime and production scheduling.

ANALYSIS OF LUBRICATING OIL IN LeTOURNEAU, INC. DRIVERS AND GEARĆ BOXES LeTourneau, Inc. has done extensive research on driver and gearbox life/maintenance programs. This research has confirmed the value of an onĆgoing lubricating oil analysis program for obtaining maximum life from the drivers and gearboxes on the crane. a.

SAMPLE COLLECTION

Oil samples should be drawn and analyzed every 250 hours of operation, again prior to an oil change and more often if suspicious of component operaĆ tion. The crane should be operated for at least one hour with continual operation of the component prior to taking a sample from a driver or gearbox. The oil samples should then be taken within 10 minutes of stopping the machine. Approximately 3Ć5 oz. is normally required for analysis. Be sure receptacle is clean.

NOTE A suction pump should be used to draw the oil sample, as this will result in the most accurate analysis reports. BE SURE to thoroughly clean the suction pump between taking samples in several components.

PROGRAM OPERATION With lubricating oil analysis, the wear of internal components can be determined without taking the machine apart. At the recommended oil change interval or as otherwise recommended; a sample of the oil should be collected and sent to a testing facility who analyzes its microscopic metal content with special emission or atomic absorption spectrophotometry equipment. When this is done regularly, a record or wear trend is established for that component or group on components from several machines. If the amount of certain metal or other foreign matter rises suddenly above the normal wear trend, it can indicate failure is imminent. The type of metal or material detected in the 4ĆOSM 4.3a, Gorilla 8/30/01

NOTE Samples must be sent promptly to the testing facility. Analysis and reporting must be likewise equally prompt. Any delay could negate the application of the analysis report. All samples must be analyzed under identical conditions or the results will not be usable. Newly changed oil or oil recently added to a system will not give a true picture when it is analyzed. Also, deviation from accepted procedures in taking the sample can invalidate the analysis results. Any of these conditions could have dangerous or misleading conseĆ quences because the sample analysis would be

COPYRIGHT 2002

LeTourneau, Inc.

9


PUBLICATION OSMĆ4

incorrect and not indicate the true condition of the component.

2. Viscosity test: If viscosity shows a large increase or decrease, then change the oil.

The magnetic plug should also be inspected and cleaned regularly. Record the appearance and weight of metal accumulated. In the event of the appearance of a large increase in the amount of metallic particles or chips, the gearbox or driver should be inspected internally. If no damage is readily evident, the compoĆ nent should be removed from service and disasĆ sembled and the source(s) of the contamination identified and repaired.

3. Insoluble material test: If the amount of insoluble material test shows a large increase, the oil should be changed. This could indicate the failure of a seal and the seals should be closely examined.

b.

PROPER DOCUMENTATION

Proper documentation is critical to the success of an ongoing lubricating oil analysis program. It is especially important to maintain accurate and detailed records when analyzing several components on one crane or a group of cranes. This documentation should include:

WEAR TREND ANALYSIS Of particular concern are the levels of silicate (contamiĆ nation) and iron (wear). The results of each sample taken should be compared to at least two or three previous samples (from the same component) in order to conduct wear trend analysis. A sudden increase in the amount of these contaminants in the oil would signal the need for corrective action such as flushing or disassembly of the component.

NOTE Flushing the driver or gearbox is strongly recommended if iron content reaches 100 ppm. If these high levels of iron content continue after flushing, disassembly and inspection should be considered. In order to maximize component life, the amount of iron contained in the oil must be kept as low as possible.

1. Date of sample 2. Serial or identification numbers of the compoĆ nent 3. Total hours of component life 4. Hours of operation since last oil change 5. Complete results of all tests conducted

NOTE

6. Serial number of the crane and position of the gearbox or driver (main hoist, aux. hoist, boom luffing, swing)

Refer to DRIVER MAINTENANCE, Page 13, for additional information on servicing drivers. Service requirements for gearboxes are found in the PREVENTIVE MAINTENANCE SCHEDĆ ULES located in the back of this section. Also, refer to PCM CRANE LUBRICATION SPECIFIĆ CATIONS, Figure 1, for lubricants recomĆ mended for use in drivers and gearboxes.

7. Appearance and weight of magnetic plug accumulation 8. Any other applicable comments about the component's operation c.

RECOMMENDED TESTS 1. Spectrographic analysis: This test checks for the metal content in the oil. The amounts in parts per million should be compared to the previous sample. If a significant increase in any of the elements appears, perform a gearcase inspection. A sudden increase in iron content will indicate excessive wear of one or more of the drive train components. A sudden increase in chromium should indicate unusual wear of a bearing. If silicon content only shows a large step change, the oil should be changed.

a.

Synthetic and speciality lubricants have become popuĆ lar with many equipment owners and may be beneficial where temperature extremes (hot and cold) are encounĆ tered. Contact LeTourneau, Inc. through your distributor to determine acceptable lubricants for your operation.

NOTE It is important to emphasize that a large increase in iron or chromium content between two consecutive tests indicates component failure. 10

SYNTHETIC AND SPECIALITY LUBRICANTS

COPYRIGHT 2002

!

CAUTION

If the service intervals recommended in the PREVENTIVE MAINTENANCE SCHEDULES are exceeded due to the use of synthetic or speciality lubricants, it is essential to monitor the component with lubricating oil analysis. The guideline of 100 ppm. of iron content will apply and the component should be flushed if this amount is reached. Disassembly and inspection should be undertaken if wear trend analysis indicates a reoccurrence after flushing.

LeTourneau, Inc.

4ĆOSM 4.3a, Gorilla 8/30/01

PUBLICATION OSMĆ4


HYDRAULIC BRAKE OIL The hydraulic brake system is equipped with a power unit which has a 20 gallon reservoir. This unit is factory equipped with fire resistant brake fluid (P/N 423Ć5122). It is recommended that oil samples be taken for analysis every 250 hours of operation or monthly. The reservoir should be drained and thoroughly cleaned every five years or when lubricating oil analysis indicates a water or solid particle contamination of 60 ppm or greater. Refer to Publication OSMĆ6, BRAKES, in the

OPERATING AND SERVICE MANUAL for additional information on servicing the hydraulic brake system.

NOTE The ultimate success of a lubricating oil analysis program rests with the owner or equipment manager. If good samples are taken, forwarded promptly, and the feedback used wisely, a lubricating oil analysis program will be very effective.

NOTES


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NOTES

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POWER LOSS LOWERING SYSTEM INSPECTION AND TEST PROCEDURES The following procedures are recommended as a minimum periodic inspection and checkout of the Power Loss Lowering System. These procedures should be conducted every 250 hours or monthly as outlined in the PREVENTIVE MAINTENANCE SCHEDULES, located in the back of this publication.

b. Inspect the auxiliary and hoist brake rotor thermoĆ couple for proper thermocouple to brake rotor clearĆ ance (.050 ± .002 inches, rotor cold).

NOTE

d. Ensure that the EMERGENCY HOIST RELEASE switch is in the OFF position.

Refer to PCM CRANE POWER LOSS LOWERĆ ING SYSTEM, located in Publication ROMĆ6 in the REPAIR AND OVERHAUL MANUAL, for a detailed explanation of the Power Loss Lowering System.

e. Ensure that the CONSTANT TENSION switch is in the OFF position.

c. Inspect the auxiliary hoist temperature transmitter for proper electrical connections and connection tightĆ ness.

f. With the MASTER switch in the ON position and the HOIST SELECT switch in the AUX position, lift any convenient load to approximately 25% of full up travel. g. Position the HOIST joystick to NEUTRAL and the BRAKE switch to the SET position.

24 VDC BATTERY BANK AND CHARGER The crane has 24 VDC battery backĆup power available for power loss lowering functions in the event of a power loss situation. A bank of four 12 VDC, maintenance free lead batteries is mounted on top of the machinery house. The system contains a regulated battery charĆ ger, which operates from 120 VAC, to restore the battery bank to full charge after the unit has supplied backĆup power to the crane. After the full charge has been reached, the charger continues to trickleĆcharge the batteries to maintain a full charge without overcharging. The battery charger is operational when the 600A Feeder Breaker to the crane is closed (ON). The charger has a 5Ćamp fuse on the 120 VAC input. An internal ganged 15A circuit breaker protects the system in the event that loading exceeds ratings. The battery charger is calibrated to float the battery bank at 27.5 VDC (the optimum voltage for the battery type). The GREEN pilot light is ON when the battery charger is properly ON and the battery is floating at proper DC voltage. The RED pilot light comes ON when the battery is connected to the charger in reverse polarity. If you see this RED light ON, immediately disconnect the charger from the battery bank. The batteries are maintenance free other than it is recommended that the connections be checked every two months for tightness.

POWER LOSS HOIST LOWER TEST PROCEDURE (AUXILIARY AND MAIN HOIST) a. Inspect the Power Loss Lowering Card and the auxiliary and main hoist Speed Sensor Filter Cards for proper electrical connections and connection tightness. 4ĆOSM 4.3a, Gorilla 8/30/01

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Uncontrolled load descent during test can cause serious injury or death! BE ALERT OBSERVE HOOK LOWERING SPEED. If at any time during this procedure it appears that the load is descending when it shouldn't be or is descending uncontrollably, it is imperative that the operator immediately move the HOIST joystick to the NEUTRAL position and release the POWER LOSS HOIST LOWER pushbutton. The following switch settings should also be made: D BRAKE switch in the SET position D EMERGENCY HOIST RELEASE switch in the OFF position D CONSTANT TENSION position

switch in the OFF

D MASTER switch in the OFF position.

!

CAUTION

The Power Loss Hoist Lower function has the potential to generate extreme brake rotor and pad temperatures (the heavier the load, the faster the temperature will rise). Always station an observer in a location where the brakes can be visually monitored when doing a power loss hoist lower. Because of the brake dust that can be generated by dragging through the brakes it is advised that the observer wear a respirator and view the procedure from the catwalk looking through the door into the crane machinery house. This observer must be able to contact the operator

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d. Ensure that the EMERGENCY HOIST RELEASE switch is in the OFF position.

and signal a procedure shutdown should the temperature sensing system obviously fail (as evidenced by a glowing red brake rotor, excessive sparking, smoke, flame, etc.).

e. With the MASTER switch in the ON position and the HOIST SELECT switch in the AUX position, lift an approximately 5,000 lb load to approximately 25% of full up travel.

NOTE The SPEED/TEMP WARNING light should be out and stay out throughout this procedure (unless brake rotor temperature exceeds approximately 700°F).

f. Position the HOIST joystick to NEUTRAL and the BRAKE switch to the SET position.

h. To activate power loss hoist lower mode, perform the following steps:

If at any time during this procedure it appears that the load is descending when it shouldn't be or is descending uncontrollably, it is imperative that the operator move the CONSTANT TENSION switch to the OFF position. The following switch settings should also be made: BRAKE switch in the SET position, EMERGENCY HOIST RELEASE switch in the OFF position, and MASTER switch in the OFF position.

1. MASTER switch in the BAT position (POWER ON light flashing). 2. BRAKE switch in the ENABLE position. 3. POWER LOSS HOIST LOWER pushbutton depressed and held. 4. HOIST joystick moved in the LOWER direction (HOIST joystick contact must close).

!

The load should accelerate to and descend at a constant rate (300 rpm of motor speed) as the load pulls through the partially released hoist brake. When satisfied that the power loss lowering system is lowering the load as expected, release the POWER LOSS HOIST LOWER pushbutton and return the HOIST joystick to NEUTRAL, at which point the brake will set and the load will stop. Take the BRAKE switch to SET and the MASTER switch to OFF. The crane is now ready for normal operations.

This procedure has the potential to generate extreme brake rotor and pad temperatures (the heavier the load, the faster the temperaĆ ture will rise and the faster the load will accelerate). Always station an observer in a location where the brakes can be visually monitored when doing a constant tension mode test lower operation. Because of the brake dust that can be generated by dragging through the brakes, it is advised that the observer wear a respirator and view the procedure from the catwalk, looking through the door into the crane machinery house. This observer must be able to contact the operator and signal a shutdown should the temperature sensing system obviously fail (as evidenced by a glowing red brake rotor, excessive sparking, smoke, flame, etc.).

Should the crane not perform as expected, refer to the POWER LOSS HOIST LOWER section of PCM CRANE POWER LOSS LOWERING SYSTEM, located in PublicaĆ tion ROMĆ6 in the REPAIR AND OVERHAUL MANUAL, for a detailed explanation of how this system works. i. Repeat Steps f" through h" above with a load on the main hoist and the HOIST SELECT switch in the MAIN position.

NOTE

CONSTANT TENSION TEST PROCEDURE (POWER LOSS OPERATIONS, AUXILIARY HOIST ONLY) a. Inspect the Power Loss Lowering Card and the auxiliary and main hoist Speed Sensor Filter Cards for proper electrical connections and connection tightness.

CAUTION

The SPEED/TEMP WARNING light should be out and stay out throughout this procedure (unless brake rotor temperature exceeds approximately 700°F). g. To activate constant tension mode under power loss conditions, perform the following steps:

b. Inspect the auxiliary hoist brake rotor thermocouĆ ple for proper thermocouple to brake rotor clearance (.050 ± .002 inches, rotor cold).

1. MASTER switch in the BAT position (POWER ON light flashing).

c. Inspect the auxiliary hoist temperature transmitter for proper electrical connections and connection tightĆ ness.

3. CONSTANT TENSION switch in the BAT position and held there (CONSTANT TENĆ SION and AUX RUN lights should come on).

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2. BRAKE switch in the ENABLE position.

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This will cause the brakes to partially release and maintain a line tension of approximately 3,300 lbs. The suspended 5,000 lb load will begin to descend and accelerate. Once movement is seen, turn the CONSTANT TENSION switch to OFF, which should set the brake and stop the load. Take the BRAKE switch to SET and the MASTER switch to OFF. The crane is now ready for normal operations. Should the crane not perform as expected, refer to the CONSTANT TENSION section of PCM CRANE POWER LOSS LOWERING SYSTEM, located in Publication ROMĆ6 in the REPAIR AND OVERHAUL MANUAL, for a detailed explanation of how this system works.

CONSTANT TENSION TEST PROCEDURE (NORMAL OPERATIONS, AUXILIARY HOIST ONLY) a. Inspect the Power Loss Lowering Card and the auxiliary and main hoist Speed Sensor Filter Cards for proper electrical connections and connection tightness.

2. BRAKE switch in the ENABLE position. 3. CONSTANT TENSION switch in the ON posiĆ tion (CONSTANT TENSION and AUX RUN lights should come on). This will cause the aux hoist motor to power up and maintain approximately 3,300 lbs of up tension on the line. This will result in all of the slack being taken out of the line but no movement of the load (3,300 lbs of tension will not be enough to lift 5,000 lbs of load). Verify aux hoist motor torque by reading the following values on the hoist motor controller tester (located in the crane control room at the top on the column): 4. IA = +0.62 to +0.68 (hoist motor armature current) 5. IF = +1.23 to +1.37 (hoist motor field current) Verify that each of the following three actions will disable constant tension mode: 6. CONSTANT TENSION switch in the OFF position. This will set the brake and make tester signal IA equal zero. Put the aux hoist back into constant tension mode by taking the CONSTANT TENSION switch back to ON before performing the next step.

b. Inspect the auxiliary hoist brake rotor thermocouĆ ple for proper thermocouple to brake rotor clearance (.050 ± .002 inches, rotor cold). c. Inspect the auxiliary hoist temperature transmitter for proper electrical connections and connection tightĆ ness.

7. BRAKE switch in the SET position. This will set the brake and make tester signal IA equal zero. Put the aux hoist back into constant tension mode by first taking the BRAKE switch to the ENABLE position and then taking the CONSTANT TENSION switch to OFF and back to ON before performing the next step.

d. Ensure that the EMERGENCY HOIST RELEASE switch is in the OFF position. e. With the MASTER switch in the ON position and the HOIST SELECT switch in the AUX position, attach the aux hook to an approximately 5,000 lb load resting on the deck of the rig, leaving a little bit of cable slack.

8. HOIST joystick out of neutral (move it in the UP torque direction). This disables constant tenĆ sion mode and automatically returns load control in either direction to the HOIST joystick.

f. Position the HOIST joystick to NEUTRAL and the BRAKE switch to the SET position.

NOTE Once disabled by any of the three means above, constant tension mode will stay disabled until the CONSTANT TENSION switch is cycled from ON to OFF and back to ON again.

If at any time during this procedure it appears that the load is descending when it shouldn't be or is descending uncontrollably, it is imperative that the operator move the CONSTANT TENSION switch to the OFF position. The following switch settings should also be made: BRAKE switch in the SET position, EMERGENCY HOIST RELEASE switch in the OFF position, and MASTER switch in the OFF position.

Should the crane not perform as expected, refer to CONSTANT TENSION MODE OPERATION AND TROUĆ BLESHOOTING, located in Publication ROMĆ6 in the REPAIR AND OVERHAUL MANUAL.

g. To activate constant tension mode when not under power loss conditions, perform the following steps: 1. MASTER switch in the ON position (POWER ON light ON). 4ĆOSM 4.3a, Gorilla 8/30/01

EMERGENCY HOIST RELEASE TEST PROCEDURE (NORMAL OPERATIONS, MAIN AND AUXILIARY HOIST) a. Position the hooks in a safe area. Position the HOIST SELECT switch to the AUX position.

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b. Position the HOIST joystick to NEUTRAL, BRAKE switch to the SET position.

If at any time during this procedure it appears that the load is descending, it is imperative that the operator move the EMERGENCY HOIST RELEASE switch to the OFF position. The following switch settings should also be made: BRAKE switch in the SET position, CONSTANT TENSION switch in the OFF position, and MASTER switch in the OFF position. c. To activate emergency release mode , perform the following steps: 1. MASTER switch in the ON position (POWER ON light ON). 2. BRAKE switch in the SET position. 3. OVERLOAD PROTECTION switch in the ON position (OVERLOAD PROTECTION ACTIVE light should come on). 4. EMERGENCY HOIST RELEASE switch in the ON position (GROSS OVERLOAD, EMERĆ GENCY HOIST RELEASE, and AUX RUN lights should come on).

PUBLICATION OSMĆ4

The Emergency Release system uses the same circuitry and generates the same results as does an Automatic Overload Protection System (AOPS) activation. Visually check that the top canister of the aux hoist motor brake remains set, that the bottom brake canister releases fully, and that LED3 on the hoist controller (GOL Veac Disable, visible through the window in the hoist controller front cover) illuminates. The external cab mounted alarm and the machinery house mounted alarm will sound with a pulsating tone. Clear the alarms with the ACKNOWLEDGE HORN BUTTON, take the EMERGENCY HOIST RELEASE switch to OFF, and take the OVERLOAD PROTECTION SWITCH to RESET and then back to ON. Should the crane not perform as expected, refer to the EMERGENCY HOIST RELEASE (NORMAL OPERAĆ TIONS) section of PCM CRANE POWER LOSS LOWERĆ ING SYSTEM, located in Publication ROMĆ6 in the REPAIR AND OVERHAUL MANUAL, for a detailed explanation of how this system works. d. Repeat steps b" and c" above with the HOIST SELECT switch in the MAIN position. e. Position the OVERLOAD PROTECTION switch to RESET unless directed otherwise by a supervisor.

NOTES

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PUBLICATION ROMĆ6

SOLID STATE CONVERSION SYSTEM

PCM CRANE POWER LOSS LOWERING SYSTEM The primary purpose of the PCM crane power loss lowering system is to enable the operator to lower a load (main or auxiliary hoist) while suffering power loss conditions to the crane's hoist system (loss of main AC power and/or 24 VDC power supply). This system can also be used to lower a load during scenarios other than power loss (such as failure or malfunction of the normal hoisting system). When the Master Switch is turned to BAT, backup batteries supply 24 VDC to the power loss lowering card (PLLC, see Figure 24) and to various other necessary backup components. The PLLC, which monitors operator commands, motor speed, and motor brake rotor temperature, manipulates a proportional hydraulic relief valve to partially release the motor park brake. This allows the load to slip through the brake and descend at a constant speed (approximately 300 rpm at the motor) via gravity. The system hydraulic pressure to the motor brake is varied in proportion to the current supplied to the proportional valve's solenoid by the PLLC. This current varies based on speed feedback to the PLLC from the motor's two speed sensors. A thermocouple monitors brake rotor temperature and halts the lowering process when the temperature exceeds approximately 700°F (371°C). Lowering is allowed to resume once the rotor has cooled to approximately 450°F (232°C). Besides the mode of operation described above (Power Loss Hoist Lower), the PLLC is also responsible for backup battery Constant Tension operation, and for monitoring the status of the normal (nonĆpower loss) Emergency Hoist Release operation (descriptions of each to follow).

!

Before initiating this procedure, inspect the main and auxiliary hoist brake rotor thermoĆ couples for proper thermocouple to brake rotor clearance (.050 ± .002 inches, rotor cold). Inspect the PLLC, the main and auxiliary speed sensor filter cards, and the main and auxiliary hoist temperature transmitters for proper electrical connections and tightness.

!

CAUTION

This procedure has the potential to generate extreme brake rotor and pad temperatures (the heavier the load, the faster the temperaĆ ture will rise). Always station an observer in a location where the brakes can be visually monitored when doing a power loss hoist lower. Because of the brake dust that can be generated by dragging through the brakes, it is advised that the observer wear a respirator and view the procedure from the catwalk, looking through the door into the crane control room. This observer must be able to contact the operator and signal a procedure shutdown should the temperature sensing system obviously fail (as evidenced by a glowing red brake rotor, excessive sparking, smoke, flame, etc.) 1. EMERGENCY HOIST RELEASE switch must be in the OFF position.

NOTE

2. CONSTANT TENSION switch must be in the OFF position.

The Power Loss Lowering System should be inspected and tested monthly in accordance with the PREVENTIVE MAINTENANCE SCHEDULES, located in Publication OSMĆ4 in the OPERATING AND SERVICE MANUAL.

3. MASTER switch must be in the BAT position (POWER ON light flashing). 4. AUX or MAIN hoist position selected with the HOIST SELECT switch. 5. BRAKE switch must be in the ENABLE position.

NOTE

6. POWER LOSS HOIST LOWER button pressed and held.

These instructions reference general electriĆ cal schematic 422Ć1678, located in the back of Section 4, Electrical System Troubleshooting (in this manual), and general hydraulic schematic 422Ć3396, located in the back of Publication OSMĆ6 in the OPERATING AND SERVICE MANUAL.

7. HOIST joystick moved in the LOWER direction (HOIST joystick contact must close and the AUX or MAIN RUN light should come on).

a. POWER LOSS HOIST LOWER: Power Loss Hoist Lower is the normal means of lowering a suspended load when operating under power loss conditions. To activate power loss hoist lower mode, the following conditions must be met: 1ĆROM 6.2d, Gorilla 5/12/99 (Rev 8/30/01)

CAUTION

For the discussion that follows, assume that the Hoist Select switch is in MAIN. When BAT is selected with the Master Switch, relay BTB becomes energized, which makes wire 11D hot through a set of normally closed CR15 contacts (see electrical schematic referenced above). 11D becoming hot energizes SOL8 and also indicates to the PLLC that the main hoist is selected. SOL8 causes its associated hydraulic valve to shift,

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FIGURE 24. POWER LOSS POWERING CARD (1 of 2) 9ĆNGOĆ1876Ć1, P10Ć64

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1ĆROM 6.2d, Gorilla 5/12/99 (Rev8/30/01)

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FIGURE 24. POWER LOSS LOWERING CARD (2 of 2) 9ĆCGĆ2471Ć1, P02Ć25

1ĆROM 6.2d, Gorilla 5/12/99 (Rev 8/30/01)

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resulting in the proportional hydraulic relief valve SOL3 being placed in series with the upper brake canister (see hydraulic schematic referenced above). When the Power Loss Hoist Lower push button is depressed and the hoist joystick is moved in the lower direction, wire EL4 to the PLLC will become hot causing CR39 and SOL3 to be energized by the PLLC. This results in a set of CR39 contacts closing, which energizes CR41 and SOL2. A set of CR41 contacts will then close energizing CR28, which energizes CTR15, which applies 24V battery power to the backup hydraulic DC pump motor. SOL2 energizing applies full system pressure (approxiĆ mately 130 psi) to the springĆapplied lower brake canister (causing it to fully release) and a variable pressure (via the PLLCĆcontrolled proportional relief valve SOL3) to the springĆapplied upper brake canister. The PLLC, which supplies approximately 14 VDC to each main hoist motor speed sensor filter card through wires 12MH1 and 12MH2, monitors main hoist motor speed on wires 92MH1 and 92MH2 from the motor speed sensors (these signals are pulse trains generĆ ated by magnetic pickups with 1 Hz corresponding to 1 rpm of motor speed). If the speed is less than 300 rpm, more current (in the form of a pulse width modulated signal) is sent to SOL3 by the PLLC, causing the relief valve to bypass less fluid to tank, resulting in more pressure to the upper brake canister (and therefore less braking effort and more motor speed for a given load). If the speed is more than 300 rpm, less current is sent to SOL3, causing the relief valve to bypass more fluid to tank, resulting in less pressure to the upper brake canister (and therefore more braking effort and less motor speed for a given load). This dynamic feedback system results in a relatively constant lowering speed for a full range of loads (up to and including rated load). Auxiliary hoist operation is similar except that CR15 will be energized resulting in wire 11G being hot and SOL9, CR40, SOL5, SOL4 and CR42 being energized as opposed to their main hoist counterparts listed above. Should motor speed exceed approximately 750 rpm in power loss hoist lower mode, the PLLC will set the brake fully (overspeed condition). Wire EL4 will have to be deĆenergized (Power Loss Hoist Lower button released, hoist joystick neutral) and then reĆenergized in order to initiate another lowering attempt. Temperature sensing circuitry and logic are discussed in the Temperature Sensing section following.

NOTE Power Loss Hoist Lower mode will be overridden by constant tension mode (wire CT3 hot) and emergency hoist release mode (wires ER1 or ER2 hot). 76

b. CONSTANT TENSION (AUXILIARY HOIST ONLY): Constant tension mode is used when the load is on the deck of a vessel that is pitching up and down due to wave motion. To activate constant tension mode under power loss conditions, the following conditions must be met: 1. EMERGENCY HOIST RELEASE switch must be in the OFF position. 2. MASTER switch must be in the BAT position (POWER ON light flashing). 3. HOIST SELECT switch must be in the AUX position. 4. BRAKE switch must be in the ENABLE position. 5. CONSTANT TENSION switch must be turned to the BAT position and held there (CONSTANT TENSION and AUX RUN lights should come on). When BAT is selected with the Master Switch, relay BTB becomes energized, which makes wire 11G hot through a set of normally open CR15 contacts (see electrical schematic referenced above). 11G becoming hot energizes SOL9 and also indicates to the PLLC that the aux hoist is selected. SOL9 causes its associated hydraulic valve to shift, resulting in the proportional hydraulic relief valve SOL5 being placed in series with the upper brake canister (see hydraulic schematic referenced above). When the Constant Tension switch is held in the BAT position, wire CT4 to the PLLC will become hot, causing CR40 and SOL5 to be energized by the PLLC. This results in a set of CR40 contacts closing, which energizes CR42 and SOL4. A set of CR42 contacts will then close energizing CR28, which enerĆ gizes CTR15, which applies 24V battery power to the backup hydraulic DC pump motor. SOL4 energizing applies full system pressure (approximately 130 psi) to the springĆapplied lower brake canister (causing it to fully release) and a reduced pressure (via the PLLCĆconĆ trolled proportional relief valve SOL5) to the springĆapĆ plied upper brake canister. (This reduced pressure is constant and is set during initial calibration of the system by lifting a 3300Ćlb. load with the aux hook, going into power loss" constant tension mode as described above, and then adjusting the mid" pot on component U9 (proportional valve drive card) on the PLLC until the load just starts slipping. This effectively applies a constant current to SOL5 to maintain approximately 3300 lbs. of line tension on the hoist cable. This preĆadjusted pressure is dependent upon CR11 being energized when the Constant Tension switch is turned to BAT. This opens a set of CR11 contacts and removes 24V from wire 43SA to the PLLC, which makes the mid pot setting on U9 effective. During this constant tension operation under power loss conditions, should the deck drop from under the load due to wave motion, the load

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PUBLICATION ROMĆ6


will also drop if it weighs more than 3300 lbs. There will be no motor power, of course, to take up the slack when the deck rises again. Top motor speed allowed by the PLLC in constant tension mode is 2665 rpm. Should motor speed exceed this maximum, the park brake will be fully set and the constant tension switch will have to be cycled from OFF back to BAT in order to resume constant tension operation. Temperature sensing circuitry and logic are discussed in the Temperature Sensing section following.

NOTE

The end result is that during an Emergency Release operation, the top brake canister of the selected hoist motor will be fully set, and the bottom brake canister will be fully released, resulting in a holding force of approximately 150% of maximum rated load. If a true gross overload exists, the load will pull through the one brake canister without causing structural damage to the crane. To reset the Emegency Release sytem, place the Emergency Hoist Release switch to OFF and then cycle the Overload Protection switch to RESET and then back to ON. The Gross Overload light should go out and the Overload Protection Active light should illuminate.

Constant tension mode will be overridden by emergency hoist release mode (wires ER1 or ER2 hot) and overrides power loss hoist lower mode (wire EL4 hot). c. EMERGENCY HOIST RELEASE (NORMAL OPERATIONS): The emergency hoist release mode is designed to be used if the hook becomes entangled in a vessel that is moving away from the crane. To activate emergency hoist release mode when not under power loss conditions, the following conditions must be met: 1. MASTER switch must be in the ON position. 2. OVERLOAD PROTECTION switch must be in the ON position (OVERLOAD PROTECTION ACTIVE light on). 3. AUX or MAIN hoist position selected with the HOIST SELECT switch. 4. EMERGENCY HOIST RELEASE switch must be put in the ON position (EMERGENCY HOIST RELEASE and AUX or MAIN RUN lights should come on). Placing the Emergency Hoist Release Switch in ON position causes CR9 to energize. A set of CR9 contacts connects wire 3F to wire GOL, which initiates the same chain of events that results from an Automatic Overload Protection System (AOPS) activation (refer to PublicaĆ tion ROMĆ6 in the REPAIR AND OVERHAUL MANUAL for more information on the AOPS). Wire GOL applies 24V to the hoist controller, which in turn energizes CR44, which energizes SOL1 (Brake Master Solenoid) and SOL8. The hoist controller also energizes CR44A, which energizes SOL9. SOL8 and SOL9 route hydraulic pressure away from the top brake canisters of the main and aux hoist motors respectively and to the proportionĆ al relief valve solenoids SOL3 and SOL5 (see Hydraulic Schematic referenced above). No current is sent to SOL3 or SOL5 from the PLLC during an Emergency Release operation, so all hydraulic pressure to the top canisters is bypassed to tank through SOL3 and SOL5, and the top canisters remain fully set. 1ĆROM 6.2d, Gorilla 5/12/99 (Rev 8/30/01)

At the same time, the hoist controller also energize CR43, which energizes either SOL2 if the main hoist is selected, or SOL4 if the aux hoist is selected. This applies full hydraulic pressure to the selected motor's bottom brake canister, releasing it fully.

NOTE Emergency hoist release mode overrides constant tension (wire CT4 hot) and power loss hoist lower (wire EL4 hot) modes. d. TEMPERATURE SENSING: A descending load opposed by friction drag torque on the motor brake rotor will generate heat. Brake rotor temperature is sensed by a thermocouple mounted .050 inches from the radial edge of the rotor (cold). As the rotor heats up it expands and its heat is transmitted through the air gap to the thermocouple. The thermocouple's millivolt signal is routed to a 4Ć20mA temperature transmitter which sends a proportional current signal to the PLLC on wire TX1 (main hoist) or TX2 (auxiliary hoist). If the rotor temperature is sensed to be greater than approxiĆ mately 700°F, the PLLC will set the park brake until rotor temperature drops to less than approximately 450°F, at which point lowering will be reĆenabled.

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NOTE Rotor temperature has no effect on emerĆ gency release mode.

!

CAUTION

The thermocouple/temperature transmitter combination is calibrated to measure rotor temperature across an air gap which decreases as the rotor heats up and expands. Should the thermocouple ever physically contact the rotating brake rotor, its sensed temperature will go up rapidly causing a premature temperature shutdown of the lowering process (refer to LED1 and LED3 in PLLC LED's, below). This will also result in rapid wear and failure of the thermocouple element, likewise causing a temperature

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shutdown (see LED1 and LED3). For these reasons it is important to maintain proper thermocouple to rotor clearance (.050 ± .002 inch, rotor cold).

The dual speed sensor arrangement is designed for redundancy; only one speed sensor and its associated processing circuit are normally necessary for power loss lowering. The PLLC allows lowering with the SPEED/TEMPERATURE warning light flashing but the cause of the flashing light should be investigated and rectified as soon as possible. Should both speed sensors or PLLC speed sensor signal processing circuits fail, the PLLC will have no speed feedback and will sense" that the load is not moving. Should this be the case, when a lower mode is initiated, the park brake will be released and the load will descend unabated. Also, since both speed feedback systems are disabled, the SPEED/TEMPERATURE light will not illuminate. It is important that the operator always maintain extreme caution when using the power loss lowering system (as with any lowering operation) and always be prepared to come out of a lowering mode (joystick neutral, POWER LOSS HOIST LOWER push button released, CONSTANT TENSION switch off, EMERGENCY HOIST RELEASE switch off) should a problem be suspected. Coming out of a lowering mode will set the park brake and stop the load. Note that having both speed sensors and/or speed sensor signal processĆ ing circuits fail at the same time is an extremely unlikely situation. Speed sensor condition and PLLC speed sensor signal processing circuitry condition are constantly monitored during normal crane operations (with malfunctions indicated by a flashing SPEED/TEMPERATURE light), so any power loss lowering situation should begin with two known good speed sensors and circuitry. A possible failure scenario to be aware of, however, would be to have both of the speed sensors not wired or improperly wired to the PLLC resulting in no speed feedback to the card. It is therefore important that the power loss lowering system be regularly checked for proper installation and functioning in accorĆ dance with the crane's preventive mainteĆ nance schedule.

NOTE Refer to Figure 25 for an illustration of the thermocouple and installation procedures. Refer to Figure 26 for an illustration of the temperature transmitters. e. SPEED/TEMPERATURE Warning Light: The SPEED/TEMPERATURE warning light (located on the operator's console) comes on in the following modes and for the following reasons (for further information on troubleshooting what is specifically causing a flashing or a steady light, refer to PLLC LED'S, below): 1. Steady Mode: The light will come on and glow steadily and the park brake will be set (exception: in emergency release mode, the park brake will remain released regardless of the status of this light) in the event of: (a) The motor brake rotor reaching its maxiĆ mum allowed temperature of approxiĆ mately 700°F. The light will go out and lowering will be allowed once the rotor temperature has cooled to less than approximately 450°F. (b) A failure of the brake rotor temperature sensing thermocouple. (c) A failure of the brake rotor 4Ć20mA temperature transmitter.

NOTE A failure of one hoist motor's thermocouple and/or temperature transmitter will cause the SPEED/TEMPERATURE warning light to come on steady but will not disable the lowering capability of the other hoist motor. For further information on troubleshooting what is specifically causing a flashing or a steady light, refer to PLLC LED's, below. 2. Flashing Mode: This light will flash in the event of:

78

(a) Motor speed greater than 250 rpm and a failure of one of the two motor speed sensors.

f. PLLC LED'S: Mounted on the PLLC are eight LED's (light emitting diodes) (refer to Figure 24). These LED's have the following labels and meanings:

(b) Motor speed greater than 250 rpm and a failure of one of the two speed sensor signal processing circuits on the PLLC.

1. LED1 (AH Temp Hi). If this LED comes on, the SPEED/TEMPERATURE warning light on the operator's console will also come on and glow

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION ROMĆ6


steadily. While the LED is on, the auxiliary park brake will be set and lowering will be disabled (exception: emergency release mode). This LED comes on if: (a) The auxiliary hoist motor brake rotor temperature is sensed to be greater than approximately 700°F (greater than 4 VDC on wire TX2). The LED goes out when the rotor temperature is sensed to be less than approximately 450°F (less than 2 VDC on wire TX2). (b) The auxiliary hoist temperature transmitĆ ter senses that the thermocouple eleĆ ment is open (approximately 5.25 VDC on wire TX2). (c) The auxiliary hoist temperature transmitĆ ter itself malfunctions (approximately 5.25 VDC on wire TX2). 2. LED2 (AH XM Open). If this LED comes on, the SPEED/TEMPERATURE warning light on the operator's console will also come on and glow steadily. This LED comes on if the auxiliary hoist temperature transmitter is sending less than .5 VDC on wire TX2 to the PLLC (normally it should always read a minimum of 1 VDC). This would indicate a probable miswired or malfunctioning transĆ mitter. While the LED is on, the auxiliary hoist park brake will be set and lowering will be disabled (exception: emergency release mode). 3. LED3 (MH Temp Hi). If this LED comes on, the SPEED/TEMPERATURE warning light on the operator's console will also come on and glow steadily. While the LED is on, the main park brake will be set and lowering will be disabled (exception: emergency release mode). This LED comes on if: (a) The main hoist motor brake rotor temperĆ ature is sensed to be greater than approximately 700°F (greater than 4 VDC on wire TX1). The LED goes out when the rotor temperature is sensed to be less than approximately 450°F (less than 2 VDC on wire TX1). (b) The main hoist temperature transmitter senses that the thermocouple element is open (approximately 5.25 VDC on wire TX1). (c) The main hoist temperature transmitter itself malfunctions (approximately 5.25 VDC on wire TX1). 1ĆROM 6.2d, Gorilla 5/12/99 (Rev 8/30/01)

COPYRIGHT 2002

4. LED4 (MH XM Open). If this LED comes on, the SPEED/TEMPERATURE warning light on the operator's console will also come on and glow steadily. This LED comes on if the main hoist temperature transmitter is sending less than .5 VDC on wire TX1 to the PLLC (normally it should always read a minimum of 1 VDC). This would indicate a probable miswired or malfunctioning transmitter. While the LED is on, the main park brake will be set and lowering will be disabled (exception: emerĆ gency release mode). 5. LED5 (AH SS1 Fail). If the auxiliary hoist motor speed is greater than 250 rpm and this LED comes on, the SPEED/TEMPERATURE warning light on the operator's console will come on and flash. This LED comes on if: (a) The auxiliary host speed sensor 1 is not sending a signal to the PLLC (see NOTE below). (b) The auxiliary hoist speed sensor 1 signal processing circuitry on the PLLC is malfunctioning (see NOTE below).

NOTE Circuitry on the PLLC essentially compares the signals received from the auxiliary hoist speed sensor 1 and auxiliary hoist speed sensor 2 and turns on LED5 if a signal is sensed from speed sensor 2 but not from speed sensor 1. Consequently if both speed sensors or both speed sensor signal processĆ ing circuits are malfunctioning, no difference between the two will be detected and LED5 will not come on. 6. LED6 (AH SS2 Fail). If auxiliary hoist motor speed is greater than 250 rpm and this LED comes on, the SPEED/TEMPERATURE warnĆ ing light on the operator's console will come on and flash. This LED comes on if: (a) Auxiliary hoist speed sensor 2 is not sending a signal to the PLLC (see NOTE below). (b) The auxiliary hoist speed sensor 2 signal processing circuitry on the PLLC is malfunctioning (see NOTE below).

NOTE Circuitry on the PLLC essentially compares the signals received from auxiliary hoist speed sensor 1 and auxiliary hoist speed sensor 2 and turns on LED6 if a signal is sensed from speed sensor 1 but not from speed sensor 2. Consequently if both speed

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PUBLICATION ROMĆ6

sensors or both speed sensor signal processĆ ing circuits are malfunctioning, no difference between the two will be detected and LED6 will not come on.

malfunctioning, no difference between the two will be detected and LED7 will not come on.

7. LED7 (MH SS1 Fail). If main hoist motor speed is greater than 250 rpm and this LED comes on, the SPEED/TEMPERATURE warnĆ ing light on the operator's console will come on and flash. This LED comes on if: (a) Main hoist speed sensor 1 is not sending a signal to the PLLC (see NOTE below). (b) The main hoist speed sensor 1 signal processing circuitry on the PLLC is malfunctioning (see NOTE below).

8. LED8 (MH SS2 Fail). If main hoist motor speed is greater than 250 rpm and this LED comes on, the SPEED/TEMPERATURE warnĆ ing light on the operator's console will come on and flash. This LED comes on if: (a) Main hoist speed sensor 2 is not sending a signal to the PLLC (see NOTE below). (b) The main hoist speed sensor 2 signal processing circuitry on the PLLC is malfunctioning (see NOTE below).

NOTE Circuitry on the PLLC essentially compares the signals received from main hoist speed sensor 1 and main hoist speed sensor 2 and turns on LED8 if a signal is sensed from speed sensor 1 but not from speed sensor 2. Consequently, if both speed sensors or both speed sensor signal processing circuits are malfunctioning, no difference between the two will be detected and LED8 will not come on.

NOTE Circuitry on the PLLC essentially compares the signals received from main hoist speed sensor 1 and main hoist speed sensor 2 and turns on LED7 if a signal is sensed from speed sensor 2 but not from speed sensor 1. Consequently, if both speed sensors or both speed sensor signal processing circuits are

NOTES

80

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PUBLICATION ROMĆ6


3 3 2 1

4 1

BRACKET INSTALLATION BRAKE CALIPER ASSEMBLY

THERMOCOUPLE BRACKET ASSEMBLY

THERMOCOUPLE ASSEMBLY

OUTSIDE EDGE OF BRAKE DISC

OUTSIDE EDGE OF BRAKE DISC

±.002" .050" CLEAR (REF)

1. 2. 3. 4.

MOUNTING BRACKET COMPRESSION FITTING THERMOCOUPLE ASSEMBLY THREAD LOADING COMPOUND - LOCTITE RC271

1. Insert compression fitting (Item 2) into bracket (Item 1) using Loctite (Item 4). 2. Install bracket onto brake caliper using caliper mount bolt as shown. Adjust bracket as necessary so that compression fitting is perpendicular to radial edge of brake disk. Tighten caliper mount bolt. 3. Loosen compression fitting nut and insert thermocouple (Item 3) through fitting bushing and teflon ferrule (internal to fitting) until thermocouple tip measures .050" above brake disk edge. Tighten fitting nut using Loctite (Item 4) and recheck for .050 ±.002" clearance. Loosen nut and readjust if necessary. 4. Route thermocouple wire as shown on machine wire layout; terminate thermocouple wire as shown on machine schematic. 1ĆCGĆ1875, P10Ć64

1ĆROM 6.2d, Gorilla 5/12/99 (Rev 8/30/01)

FIGURE 25. HYDRAULIC BRAKE THERMOCOUPLE INSTALLATION COPYRIGHT 2002

LeTourneau, Inc.

TAĆ8987ĆCG

81

TX2 CASE GRND ACT2 (YEL) ACT1 (RED)

AUX HOIST 5 6 7 8

SET 2

4

SET 1

3B

PUBLICATION ROMĆ6

9


4

5

T/C , MV

6

7

8 9 OUT+

3

3

3B TX1 CASE GRND MTC 1 MTC 2 (RED) (YEL)

9 SET 2

MAIN HOIST 5 6 7 8

SET 1

3

4

5

T/C , MV

6

7

8 9 OUT+

3

4

TEMP XMIT PANEL 422Ć8556

TEMP XMIT AUX HOOK 418Ć0161

TEMP XMIT MAIN HOOK 418Ć0161

FIGURE 26. HYDRAULIC BRAKE THERMOCOUPLE TEMPERATURE TRANSMITTERS 1ĆCGĆ1877, P10Ć64

TAĆ8988ĆCG

NOTES

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LeTOURNEAU, INC., PCM 120SS ELECTRIC DECK CRANE REPAIR AND OVERHAUL MANUAL STRUCTURAL COMPONENTS

Page

Page

TABLE OF CONTENTS

TABLE OF CONTENTS


PCMĆ120SS FLOATING SHEAVE HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . 2

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CRANE TESTING, EXAMINATION, AND CERTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 31 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SURVEY AND APPROVAL . . . . . . . . . . . . . . . . . . . . 3 ANNUAL EXAMINATIONS . . . . . . . . . . . . . . . . . . . . 3

PCMĆ120SS HOOK AND BLOCK ASSEMBLY . . . . . . 33

CONTROL BOOK AND CERTIFICATE . . . . . . . . . . 3

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 33

CRITICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 5

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

CRITICAL MECHANICAL COMPONENTS . . . . . . . 5 CRITICAL STRUCTURAL COMPONENTS . . . . . . . 5

CABLE DRUM LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . 35

CRITICAL RIGGING COMPONENTS . . . . . . . . . . . 5

PCMĆ120SS STRUCTURAL REPAIRS . . . . . . . . . . . . 37

PCMĆ120SS MACHINERY HOUSE AND WINCH INSTALLATION - BOOM, MAIN HOOK AND AUXILIARY HOOK ASSEMBLIES . . . . . . . . . . . . . . . . 7

WELDING REQUIREMENTS . . . . . . . . . . . . . . . . . . 37 STRUCTURAL MATERIALS . . . . . . . . . . . . . . . . . . . 37 STRUCTURAL REPAIR PROCEDURES . . . . . . . . . 37

MACHINERY HOUSE DESCRIPTION . . . . . . . . . . . 7

PCMĆ350SS/120SS ELECTRIC DECK CRANE PAINT RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 39

PCMĆ120SS COLUMN AND SWING TABLE . . . . . . . 9 DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 9 INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 9

MATERIALS AND EQUIPMENT RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . 39

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . 39

PCMĆ120SS TURNTABLE ROLLER ASSEMBLY . . 13

PAINT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 40

DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13

POST PAINT INSPECTION AND SERVICES . . . . . 40

INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 13 LIST OF ILLUSTRATIONS

REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13 FIGURE

PCMĆ120SS SWING GEAR UNIT ASSEMBLY . . . . . . 15

Page

1

MACHINERY HOUSE AND WINCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .

8

2

INNER COLUMN AND SWING TABLE . . . . .

10

PCMĆ120SS GANTRY ASSEMBLY . . . . . . . . . . . . . . . 19

4

SWING TABLE ROLLER ADJUSTMENT . . .

14

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5

SWING GEAR UNIT ASSEMBLY . . . . . . . . . .

16

INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 19

6

GANTRY GROUP - PCM 120 . . . . . . . . . . .

20

REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 19

7

BOOM AND AUXILIARY HOIST - PCM 120

27

PCMĆ120 BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . 25

8

BOOM TIP INSTALLATION WITH AUXILIARY HOIST - PCM 120 . . . . . . . . . . .

29

9

BOOM GROUP WITH AUXILIARY HOIST PCM 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

10

FLOATING SHEAVE HOUSING ASSEMBLY

32

11

MAIN HOOK AND BLOCK ASSEMBLY PCM 120 (50ĆTON) . . . . . . . . . . . . . . . . . . . . .

34

12

LOCK PIN MOUNT STRUCTURE INSTALLATION - PCMĆ120SS . . . . . . . . . . .

36

SWING GEAR UNIT DC MOTOR . . . . . . . . . . . . . . . 15 SWING GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BOOM DISASSEMBLY AND REMOVAL . . . . . . . . . 25 BOOM INSPECTIONS AND SERVICES . . . . . . . . . 25 BOOM REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 25 PCMĆ120SS GANTRY SHEAVE HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1ĆROM 1.2a, 120SS (Gorilla) 4/20/99

COPYRIGHT 2002

LeTourneau, Inc.

1

PCM 120SS ELECTRIC DECK CRANE STRUCTURAL COMPONENTS

PUBLICATION ROMĆ1

SCOPE OF THIS PUBLICATION Publication ROSĆ1, STRUCTURAL COMPONENTS, is to assist maintenance personnel and operators in the location, inspection, adjustment and repair or replaceĆ ment of the various structural components of the crane.

NOTE In several places in this publication, the terms qualified" or competent" person are used with regards to inspection, repair and certification of the crane and its components. A qualified" or competent" person is defined as follows: A person who, by possession of a professional degree, certificate of professionĆ al standing or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

NEVER remove the DC drive motors access covers unless the electrical system is turned off, locked out, and grounded. Contact with high voltage terminals inside the motors will result is serious injury or loss of life.

NOTE

BEFORE attempting to disassemble any of the major components of the machine BE SURE to provide hoists or cranes and lifting devices of adequate capacity and height.

Mandatory rules of this publication per ANSI/ASME are characterized by the word SHALL." If a provision is of an advisory nature, it is indicated by the word SHOULD" and is recommended to be considĆ ered, the advisability of which depends on the facts in each situation.

NEVER stand under or place any body part under components while hoisted. Serious injury, loss of life could result in the event of an accident.

!

WARNINGS AND CAUTIONS Before any inspections or repairs are performed to the structural components of the crane it is critically important to read and comply with the following warnings and cautions. These warnings and cautions will not be reiterated in the following text:

When inspecting or performing maintenance or repair operations on elevated structures of the crane, NEVER proceed beyond the safety of handrailed platforms. Serious injury or loss of life from falling is possible outside these areas.

CAUTION

To prevent injury, wear hard hat, protective glasses and other protective equipment as required by job conditions. ALWAYS wear gloves when handling wire rope.

!

CAUTION


!

CAUTION

BEFORE welding on any structural members of the machine refer to Publication LETĆ1, FIELD WELDING PROCEDURES, located in the back of Section 1, of the REPAIR AND OVERHAUL MANUAL. Serious damage to electrical and electronic controls is possible unless precautions described in this publicaĆ tion are adhered to.

Ladders and catwalks attached to the crane are designed for servicing of the crane only while the crane is stopped. No personnel are allowed on any structure of the crane during operation. Serious injury or loss of life could result from falling or crushing. 2

Place a DO NOT OPERATE sign on the controls of the machine and secure the controls before performing any maintenance or repair operations. Serious injury or death is possible if the machine is started or moved while maintenance or repair operations are being conducted.

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION ROMĆ1


CRANE TESTING, EXAMINATION, AND CERTIFICATION The following general guidelines for the testing, exĆ amination and certification of the crane are included to alert the deck supervisor, operator and maintenance personnel of these requirements and the CRITICAL IMPORTANCE of these procedures for the continued safe operation of the crane.

NOTE

ANNUAL EXAMINATIONS Cranes shall undergo a thorough examination at least every twelve (12) months by a competent person, or more frequently if required by the certifying authority. a.

It is the responsibility of the deck supervisor, crane operator, and maintenance personnel to make sure the applicable tests and certificaĆ tions required by the certifying authority under which the crane is being operated are met. It is also the responsibility of the above personnel to have the required documentation of these tests, examinations, and certification on hand and in the format required by the certifying authority. There are many different certifying authorities worldwide and these guidelines should not be considered all inclusive. Certifying authorities may have the power to impose fines and harsher penalties for willful or neglect violations of crane testing, examination, and certification.

STRUCTURAL INSPECTION

The annual thorough inspection shall comprise control and function testing of the crane as well as visual control of elongation, wear and tear, corrosion, cracking and formation of fractures, etc. The examination shall be carried out in such a way that it, as far as possible, will give a reliable knowledge of the safety of the examined components. b.

INSPECTIONS FOR OVERLOADED CRANE

A crane which has been exposed to a load moment exceeding 110% of the permitted load moment (includĆ ing maximum calculated for dynamic load) shall be thoroughly examined by a competent person before it is again taken into use.

CONTROL BOOK AND CERTIFICATE

SURVEY AND APPROVAL Before a crane is, or crane components are, first taken into use, and later every four (4) years, a competent person shall have controlled constructions and calculaĆ tions, carried out testing and examination of strength, quality of materials, workmanship and structural design as well as certification in connection with this in compliance with the requirements of the certifying authority. After the crane has been tested and thoroughly examined with a satisfactory result by a qualified person, a certificate will be issued. The original test certificate shall be filed on board with the Cargo Gear


Register (Control Book Ć ILO Form No. 1). A copy of this certificate may be requested by the certifying authority.

The results of initial testing, tests and examinations every four (4) years as well as the annual examinations and all kinds of tests and examinations after repairs or alterations of the crane or hoisting gear, shall be entered in the Control Book (ILO Form No. 1). All controls, crane functions and safety devices shall be inspected and tested annually and when found to function properly the results shall be entered into the Control Book. The entry shall be written by the competent person who carried out the inspection and the examination. Control Book and Certificate shall both be kept on board. The Control Book and certificate shall be available for the surveyor of the certifying authority.

COPYRIGHT 2002

LeTourneau, Inc.

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4

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PUBLICATION ROMĆ1


PUBLICATION ROMĆ1


CRITICAL COMPONENTS The following is a list of components of the crane which should be considered as critical components." These components are ones which affect the safety of the crane from a structural and load hoisting standpoint. These components should be of prime concern to the deck supervisor, operator and maintenance personnel with regards to certification, inspection, maintenance and prompt repair per the appropriate guidelines.

CRITICAL MECHANICAL COMPONENTS a. All lines and linkage between the brake control element and the component to be controlled. b.

Hoist, boom, and swing brake systems

c. Drums, shafts, and gears of hoisting and swing systems

CRITICAL STRUCTURAL COMPONENTS a.

Boom chord members

b.

Boom section connection components

c.

Boom foot pins

d. Primary load members of gantries, masts and AĆframes e. Load transfer members of the rotating upper structure f.

Pedestal and swing circle transition pieces

CRITICAL RIGGING COMPONENTS a.

All running wire ropes in hoist system

b. All standing wire rope in load restraint and support system

d.

Swing bearing and gear

c.

Hook block assembly

e.

Wire rope sheaves and sheave shafts

d.

Wire rope deadĆend connection devices

f.

Electric drive motors for hoists, boom, and swing

e.

Floating harness or bridle assemblies


COPYRIGHT 2002

LeTourneau, Inc.

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6

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PUBLICATION ROMĆ1


PUBLICATION ROMĆ1


PCMĆ120SS MACHINERY HOUSE AND WINCH INSTALLATION BOOM, MAIN HOOK AND AUXILIARY HOOK ASSEMBLIES NOTE

The PCMĆ120SS Electric Deck Crane is equipped with a Winch Housing Assembly positioned on the side of the Machinery House. The Winch Housing Assembly consists of three major parts; the Boom Gear Drive Assembly, the Hook Gear Drive Assembly, and the Auxiliary Gear Drive Assembly.

Refer to WARNINGS AND CAUTIONS, page 2, before performing any inspection or repair to the structural members of the crane.

Refer to Section 4 location electrical, nents.

REMOVAL OF WINCH HOUSING ASSEMBLY DC DRIVE MOTORS AND DRIVERS

MACHINERY HOUSE DESCRIPTION Access to the Machinery House and the electrical control components, swing and hoisting machinery can be gained through the access door. A ventilation and service hatch is provided for cooling and maintenance servicing. This compartment contains the Solid State control components, relay switches, transformers, fuse boxes and other switch gear of the crane. Refer to the PARTS CATALOG for location of specific control deĆ vices.

It is necessary to remove the driver and DC motor for any of the Winch Housing Drive Assemblies to work on either the driver unit or motor except for minor repair or adjustments. Instructions are provided in Section 2, DC MOTORS, for an inĆplace inspection of the DC drive motors. InstrucĆ tions are provided in Section 7, DRIVERS, for an inĆplace inspection of the drivers' internal components and the subsequent removal of a DC drive motor and driver as a unit if the inspections warrant removal.

Due to the presence of potentially injurious conditions, only qualified personnel should enter the Machinery House. Before attempting to work on a component, make sure all electrical power is turned off and locked out and a DO NOT OPERATE sign is attached to the controls. Also, station an operator at the remote control operator's console or in the cab if energized tests of the components are made.


the Troubleshooting guide in for information concerning the of malfunctioning or damaged electronic or mechanical compoĆ

!

CAUTION

Under no circumstances should the owner attempt to disassemble the driver past the removal of the cover during the inĆplace inspection. This is especially important if the driver is in warranty. Unauthorized disassemĆ bly will void the warranty.

COPYRIGHT 2002

LeTourneau, Inc.

7


PUBLICATION ROMĆ1

3

1 2

4 5

1

3 4 5

3

4

5

8

8

6

7

1. 2. 3. 4. 5. 6. 7. 8.

CABLE DRUM STR. BOLT NĆ3 DRIVER OĆRING NĆ9 MOTOR MACHINERY HOUSE SWING TABLE CAPSCREW

FIGURE 1. MACHINERY HOUSE AND WINCH INSTALLATION TAĆ8995ĆCG

1ĆCGĆ1857, P10Ć58

8

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION ROMĆ1


PCMĆ120SS INNER COLUMN AND SWING TABLE ASSEMBLY NOTE

The Column and Swing Table Assembly is the turn table and outer column structure which allows the crane to rotate around the inner column and gear structure. Refer to Figure 2.

DISASSEMBLY PROCEDURES

Use care to prevent damage to grease seals, bearings and spacer.

INSPECTIONS AND SERVICES a. Thoroughly clean all bearings, bearing spacers, grease seals and capscrews. b.


Examine for burrs, nicks and dress out.

NOTE Small burrs and nicks can be dressed out, but damaged or worn bearings and bushings must be replaced.

NOTE A suitable hoisting device such as an auxiliary crane will be required for disassembly and reassembly procedures.

c. Examine bearings, spacers and grease seals. Replace if damaged or worn.

a. Tighten (8) bolts, 4 in the Outer Column Structure and 4 in the Swing Table. These bolts are used to support and keep the Swing Table Assembly centered.

d. Use proper lubricant on bearings, spacers and grease seals as prescribed PCM CRANE LUBRICATION SPECIFICATIONS, Publication OSMĆ4, Figure 1, located in the OPERATING AND SERVICE MANUAL.

!

CAUTION

REASSEMBLY

It is essential to install eight 1Ć1/4" UNF bolts, as shown on Figure 3, Item (1), to support and keep the swing table centered. The bolts should be installed four in the swing table and four in the column structure. Failure to install the bolts could result in damage to the crane and a potentially hazardous situation.

a. Install bearings, spacer and grease seals in bearing hub.

NOTE Use care to prevent damage to grease seals during reassembly and installation.

b. Remove (6) bolts holding seal cap to spindle on top of inner column and gear structure.

b. With a suitable hoisting device, position upper bearing assembly over spindle.

c. Remove (24) bolts that retain the upper bearing assembly to the Swing Table. DO NOT reuse these bolts.

c. Remove the three jacking screws from the bearing hub.

d. Using (3) of the bearing hub bolts, jack entire upper structure assembly from spindle, using tapped holes in the bearing hub. e. With a suitable hoisting device, lift the upper bearing assembly from spindle.

NOTE

e.

Relieve tension on lineĆup bolts.

f. Recheck torque on bearing hub and seal cap bolts.

NOTE

BE SURE the hoisting device is adequate and that the Swing Table Assembly is secured to the inner column structure with the lineĆup bolts.

Check to be sure lineĆup bolts have been backed off enough to prevent any interference in the cranes rotation.

f. Remove the two grease seals from the bearing hub. g. With a suitable tool, drive the thrust bearing, bearing spacer and roller bearing out of bearing hub. 1ĆROM 1.2a, 120SS (Gorilla) 4/20/99

d. Bolt seal cap to spindle. Refer to the CAPSCREW TORQUE CHART, located in the appendix of this manual for the proper torque.

g. Refill upper bearing assembly with proper lubriĆ cant through pipe on side of bearing hub. Refer to the PCM CRANE LUBRICATION SPECIFICATIONS, Figure 1 in Publication OSMĆ4, located in the OPERATING AND SERVICE MANUAL.

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LeTourneau, Inc.

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3 4 12

5 6

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8 13

9 10 18 17

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22

27

23

28 29

24 30 21

31

25

26 32

1ĆNGOĆ2265, P12Ć34

10

FIGURE 2. INNER COLUMN AND SWING TABLE COPYRIGHT 2002

LeTourneau, Inc.

TAĆ8992ĆCG


PUBLICATION ROMĆ1


INNER COLUMN AND SWING TABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.


OIL LEVEL GAUGE PIPE CAP PIPE NIPPLE ELBOW BOLT TUBE STR. BOLT SEAL CAP BOLT BEARING HUB NIPPLE ELBOW MACHINERY HOUSE OUTER COLUMN STR. BOLT LOCKWASHER BOLT GREASE FITTING RETAINER PLATE ROLLER PIN OIL SEAL ROLLER BEARING ASSY. RETAINER SPACER & SEAL RETAINER RETAINER BOLT THRUST BEARING BEARING SPACER ROLLER BEARING GREASE SEAL INNER COLUMN STR.

COPYRIGHT 2002

LeTourneau, Inc.

11


PUBLICATION ROMĆ1

5 6 7 4 2

1

3

1

4

1

1

1. 2. 3. 4.

BOLT, 1Ć1/4" UNF SWING TABLE INNER COLUMN STR. BOLT, 1" UNF

5. ELBOW STR. 6. WIRE TUBE STR. 7. UPPER BEARING ASSY.

FIGURE 3. PCMĆ120SS SWING BEARING REPLACEMENT - UPPER COLUMN ASSEMBLY 1ĆNGOĆ2264, P10Ć60

12

TAĆ9488ĆS8

COPYRIGHT 2002

LeTourneau, Inc.


PCMĆ120SS SWING TABLE ROLLER ASSEMBLY NOTE

The Swing Table Roller Assembly, located on the bottom of the outer column allows the crane to rotate. Refer to Figure 2.

Small burrs and nicks can be dressed out, but damaged or worn bearings and bushings must be replaced.


c. Examine oil seals, rings and retainers. Replace if damaged or worn.

REASSEMBLY PROCEDURES


a. Install bearings, bushings and oil seals. Lubricate bearings.

NOTE

NOTE

A suitable hoisting device such as an auxiliary crane will be required for disassembly and reassembly procedures.

Use care to prevent damage to oil seals during reassembly and installation.

a. Reduce load on the rollers by removing the boom or raising the boom to its maximum UP position. b. Remove the capscrews and bolt retainer pads on top of the roller assembly. c. With proper hoisting device lift out the entire Swing Table Roller Assembly.

b. With Swing Table Roller Assembly completely together, use a suitable hoisting device to position roller assembly into the roller housing structure. c. Install all rollers with the dimple on the roller flange closest to the column.

NOTE

NOTE

The dimple indicates the high side of the roller pin.

Be sure that a suitable such as an auxiliary crane is used and that the Swing Table Roller Assembly is well secured to it. d. Remove the oil seal and oil seal ring from under the bearing and remove the bearing roller from the bearing pin. e.

d. Adjust all rollers out until they touch the swing gear. Position of the rollers can be seen through the viewing access hole next to the roller flange.

NOTE Large adjustment is made by rotating the roller flange independently of the retainer pad. Smaller adjustment can be made using the slotted holes of the retainer pad.

Remove the bearing and roller off the bearing pin.

f. Remove oil seal holder, oil seal and oil seal ring from bearing pin.

e. Using a feeler gauge between the rollers and the swing gear, adjust the three nonĆloaded rollers in, leaving a .020 inch gap between the roller and the gear.

NOTE Use care to prevent damage to oil seal, rings, holder, bearing and rollers.

f. Secure the bolt retainer pads to roller flanges and roller table.

INSPECTIONS AND SERVICES a. Thoroughly clean all bearings, rollers, oil seals, rings, pins, capscrews, magnetic particle test all pins and rollers. b.

Examine for nicks, burrs and dress out.

1ĆROM 1.2b, 120SS (Gorilla) 4/20/99

g. Place grease fitting on top on the pin roller and lubricate the bearing thoroughly in accordance with Figure 1, PCM LUBRICATION SPECIFICATIONS, PubliĆ cation OSMĆ4, located in the OPERATING AND SERĆ VICE MANUAL.

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LeTourneau, Inc.

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PUBLICATION ROMĆ1

THREADED LIFTING EYES

PRYBAR

ROLLER

ACCESS HOLE

SWING GEAR

FEELER GAUGE .020”

FIGURE 4. SWING TABLE ROLLER ADJUSTMENT 1ĆCGĆ1845, P10Ć52

14

TAĆ8981ĆP COPYRIGHT 2002

LeTourneau, Inc.

1ĆROM 1.2b, 120SS (Gorilla) 4/20/99

PUBLICATION ROMĆ1


PCMĆ120SS SWING GEAR UNIT ASSEMBLY The Swing Gear Unit Assembly controls the rotation of the crane and is powered by a SĆ1A, DC motor driving through a #5 gearbox assembly mounted out from the Swing Table and King Pin Structure. The Swing Gear Unit output shaft operates on the round gear rack of the Swing Table to obtain crane rotation. Refer to Figure 5 for an illustration of the components of the Swing Gear Unit Assembly.

SWING GEAR UNIT DC MOTOR The Swing Gear Unit DC motor when used in conjuncĆ tion with the LeTourneau, Inc. power and control system provides the operator with a wide range of control of motor speed and output power. These motors are

1ĆROM 1.2c, 120SS (Gorilla) 4/20/99

especially wound to provide maximum output throughĆ out the full range of motor speed. A multiple disc friction type spring applied electroĆmechanically released SCR powered motor brake is an integral part of the motor. Refer to Section 2 for disassembly, inspection, repair and reassembly procedures for the DC swing motor. Also, refer to the LeTourneau, Inc. Publication TAKING CARE OF YOUR DC MOTOR, located in the back of Section 2 for additional information on maintenance, troubleshooting and repair of DC motors.

SWING GEARBOX Refer to Section 6, Gearboxes, for information concernĆ ing the disassembly, repair and replacement and reassembly procedures for the # 5 gearbox assembly.

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LeTourneau, Inc.

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1

2

18

3 4 5 19 17

16

6

7 15 8

9

14 10 13

12

11

1ĆCGĆ1858, P10Ć58

16

FIGURE 5. SWING GEAR UNIT ASSEMBLY COPYRIGHT 2002

LeTourneau, Inc.

TAĆ8994ĆCG


PUBLICATION ROMĆ1


SWING GEAR UNIT AS SEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

LID STRUCTURE TOGGLE LATCH OĆRING BOLT LOCKWASHER OĆRING SĆ1A DC MOTOR BOLT BOLT WASHER BAR LOCKNUT #5 SWING GEARBOX LOCKWASHER BOLT TERMINAL TUBE TERMINAL TUBE COVER STRUCTURE MACHINERY HOUSE & WINCH GROUP 19. SWING TABLE GROUP


COPYRIGHT 2002

LeTourneau, Inc.

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18

COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1


PUBLICATION ROMĆ1


PCMĆ120SS GANTRY ASSEMBLY The PCMĆ120SS Electric Deck Crane is equipped with a rigid steel pipe assembly that is pinned to the Swing Table Structure. The Gantry Sheave Housing Assembly is pinned to the top of the Gantry Structure to give proper fleet angle. The Boom Positive Stop is pinned to the Gantry Structure to stop the boom at a minimum radius. Refer to Figure 6 for an illustration of the components of the Gantry Assembly.

Refer to WARNINGS AND CAUTIONS, page 2 before performing any inspection or repair to the structural members of the crane.

a. Remove bolts, keeper plates and pins from the top of the boom stop support. Remove bolts, keepers and pins from back of boom stop assembly. Hoist Boom Stop Structure away. b. Remove bolts, keeper plates and pins from base of boom stop support and hoist it away. c. With a suitable hoisting device secured to the top of the front Gantry Structure, remove bolts, keeper plates and pins from the top and bottom of the Rear Gantry and pins from the top and bottom of the Rear Gantry Structure and hoist away. d. Remove bolts, keeper plates and pins from base of Front Gantry Structure and hoist away.

NOTE

INSPECTIONS AND SERVICES Thoroughly clean all pins, nuts and bolts with a suitable solvent and allow to air dry. Any worn parts should be replaced.


NOTE

DISASSEMBLY

All shafts and gears must be magnetic particle tested.

Place boom in boom rest, and with a suitable hoisting device, remove the Gantry Sheave Housing Assembly.

NOTE


Refer to GANTRY SHEAVE HOUSING ASĆ SEMBLY, page 23.


To reassemble the Gantry Assembly, reverse the procedures in DISASSEMBLY, above.

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LeTourneau, Inc.

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2

1

3

25 6

7 2 24 1

7

4 5 23

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6

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2 1

21 20 7

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16

18 17 15 6

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7 1 19

2

8

9 14

10

13

12

6

6

11

9

6

FIGURE 6. GANTRY GROUP - PCM 120 1ĆCGĆ1859, P10Ć59

20

TAĆ8998ĆCG

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LeTourneau, Inc.


PUBLICATION ROMĆ1


GANTRY GROUP - PCM 120 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.


BOLT LOCKING BAR PIN R.H. VERTICAL GANTRY STR. L.H. VERTICAL GANTRY STR. PIN PIN CENTER PIPE STR. FRONT GANTRY STR. BOLT GREASE FITTING BOLT BEARING RETAINING SHEAVE PIN SPACER SHEAVE SEAL BEARING SPACER SUPPORT STR. - SHOCK PIN PUSHER STR. SPRING BOLT BOOM STOP SUPPORT STR.

COPYRIGHT 2002

LeTourneau, Inc.

21


22

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LeTourneau, Inc.

PUBLICATION ROMĆ1


PUBLICATION ROMĆ1


PCMĆ120SS GANTRY SHEAVE HOUSING ASSEMBLY NOTE

The Gantry Sheave Housing Assembly is made up of three (3) sheave wheels and four (4) divider plates. Its function is to assist in the raising and lowering of the boom. Refer to Figure 6 for an illustration of the Gantry Sheave Housing Assembly.


NOTE Sheaves and sheave wheel pins are to be magnetic particle tested.


REASSEMBLY a. Reassemble and lubricate wheel bearing assemĆ blies.

NOTE

b. Insert bearing assembly and spacer into first wheel. Put wheel into position between spacers and slide sheave wheel pin through spacers, wheel bearing and wheel.


DISASSEMBLY a. With a suitable hoisting device attached, remove the pin retainers and pin from the Gantry Sheave Housing Assembly. This will allow the whole Gantry Sheave Housing Assembly to drop down. b.

Remove the square nuts, pins and pipe spacers.

NOTE

c. Repeat procedure in Step b" until all wheels, bearing assemblies and spacers are in place and the sheave wheel pin is all the way through the sheave divider plates. d. Replace retainer plates with three (3) 1/2Ćinch bolts each side of sheave wheel pin. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque. e. Replace sheave housing pin and at the same time replace the three (3) spacer pipes, one between each sheave housing plate. Replace square nuts on sheave housing pins. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque.

Only one sheave housing pin needs to be removed and if the back pin is removed a complete inspection of all wire ropes can be made.

NOTE

c. Remove bolts and retainer plates on sheave wheel pin. Remove pin with caution.

!

CAUTION

f. With a suitable hoisting device, raise Gantry Sheave Housing Assembly up and connect back to top of gantry with the gantry hinge pin. Replace keeper plates with two (2) 5/8Ćinch bolts in the end of each pin. Tighten bolts. Refer to the CAPSCREW TORQUE CHART, in the appendix of this manual for the proper torque.

In removing the sheave wheel pin, care should be taken not to drop or damage the sheave wheels, wheel bearings and spacers.

INSPECTIONS AND SERVICES a. Thoroughly clean all parts to the Gantry Sheave Housing Assembly. b. Inspect all pins, wheels, bearings and spacers. Replace if damaged or worn.


Make sure all wire ropes are in proper order.

g. Lubricate bearing assemblies through the grease fitting on the end of the sheave wheel pin as specified in Figure 1, PCM CRANE LUBRICATION SPECIFIĆ CATIONS, in Publication OSMĆ4, located in the OPERĆ ATING AND SERVICE MANUAL.

COPYRIGHT 2002

LeTourneau, Inc.

23


24

COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1


PUBLICATION ROMĆ1


PCMĆ120SS BOOM ASSEMBLY The PCMĆ120SS Electric Deck Crane is equipped with a rigid steel boom made up of four sections. The lower structure is 20 feet in length. There are two middle sections; one of 40 feet and one of 20 feet in length. The upper boom section is 20 feet in length. Sections are connected using bolt plates, bolts and nuts. Each joint of the boom has a male and a female fit for additional safety. Refer to Figures 7, 8 and 9 for illustrations of the Boom Assembly.

g.

Spool boom wire rope onto the cable drum.

h. Attach suitable hoisting device to boom structure and lower to a prepared work surface. Remove locking bars, base pins, and self aligning bushings. i. In succession, remove the capscrews and nuts that hold the upper, middle and lower boom sections together and remove each with a suitable hoisting device. j. Remove pin retainers, sheave pins, bearings and 30Ćinch sheave wheels from boom tip and boom tip extension structure.


k. Remove cotter pin and sheave pin from guide sheave housing assembly. l. Remove bolts, lockwashers and lock plate from guide sheave housing assembly and drive out sheave housing pin. Remove the 22Ćinch sheave wheel. Remove bearing seal and bearing assembly.

NOTE A suitable hoisting device such as an auxiliary crane will be required for disassembly and reassembly procedures.

BOOM INSPECTIONS AND SERVICES

BOOM DISASSEMBLY AND REMOVAL a. Hoist the Main Hoist and Auxiliary Hoist Hook (optional) and block assemblies close enough to the tip to prevent the wire ropes from fouling when the boom is lowered.

a. Thoroughly clean all bearings, bushings, spacers, nuts, pins and grease fittings in a solvent and allow to air dry. b. Inspect all components for excessive wear and/or damage. Replace or repair when necessary.

b. Above a flat working surface, lower the boom until the tip almost touches.

!

CAUTION

Replace ALL nuts and bolts for boom connections every four years of operation, also bolts and nuts are to be replaced if any boom sections must be replaced. Failure to comply with this instruction could result in serious injury or death and damage to the crane.

DO NOT lower the boom below a parallel with the base of the boom. Do not let the tip touch the deck surface because it might bend or damage the boom structure. c. Remove the Main Hoist Hook and Block Assembly and the Auxiliary Hoist Hook and Block Assembly (optional).

NOTE

d. Spool Main Hook and Auxiliary Hook (optional) lines on to the drums.

ALL pins and critical welds are to be magnetic particle tested.

e. With a suitable lifting device, lower the Floating Sheave Assembly on top of boom and secure.

BOOM REASSEMBLY

f. Remove boom wire rope dead end for gantry sheave assembly.

To reassemble the Boom Assembly, reverse the proceĆ dures in Boom Dissassembly and Removal, above.


COPYRIGHT 2002

LeTourneau, Inc.

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26

COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1


1

2

12

3

4

19

13

20

20

14

11

5

22

21

18

6

A

10 16 15 21

9

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17

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VIEW - D

VIEW – A

VIEW – B

8

VIEW – C

SECTION A-A

D

A

C B

1

B

2

3

4

5 6

1. 2. 3. 4. 5. 6.

BOOM BASE STR. BOOM MID SECTION, 40 FT. BOOM MID SECTION, 20 FT. BOOM TOP STR. CABLE SHEAVE INSTALLATION BOOM TIP EXTENSION STR.

7. 8. 9. 10. 11.

PLATE BOLT CAP PLATE GREASE FITTING LUFFING CABLE

12. 13. 14. 15. 16.

BOLT NUT IDLER WASHER NUT

17. 18. 19. 20. 21. 22.

IDLER MOUNT STR. BASE PIN BUSHING LOCK BAR BOLT SLEEVE

FIGURE 7. BOOM AND AUXILIARY HOIST - PCM 120 1ĆCGĆ1860, LdgrĆ22

1ĆROM 1.2, FOĆ1, 120SS (Gorilla) 4/20/99

TAĆ8999ĆCG

COPYRIGHT 2002

LeTourneau, Inc.

27


28

COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1


PUBLICATION ROMĆ1

11


12

14 1

5

2

4

6

3 7

16

13 12 11 12 5

14

4

13 12

5

11

6

17

7

6

4 8

7

16 9

6 5

4 10

7

5 6

4

7

4

15

11 6

12 13

14

12 5

11 12

7

13 14

11 12 14 13 12 11

12 11

1. 2. 3. 4. 5.

BOLT LOCKWASHER TOP PLATE PIN RETAINER BOLT

1ĆCGĆ1861, P10Ć59

6. 7. 8. 9.

GREASE FITTING BOLT PLATE PLATE

10. 11. 12. 13.

GREASE FITTING BOLT PLATE PLATE

14. 15. 16. 17.

SHEAVE SHEAVE PIN SHEAVE PIN BOOM TIP EXT. STR.

FIGURE 8. BOOM TIP INSTALLATION WITH AUXILIARY HOIST - PCM 120


COPYRIGHT 2002

LeTourneau, Inc.

TAĆ9001ĆCG

29


PUBLICATION ROMĆ1

2 1

3

10 7

6

4 5 5

6 9

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

7

BRIDLE LINE ASSY. WIRE ROPE ASSY. SINGLE SHEAVE DYNAMETER MAIN HOOK LINE ASSY. ANTI TWOĆBLOCK SENSOR CLAMP OPEN WEDGE SOCKET OVERHAUL BALL ASSY. HOOK & BLOCK ASSY. LINE LOAD CELL

8

FIGURE 9. BOOM GROUP WITH AUXILIARY HOIST - PCM 120 1ĆCGĆ1854, P10Ć57

30

TAĆ9002ĆCG

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION ROMĆ1


PCMĆ120SS FLOATING SHEAVE HOUSING ASSEMBLY NOTE

The Floating Sheave Housing Assembly is a pulley made up of three (3) 30Ćinch sheave wheels. Its function is the raising and lowering of the crane's boom. Refer to Figure 10 for an illustration of the components of the Floating Sheave Housing Assembly.

Magnetic particle tests should be conducted on all critical welds and pins during disassembly or every four (4) years.

INSPECTIONS AND SERVICES a. Thoroughly clean all parts of the Floating Sheave Housing Assembly.


b. Inspect all pins, wheels, bearings and spacers. Replace if damaged or worn.

NOTE

NOTE



REASSEMBLY

DISASSEMBLY a. Lower the Floating Sheave Housing Assembly into the cradle provided on the top of the boom. Remove the two (2) 1/2Ćinch bolts and retainer plate that holds the bridal connector pin in place. With proper hoisting device remove pin. b. Lower Floating Sheave Housing Assembly to a prepared working surface. c. Remove the square nuts, bolts and pipe spacers that hold the 4 side and inner plates together.

NOTE


c. Replace the retainer plates and 5/8Ćinch bolts. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque. d. Replace spacers and sheave housing pins, one spacer between each sheave housing plate. Replace 2 inch square nuts.


d. Remove 5/8Ćinch bolts and retainer plates that hold the sheave wheel pin. Remove pin with caution.

In removing the sheave wheel pin care should be taken not to drop or damage the sheave wheels, wheel bearings and spacers.

b. Insert bearing assemblies and spacers into sheave wheels. Put into position and slide sheave wheel pin through spacers, wheel bearings and sheave wheels.

NOTE


NOTE

a. Reassemble and lubricate wheel bearing assemĆ blies.

e. Replace bridle connector and secure into place with bridal connector pin and spacers. Replace retainer plates with 5/8Ćinch bolts. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque. f. Lubricate bearing assemblies through the grease fitting on the end of sheave housing wheel pin as specified in Figure 1, PCM CRANE LUBRICATION SPECIFICATIONS, in Publication OSMĆ4, located in the OPERATING AND SERVICE MANUAL.

COPYRIGHT 2002

LeTourneau, Inc.

31


PUBLICATION ROMĆ1

1

2

3 4 5

6

22

7

8 8

23

11

10

15

12 21

9

9

7 8 13 20 11 14

15 19

15

19

14 17 18 16

17

1. 2. 3. 4. 5. 6. 7. 8. 1ĆCGĆ1862, P10Ć59

32

UPPER BRIDLE STR. LOWER BRIDLE STR. PIN RETAINER BOLT SPACER RETAINER PLATE BOLT

9. 10. 11. 12. 13. 14. 15. 16.

NUT RETAINER GREASE FITTING BOLT SHEAVE BEARING SPACER SPACER SEAL

17. 18. 19. 20. 21. 22. 23.

BEARING SPACER BEARING BOLT CENTER PIN PIN SIDE PLATE INNER PLATE

FIGURE 10. FLOATING SHEAVE HOUSING ASSEMBLY COPYRIGHT 2002

LeTourneau, Inc.

TAĆ8977ĆCG


PUBLICATION ROMĆ1


PCMĆ120SS HOOK AND BLOCK ASSEMBLY The Hook and Block Assembly is in two parts. The Hook Assembly itself and the Sheave Housing Assembly. The Hook and Block Assembly is used for hoisting materials. Refer to Figure 11 for an illustration of the components of the Hook and Block Assembly.

DISASSEMBLY a. Lower the Hook and Block Assembly to a prepared working surface. b. The Hook Assembly itself is disassembled by first removing the keeper plates that retain the swivel block.

measure the same as original, if not, discard the hook.

REASSEMBLY a. In reassembling the Sheave Housing Assembly, first reassemble an lubricate all bearing assemblies. b. Insert bearing assemblies and spacers into the first wheel. Put wheel into position between spacers, bearing seals, wheel bearings and sheave wheel.

NOTE

c. With a suitable hoisting device attached to the Hook Assembly, remove the tie bolts and tie pins that hold the Sheave Housing Assembly together. d. Remove the bolts that hold the retainer plates on the sheave wheel pin. Remove the pin with caution.

NOTE

c. Place Hook Assembly between sheave housing plates. d. Repeat procedure b" in this section until all wheels, bearing assemblies, spacers and seals are in place and the sheave wheel pin is all the way through sheave and divider plates.

In removing the sheave wheel pin, care should be taken not to drop or damage the sheave wheels, wheel bearings, spacers, seals and Hook Assembly. e. Remove Hook Assembly to a prepared working surface. f. Remove the cotter pin and 4Ćinch hook nut and carefully remove the hook itself so as not to damage the bearing assembly. g.

Outside sheave plates are wider than the two divided plates, so the two wider bearings spacers must go to the outside.

Remove the bearing assembly.

e. Replace sheave wheel pin retainer plates and bolts. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque. f. Replace sheave housing tie bolts and tie pins and at the same time replace the 3Ćinch spacer pipes. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque.

NOTE

INSPECTIONS AND SERVICES a. Thoroughly clean all parts of the Hook and Block Assembly. b. Inspect all pins, wheels, bearing assemblies, spacers and seals. Replace if damaged or worn.

NOTE Hook wheels and pins are to be Magnetic Particle Tested every four (4) years or if disassembled, to A.P.I. 2C 1983.

NOTE Check crane hooks for deformation or cracks. Hooks will be discarded where cracks exist or throat opening is 15 percent more than the original throat opening. Hooks will also be discarded where they are bent or twisted more than 10° from the plane of the original hook configuration. The shank of the hook shall

1ĆROM 1.2d, 120SS (Gorilla) 4/20/99

Make sure all wire ropes are in proper order. g. Lubricate bearing assemblies through the grease fitting on the end of the sheave housing wheel pin as specified in Figure 1, PCM CRANE LUBRICATION SPECIFICATIONS, in Publication OSMĆ4, located in the OPERATING AND SERVICE MANUAL. h. Lubricate the hook thrust bearing located on the side of the swivel bearing block as specified in Figure 1, PCM CRANE LUBRICATION SPECIFICATIONS, in PubĆ lication OSMĆ4, located in the OPERATING AND SERĆ VICE MANUAL. i. Perform a No Load Test" prior to putting back in service.

NOTE The Auxiliary Hook Assembly is a vendor supplied item. Refer to the Parts Catalog for ordering information.

COPYRIGHT 2002

LeTourneau, Inc.

33


PUBLICATION ROMĆ1

1 2 3

28

29

4

5 6

3

1

7

8 27 9 10 11 14 1 26

15

25 3

16

2

11 24 10

17

13

23 18

12

22 19

20

21

1. 2. 3. 4. 5. 6. 7.

SPACER KEEPER PLATE BOLT BEARING RETAINER GREASE FITTING BOLT NUT

8. 9. 10. 11. 12. 13. 14.

RETAINER ROD SHEAVE BEARING SPACER BEARING SPACER SEAL BEARING BOLT

15. 16. 17. 18. 19. 20. 21.

LOCKWASHER COVER STR. COTTER PIN THRUST BEARING BEARING BLOCK HOOK LATCH KIT

22. 23. 24. 25. 26. 27. 28. 29.

FELT SEAL NUT OĆRING TIE PIN MOUNT PLATE SHEAVE PIN SIDE PLATE DIVIDER PLATE

FIGURE 11. MAIN HOOK AND BLOCK - PCM 120 (50ĆTON) 1ĆCGĆ1863, P10Ć60

34

TAĆ8971ĆCG

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION ROMĆ1


CABLE DRUM LOCK PIN The cable drums for the main and auxiliary hooks and boom luffing are equipped with a safety lock pin mount structure to prevent the cable drum from turning if the brake is released for service or repair or if the DC drive motor must be removed. The pin for the applicable drum

should be installed anytime these operations or any other operation which requires the drum to remain stationary are being conducted. Refer to Figures 12 for illustrations of the lock pin mount structure for the PCM 120SS.

NOTES


COPYRIGHT 2002

LeTourneau, Inc.

35


PUBLICATION ROMĆ1

1

B 2

B A

A

5 4

6 7

3

4

6

5 7 8

8 VIEW A-A

1. 2. 3. 4. 5. 6. 7. 8.

MACHINERY HOUSE KING PIN & SWING TABLE STR. CABLE DRUM STR. LOCK PIN STR. BOLT LOCK PIN MOUNT STR. BOLT PLATE

VIEW B-B

FIGURE 12. LOCK PIN MOUNT STRUCTURE INSTALLATION - PC 120 TAĆ8950ĆCG

1ĆNGOĆ1591, P10Ć31, 6/1/98

36

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION ROMĆ1


PCMĆ120SS STRUCTURAL REPAIRS The following instructions pertain to structural repairs of the crane and welding procedures which relate to safety and integrity of the load bearing members.

WELDING REQUIREMENTS Certain materials are manufactured exclusively by LeTourneau, Inc. Substitution of these materials is not to be attempted without prior approval by LeTourneau, Inc. due to the possible incompatibility of alternate materials. Should the owner desire, LeTourneau, Inc. will provide personnel and materials for repairs and/or replacements if requested.

BOOM DIAGONAL PIPES: 3" XĆHVY. X .300 wall thickness and are made from AĆ53 Gr.B or equal.

STRUCTURAL REPAIR PROCEDURES Before any structural repairs are made magnetic particle and dye penetrant tests shall be conducted.

!

CAUTION

BEFORE proceeding with any structural repairs and/or replacements, BE SURE that there is no load on the crane and power has been disconnected from the crane.

Instructions for welding of LeTourneau, Inc. structural steel are included in LeTourneau, Inc. Publication LeTĆ1, FIELD WELDING PROCEDURES, located in the back of Section 1, in the REPAIR AND OVERHAUL MANUAL. It is ESSENTIAL to review these procedures and contact both your distributor and LeTourneau, Inc. prior to attempting ANY structural repairs to this crane. Anyone performing structural repairs to the crane shall meet the following qualifications:

The boom should be supported in either the boom rest or temporary supports.

NOTE

NOTE

Anyone performing structural repairs to the crane shall meet the following qualifications: American Welding Society Specifications for Welding Machinery and Equipment ClassificaĆ tion and Application of Welded Joints for AWS D14.4 Ć 77.

No repairs and/or replacements shall be undertaken without prior approval from LeTourneau, Inc. and the certifying authority under which the crane is operating. Any repairs shall be witnessed by an attending surveyor of the certifying authority.

STRUCTURAL MATERIALS COLUMN PLATES: 1" thick and made from NĆ20 BHT MAIN BOOM PIPES: 6Ć5/8" O.D. LET. X .375 wall thickness and are made from high strength steel (70,000 minimum yield, 100,000 minimum tensile charpy of 20 lb. at -40).

!

CAUTION

It is essential to isolate the Load Moment Indicator system from the crane's electrical system prior to welding repairs or damage will result.

If emergency repairs and/or replacements are necesĆ sary, the certifying authority shall be provided with a detailed description of the extent of the repair and/or replacement, materials and procedures used, plus any other pertinent data, at the earliest possible time. Arrangements shall also be made for an inspection by the certifying authority's representative.

NOTES


COPYRIGHT 2002

LeTourneau, Inc.

37


PUBLICATION ROMĆ1

NOTES

38

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION ROMĆ1


PCMĆ350SS/120SS ELECTRIC DECK CRANE PAINTING RECOMMENDATIONS These instructions cover surface preparation, coating system and inspection requirements to be used in the painting of LeTourneau, Inc. Electric Deck Cranes. The recommended two coat system with two part inorganic zinc silicate primer combats corrosion by the elimination of rust creep" or undercutting of all blasted steel surfaces including the crane's Machinery House, ColĆ umn, Gantry, Boom and other structural components. These instructions are minimal requirements for normal conditions. Local conditions and overall condition of the crane's painted surfaces may require additional meaĆ sures to ensure quality paint work.

NOTE

Sandblast Equipment: Pangborn Blast System or equivalent Paint Equipment: Devilbiss Air Spray Gun - Model MBC 510 with air cap AUĆ1239Ć704; 10 gallon Pressure Feed Tank with Air Motor Agitator Q.S.A. 503 or equivalent

NOTE Materials and equipment listed above are used successfully by LeTourneau, Inc. in the manufacturing process. Substitute items that meet specifications listed are acceptable.

a. Securely seal the ventilator fan, access door and any other place blasting sand or paint overspray might enter the Machinery House or Operator's Cab (optionĆ al). Cover the glass and weatherstripping on the Operator's Cab (optional). Use masking tape or other suitable material to seal these areas. b. Cover or remove the wire rope as necessary to prevent contamination from blasting sand and paint.

CAUTION

c. Cover and seal the swing gear and swing pinion to be sure no contamination from sand or paint occurs.

Surface preparation and painting requires working in close proximity with chemicals and vapors which can cause skin and respiratory injury. Read and follow all safety precautions mentioned in paint manufacturers specificaĆ tions.

d. Protect any exposed electrical wiring or terminals from damage by sandblasting. e. Sandblast to a commercial blast clean finish (almost near white) per Steel Structures Paint Council, Surface Preparation Specification SSPCĆSPĆ10Ć63T. The grit size should be Mesh/U.S. Sieve Series and be clean, washed silica such as Lone Star #1 or equal. Nozzle velocity of the abrasive should not be less than 100 psi.

Also, follow these additional safety precauĆ tions: 1. Wear the appropriate respirators, eye protection and protective clothing to prevent injury. Do not use solvents or thinners to clean skin.

!

NOTE Do not reuse blasting sand. Oil and grease should be removed by hosing or by wiping with a suitable solvent.

MATERIALS AND EQUIPMENT RECOMMENDATIONS

NOTE

MATERIALS RECOMMENDED

Sandblast Media: Lone Star #1 Bulk Blast Media or equivalent Paint and Primer: Refer to manufacturer's product information following this article. 1ĆROM 1.2d, 120SS (Gorilla) 4/20/99

CAUTION

Use caution to not damage seals when sandblasting in close proximity to swing gearbox and drivers.

2. Do not smoke, eat or drink in the surface preparation and painting area. Also, keep sparks, heat and open flames away from the these areas.

a.

EQUIPMENT RECOMMENDED

SURFACE PREPARATION

Refer to paint manufacturer's specification sheets for physical properties, performance limitations, additional instructions for surface preparation, application and safety precauĆ tions specific to the application of their products. Specification sheets for the original equipment paint are provided at the end of this article.

!

b.

COPYRIGHT 2002

After sandblasting, ALL welds should be inspected by a qualified person and any that are suspected of being cracked are to be dye penetrant and magnetic particle tested. Refer to STRUCTURAL REPAIRS, and publication

LeTourneau, Inc.

39


PUBLICATION ROMĆ1

LeTĆ1, FIELD WELDING PROCEDURES, locaĆ ted in Section 1 in the REPAIR AND OVERHAUL MANUAL before attempting ANY welding repairs to the structural components of the crane.

!

Care must be taken to minimize surface contamination from atmospheric pollution such as dust, industrial fallout etc.

f. All rough welds, burrs, weld splatter and other sharp surface projections should be ground smooth. Any grinding done after sandblasting should be reĆ blasted to obtain a surface like the remainder of the area to be painted. g. Sandblasting and painting operations should be scheduled so that they will not be in progress at the same time or so that blasting is not in progress while there is wet paint within the range of sandblasting contamination. The blast cleaned surface should be coated with one coat of primer as specified during the same day as blasted and also before any visible rust occurs. Sandblasted steel wet by rain or moisture prior to priming should be reĆblasted.

NOTE Surfaces which do not require painting should be masked or otherwise protected during the painting of adjacent work. Also, be aware of possible damage to surrounding rig compoĆ nents from overspray and take appropriate measures to protect them.

NOTE A color contrast has been purposely estabĆ lished between the primer and the finish coat. The color contrast is designed to act as an indicator to insure complete coverage with both primer and finish coat. The contrast is not to be so great as to markedly influence the appearance of the top coat.

POST PAINTING INSPECTION AND SERVICES Post painting inspection and servicing should be conducted by a qualified person to be sure the requirements listed the paint manufacturer's specificaĆ tions are met and that no damage to crane components by contamination from sandblasting and painting will occur. The following inspections and services should be performed: a. Inspect the paint to be sure that a film thickness as listed in Figure 13 is met. Measurement should be made by Dry FilmĆMikrotest or equivalent gauge.

PAINT APPLICATION a. Primer and paint used should be the original used in the manufacturing process or equivalent, conform to the paint manufacturers specifications and be applied listed in Figure 13. b. Painting should be done in a neat and workmanĆ like manner and all joints and crevices should be filled where necessary and thoroughly painted. Paint should be applied only on surfaces that are completely dry. c. Painting should only be permitted within a range of temperature and humidity recommended by the paint manufacturer as published in specifications for the particular product.

40

CAUTION

b. Inspect Machinery House, control panels, motors, wiring, and terminals for contamination from sandblastĆ ing and painting. Vacuum out any contamination. c. Inspect the slewing bearing, gear, gearbox pinion and lubricant to be sure no contamination from sandblasting and painting is present. Clean and lubricate as required. d. Inspect the wire rope to be sure no contamination from sandblasting and painting is present. Clean and lubricate as required. e. Inspect pins and bushings for contamination from sandblasting and painting and clean as required.

COPYRIGHT 2002

LeTourneau, Inc.


PUBLICATION ROMĆ1


Component

Metal Prep

Outer Column and Gear Str. (PC 350); Inner Column and Gear Str. (PC 120) Swing Table, Gantry Boom (except tip), Machine House Exterior, Other crane structures

Near white shot or sand blast SSPCĆ10

Primer

Tie Coat

One coat inorganic One coat red zinc primer 2Ć1/2 expoxy 1 MIL DFT to 3 MLS DFT

One Coat Grey HiĆSol expoxy 4-6 MILS DFT One Coat Yellow HiĆSolids epoxy 4-6 MILS DFT One Coat Orange HiĆSolids epoxy 4-6 MILS DFT

Boom Tip

Machine House Interior

Wire brush to remove rust and loose scale. Wash to remove oil, grease and foreign matter.

Welded Hand Railjoints

YELLOW

One coat epoxy primer 4 MILS DFT

None

One Coat Whle Polyurethane 1.5 to 2 MILS DFT

None

None

Two coats cold galv. compound, 2-3 MILS total DFT

ORANGE

FIGURE 13. PCM CRANE PAINT REQUIREMENTS 1ĆCGĆ1565, P10Ć33


Top Coat

COPYRIGHT 2002

LeTourneau, Inc.

TAĆ8941ĆCG

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PUBLICATION ROMĆ1

LeTOURNEAU, INC., PCM 350SS ELECTRIC DECK CRANE REPAIR AND OVERHAUL MANUAL STRUCTURAL COMPONENTS TABLE OF CONTENTS

TABLE OF CONTENTS

Page


Page

PCMĆ350SS BOOM ASSEMBLY . . . . . . . . . . . . . . . . . 23

WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . 2

BOOM DISASSEMBLY AND REMOVAL . . . . . . . . . 23

CRANE TESTING, EXAMINATION, AND CERTIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

BOOM INSPECTIONS UPON DISASSEMBLY . . . . 23 BOOM REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 23

SURVEY AND APPROVAL . . . . . . . . . . . . . . . . . . . . 3

PCMĆ350SS FLOATING SHEAVE HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

ANNUAL EXAMINATIONS . . . . . . . . . . . . . . . . . . . . 3 CONTROL BOOK AND CERTIFICATE . . . . . . . . . . 3

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

CRITICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 5


CRITICAL MECHANICAL COMPONENTS . . . . . . . 5

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

CRITICAL STRUCTURAL COMPONENTS . . . . . . . 5

PCMĆ350SS HOOK AND BLOCK ASSEMBLY . . . . . . 31

CRITICAL RIGGING COMPONENTS . . . . . . . . . . . 5

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

PCMĆ350SS MACHINERY HOUSE AND WINCH INSTALLATON BOOM, MAIN HOOK, AND AUXILIARY HOOK ASSEMBLIES . . . . . . . . . . . . . . . . 7


MACHINERY HOUSE DESCRIPTION . . . . . . . . . . . 7

CABLE DRUM LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . 33

REMOVAL OF WINCH HOUSING ASSEMBLY DC DRIVE MOTORS AND DRIVERS . . . . . . . . . . . . 7

PCMĆ350SS STRUCTURAL REPAIRS . . . . . . . . . . . . 35

PCMĆ350SS SWING TABLE AND KING PIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

STRUCTURAL MATERIALS . . . . . . . . . . . . . . . . . . . 35

WELDING REQUIREMENTS . . . . . . . . . . . . . . . . . . 35 STRUCTURAL REPAIR PROCEDURES . . . . . . . . . 35


PCMĆ350SS/120SS ELECTRIC DECK CRANE PAINTING RECOMMENDATIONS . . . . . . . . . . . . . . . . 37

INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 9 REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 9

MATERIALS AND EQUIPMENT RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . 37

PCMĆ350SS LOWER BEARING AND SOCKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . 37


PAINT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 38


POST PAINTING INSPECTION AND SERVICES . . 38

REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13

LIST OF ILLUSTRATIONS

PCMĆ350SS SWING GEAR UNIT ASSEMBLY . . . . . . 15

FIGURE

SWING GEAR UNIT DC MOTOR . . . . . . . . . . . . . . . 15

1

SWING GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PCMĆ350SS GANTRY ASSEMBLY . . . . . . . . . . . . . . . 17 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSPECTIONS UPON DISASSEMBLY . . . . . . . . . . 17 REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 17

Page

WINCH INSTALLATION . . . . . . . . . . . . . . . . 8

2

SWING TABLE ROLLER ASSEMBLY . . . . 10

3

SWING TABLE ROLLER ADJUSTMENT . 11

4

SWING GEAR UNIT INSTALLATION

5

GANTRY ASSEMBLY

6

BOOM AND AUXILIARY HOIST . . . . . . . . 25

PCMĆ350SS GANTRY SHEAVE HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7

FLOATING SHEAVE HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 30

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8

MAIN HOOK AND BLOCK PCM 350SS (75ĆTON) . . . . . . . . . . . . . . . . 32

9

LOCK PIN MOUNT STRUCTURE INSTALLATION - PCM 350SS . . . . . . . . . 34

10

PCM CRANE PAINT REQUIREMENTS . . 39


1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

COPYRIGHT 2002

LeTourneau, Inc.

1


PUBLICATION ROMĆ1

SCOPE OF THIS PUBLICATION Publication ROMĆ1, STRUCTURAL COMPONENTS, is to assist maintenance personnel and operators in the location, inspection, adjustment and repair or replaceĆ ment of the various structural components of the crane.

NOTE In several places in this publication, the terms qualified" or competent" person are used with regards to inspection, repair and certification of the crane and its components. A qualified" or competent" person is defined as follows: A person who, by possession of a professional degree, certificate of professionĆ al standing or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

NEVER remove the DC drive motors access covers unless the electrical system is turned off, locked out, and grounded. Contact with high voltage terminals inside the motors will result is serious injury or loss of life.

Do not perform welding on hooks.

BEFORE attempting to disassemble any of the major components of the machine BE SURE to provide hoists or cranes and lifting devices of adequate capacity and height. NEVER stand under or place any body part under components while hoisted. Serious injury, loss of life could result in the event of an accident.

NOTE Mandatory rules of this publication per ANSI/ASME are characterized by the word SHALL." If a provision is of an advisory nature, it is indicated by the word SHOULD" and is recommended to be considĆ ered, the advisability of which depends on the facts in each situation.

Ladders and catwalks attached to the crane are designed for servicing of the crane only while the crane is stopped. No personnel are allowed on any structure of the crane during operation. Serious injury or loss of life could result from falling or crushing.

WARNINGS AND CAUTIONS Before any inspections or repairs are performed to the structural components of the crane it is critically important to read and comply with the following warnings and cautions. These warnings and cautions will not be reiterated in the following text:

!

To prevent injury, wear hard hat, protective glasses and other protective equipment as required by job conditions. ALWAYS wear gloves when handling wire rope.

!

CAUTION


When inspecting or performing maintenance or repair operations on elevated structures of the crane, NEVER proceed beyond the safety of handrailed platforms. Serious injury or loss of life from falling is possible outside these areas.

!

CAUTION

BEFORE welding on any structural members of the machine refer to Publication LETĆ1, FIELD WELDING PROCEDURES, located in the back of Section 1, of the REPAIR AND OVERHAUL MANUAL. Serious damage to electrical and electronic controls is possible unless precautions described in this publicaĆ tion are adhered to.

Place a DO NOT OPERATE sign on the controls of the machine and secure the controls before performing any maintenance or repair operations. Serious injury or death is possible if the machine is started or moved while maintenance or repair operations are being conducted. 2

CAUTION

COPYRIGHT 2002

LeTourneau, Inc.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


CRANE TESTING, EXAMINATION, AND CERTIFICATION The following general guidelines for the testing, exĆ amination and certification of the crane are included to alert the deck supervisor, operator and maintenance personnel of these requirements and the CRITICAL IMPORTANCE of these procedures for the continued safe operation of the crane.

NOTE

ANNUAL EXAMINATIONS Cranes shall undergo a thorough examination at least every twelve (12) months by a competent person, or more frequently if required by the certifying authority. a.

It is the responsibility of the deck supervisor, crane operator, and maintenance personnel to make sure the applicable tests and certificaĆ tions required by the certifying authority under which the crane is being operated are met. It is also the responsibility of the above personnel to have the required documentation of these tests, examinations, and certification on hand and in the format required by the certifying authority. There are many different certifying authorities worldwide and these guidelines should not be considered all inclusive. Certifying authorities may have the power to impose fines and harsher penalties for willful or neglect violations of crane testing, examination, and certification.

STRUCTURAL INSPECTION

The annual thorough inspection shall comprise control and function testing of the crane as well as visual control of elongation, wear and tear, corrosion, cracking and formation of fractures, etc. The examination shall be carried out in such a way that it, as far as possible, will give a reliable knowledge of the safety of the examined components. b.

INSPECTIONS FOR OVERLOADED CRANE

A crane which has been exposed to a load moment exceeding 110% of the permitted load moment (includĆ ing maximum calculated for dynamic load) shall be thoroughly examined by a competent person before it is again taken into use.

CONTROL BOOK AND CERTIFICATE

SURVEY AND APPROVAL Before a crane is, or crane components are, first taken into use, and later every four (4) years, a competent person shall have controlled constructions and calculaĆ tions, carried out testing and examination of strength, quality of materials, workmanship and structural design as well as certification in connection with this in compliance with the requirements of the certifying authority. After the crane has been tested and thoroughly examined with a satisfactory result by a qualified person, a certificate will be issued. The original test certificate shall be filed on board with the Cargo Gear

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

Register (Control Book Ć ILO Form No.1). A copy of this certificate may be requested by the certifying authority.

The results of initial testing, tests and examinations every four (4) years as well as the annual examinations and all kinds of tests and examinations after repairs or alterations of the crane or hoisting gear, shall be entered in the Control Book (ILO Form No.1). All controls, crane functions and safety devices shall be inspected and tested annually and when found to function properly the results shall be entered into the Control Book. The entry shall be written by the competent person who carried out the inspection and the examination. Control Book and Certificate shall both be kept on board. The Control Book and certificate shall be available for the surveyor of the certifying authority.

COPYRIGHT 2002

LeTourneau, Inc.

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PUBLICATION ROMĆ1


CRITICAL COMPONENTS The following is a list of components of the crane which should be considered as critical components." These components are ones which affect the safety of the crane from a structural and load hoisting standpoint. These components should be of prime concern to the deck supervisor, operator and maintenance personnel with regards to certification, inspection, maintenance and prompt repair per the appropriate guidelines.

CRITICAL MECHANICAL COMPONENTS a. All lines and linkage between the brake control element and the component to be controlled. b.

Hoist, boom, and swing brake systems

c. Drums, shafts, and gears of hoisting and swing systems

CRITICAL STRUCTURAL COMPONENTS a.

Boom chord members

b.

Boom section connection components

c.

Boom foot pins

d. Primary load members of gantries, masts and AĆframes e. Load transfer members of the rotating upper structure f.

Pedestal and swing circle transition pieces

CRITICAL RIGGING COMPONENTS a.

All running wire ropes in hoist system

b. All standing wire rope in load restraint and support system

d.

Swing bearings and gear

c.

Hook block assembly

e.

Wire rope sheaves and sheave shafts

d.

Wire rope deadĆend connection devices

f.

Electric drive motors for hoists, boom, and swing

e.

Floating harness or bridle assemblies

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

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LeTourneau, Inc.

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PUBLICATION ROMĆ1

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PUBLICATION ROMĆ1


PCMĆ350SS MACHINERY HOUSE AND WINCH INSTALLATION BOOM, MAIN HOOK, AND AUXILIARY HOOK ASSEMBLIES

The PCMĆ350SS Electric Deck Crane is equipped with a Winch Housing structure positioned on the side of the Machinery House. The Winch Housing structure conĆ sists of three major parts; the Boom Gear Drive Assembly, the Hook Gear Drive Assembly, and the Auxiliary Gear Drive Assembly.

be gained through the access door. A ventilation and service hatch is provided for cooling and maintenance servicing. This compartment contains the Solid State control components, relay switches, transformers, fuse boxes and other switch gear of the crane. Refer to the PARTS CATALOG for location of specific control deĆ vices.

REMOVAL OF WINCH HOUSING ASSEMBLY DC DRIVE MOTORS AND DRIVERS


It is necessary to remove the driver and DC motor for any of the Winch Housing Drive Assemblies to work on either the driver unit or motor except for minor repair or adjustments.

Due to the presence of potentially injurious conditions, only qualified personnel should enter the Machinery House. Before attempting to work on a component, make sure all electrical power is turned off and locked out and a DO NOT OPERATE sign is attached to the controls. Also, station an operator at the remote control operator's console or in the cab if energized tests of the components are made.

Instructions are provided in Section 2, DC MOTORS, for an inĆplace inspection of the DC drive motors. InstrucĆ tions are provided in Section 7, DRIVERS, for an inĆplace inspection of the drivers' internal components and the subsequent removal of a DC drive motor and driver as a unit if the inspections warrant removal.

!

MACHINERY HOUSE DESCRIPTION Access to the Machinery House and the electrical control components, swing and hoisting machinery can

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

COPYRIGHT 2002

CAUTION

Under no circumstances should the owner attempt to disassemble the driver past the removal of the cover during the inĆplace inspection. This is especially important if the driver is in warranty. Unauthorized disassemĆ bly will void the warranty.

LeTourneau, Inc.

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PUBLICATION ROMĆ1

1

3

2 4 5 1 3

4 5

3 4

5

8

8

6 7

1. 2. 3. 4. 5. 6. 7. 8.

CABLE DRUM STR. BOLT NĆ3 DRIVER OĆRING NĆ9 MOTOR MACHINERY HOUSE SWING TABLE & KING PIN STR. CAPSCREW

FIGURE 1. WINCH INSTALLATION - PCM 350SS 1ĆCGĆ1843, P10Ć52

8

TAĆ8919ĆCG

COPYRIGHT 2002

LeTourneau, Inc.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


PCMĆ350SS SWING TABLE AND KING PIN ASSEMBLY NOTE

The Swing Table King Pin Assembly, located on top of the pyramid, is the upper portion of the whole Swing Table Assembly which allows the crane to rotate.


Small burrs and nicks can be dressed out, but damaged or worn bearings and bushings must be replaced. c. Examine oil seals, rings and retainers. Replace if damaged or worn.



a. Install bearings, bushings and oil seals. Lubricate bearings.

NOTE

NOTE

Use care to prevent damage to oil seals during reassembly and installation.

A suitable hoisting device such as an auxiliary crane will be required for disassembly and reassembly procedures. a. Reduce load on the rollers by removing the boom or raising the boom to its maximum UP position. b. Remove the capscrews and bolt retainer pads on top of the roller assembly.

b. With Swing Table Roller Assembly completely together, use a suitable hoisting device to position roller assembly into the Roller Housing Structure. c. Install all rollers with the dimple on the roller flange closest to the column.

NOTE

c. With proper hoisting device lift out the entire Swing Table Roller Assembly.

NOTE

d. Install two threaded lifting eyes into two of the holes on the roller. Leave an empty hole between the two lifting eyes. Insert a long pry bar through the lifting eyes to turn the rollers. Refer to Figure 3.

Be sure that a suitable such as an auxiliary crane is used and that the Swing table Roller Assembly is well secured to it. d. Remove the oil seal and oil seal ring from under the bearing and remove the bearing roller from the bearing pin. e.

The dimple indicates the high side of the roller pin.

e. Adjust all rollers out until they touch the swing gear. Position of the rollers can be seen through the viewing access hole next to the roller flange.

NOTE

Remove the bearing and roller off the bearing pin.

Large adjustment is made by rotating the roller flange independently of the retainer pad. Smaller adjustment can be made using the slotted holes of the retainer pad.

f. Remove oil seal holder, oil seal and oil seal ring from bearing pin.

NOTE

f. Using a feeler gauge between the rollers and the swing gear, adjust the three nonĆloaded rollers (oppoĆ site the boom) in, leaving a .020 inch gap between the roller and the gear (refer to Figure 3).

Use care to prevent damage to oil seal, rings, holder, bearing and rollers.

INSPECTIONS AND SERVICES a. Thoroughly clean all bearings, rollers, oil seals, rings, pins, capscrews, and magnetic particle test all pins and rollers. b. Examine for nicks, burrs and if any are noted, use a hand grinder to remove them. 1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

g. Secure the bolt retainer pads to roller flanges and roller table. h. Place grease fitting on top on the pin roller and lubricate the bearing thoroughly in accordance with Figure 1, PCM CRANE LUBRICATION SPECIFIĆ CATIONS, Publication OSMĆ4, located in the OPERATĆ ING AND SERVICE MANUAL.

COPYRIGHT 2002

LeTourneau, Inc.

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2

PUBLICATION ROMĆ1

23

22

3

21

4 20

5

6

7 19 8

5

9

10

11

12

18

13

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

14

GREASE FITTING BOLT PAD ROLLER PIN OIL SEAL ROLLER BEARING OIL SEAL RING OIL SEAL HOLDER RETAINER RING OIL SEAL BUSHING BEARING SOCKET STR. OIL SEAL HEX NUT BOLT COLUMN & GEAR STR. SWING TABLE & KING PIN STR. BOLT OĆRING MANHOLE COVER BOLT

15 17 16

1ĆCGĆ1844, P10Ć52

10

FIGURE 2. SWING TABLE ROLLER ASSEMBLY COPYRIGHT 2002

LeTourneau, Inc.

TAĆ8904ĆCG

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


THREADED LIFTING EYES

PRYBAR

ROLLER

ACCESS HOLE

SWING GEAR

FEELER GAUGE .020”

FIGURE 3. SWING TABLE ROLLER ADJUSTMENT 1ĆCGĆ1845, P10Ć52

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

TAĆ8981ĆP COPYRIGHT 2002

LeTourneau, Inc.

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12

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LeTourneau, Inc.

PUBLICATION ROMĆ1

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PUBLICATION ROMĆ1


PCMĆ350SS LOWER BEARING AND SOCKET ASSEMBLY NOTE

The Lower Bearing And Socket Assembly, located at the bottom of the pyramid, is the lower portion of the whole Swing Table Assembly which allows the crane to rotate. Refer to Figure 2.


Small burrs and nicks can be dressed out, but damaged or worn bearings and bushings must be replaced. c.

d. Use proper lubricant on bearings, bushing and oil seals as specified in PCM CRANE LUBRICATION SPECIFICATIONS, Figure 1, Publication OSMĆ4, loĆ cated in the OPERATING AND SERVICE MANUAL.


NOTE Magnetic particle tests should be conducted on all gears and shafts every four (4) years or when disassembled for repairs.

NOTE A jack and a hoisting device such as an auxiliary crane of sufficient size and capacity will be required for disassembly and reasĆ sembly procedures. a.

REASSEMBLY PROCEDURES a.

Remove capscrews from bearing socket structure.

Use care to prevent damage to oil seals during reassembly and installation. b. With a suitable hoisting device, lift the Lower Bearing and Socket Assembly up the pyramid structure.

NOTE

d. With a suitable hoisting device, attach a sling to bearing socket structure. e. Rotate bearing socket structure to 45°. This will allow bearing socket to pass column base plate.

NOTE

Replace capscrews into bearing socket structure.

f. Replace the nut on the bottom of the swing turn table.

a. Thoroughly clean bearings, bushing, oil seals and capscrews.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

c. Rotate bearing socket structure 45° to allow it to pass up through the column base plate and into place. e. Relieve tension on jacking device to put load back on the thrust bearing.

INSPECTIONS AND SERVICES

Examine for burrs and nicks.

BE SURE the Lower Bearing and Socket Assembly is well secured before hoisting.

d.

BE SURE that a suitable hoisting device is used and the Lower Bearing socket Assembly is well secured before removal.

b.

Install bearings, bushing and oil seals.

NOTE

Remove nut on the bottom of the swing table tube.

b. With a suitable jacking device placed between the swing gear and bottom of the swing table, jack upward to relieve the load on the thrust bearing. c.

Examine oil seals and replace if damaged or worn.

g. Lubricate the bearing through the fitting on the side of the assembly as specified in Figure 1, PCM CRANE LUBRICATION SPECIFICATIONS in Publication OSMĆ4, located in the OPERATING AND SERVICE MANUAL.

COPYRIGHT 2002

LeTourneau, Inc.

13


14

COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


PCMĆ350SS SWING GEAR UNIT ASSEMBLY The Swing Gear Unit Assembly controls the rotation of the crane and is powered by a S1A, DC motor driving through a #5 gearbox assembly mounted out from the swing table and king pin structure. The Swing Gear Unit output shaft operates on the round gear rack of the swing table to obtain crane rotation. Refer to Figure 4 for an illustration of the components of the Swing Gear Unit Assembly.

type spring applied electroĆmechanically released moĆ tor brake is an integral part of the motor. Refer to Section 2 for disassembly, inspection, repair, and reassembly procedures for the DC swing motor. Also, refer to the LeTourneau, Inc. Publication TAKING CARE OF YOUR DC MOTOR, located in the back of Section 2 for additional information on maintenance, troubleĆ shooting, and repair of DC motors.

SWING GEAR UNIT DC MOTOR The Swing Gear Unit DC motor when used in conjuncĆ tion with the LeTourneau, Inc. power and control system provides the operator with a wide range of control of motor speed and output power. These motors are especially wound to provide maximum output throughĆ out the full range of motor speed. A multiple disc friction

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

SWING GEAR BOX Refer to Section 7, SWING GEARBOX, for information concerning the disassembly, repair and replacement and reassembly procedures for the #5 swing gearbox assembly.

COPYRIGHT 2002

LeTourneau, Inc.

15


PUBLICATION ROMĆ1

1

2

3 4 5 17

6 16 7

15 14

8

13 9

10 12

11

1. 2. 3. 4. 5. 6. 7. 8. 9.

LID STR. TOGGLE LATCH OĆRING BOLT LOCKWASHER OĆRING SĆ1A DC MOTOR BOLT BOLT

1ĆCGĆ1846, P10Ć53

16

10. 11. 12. 13. 14. 15. 16. 17.

WASHER BAR LOCKNUT #5 SWING GEARBOX LOCKWASHER BOLT TERMINAL TUBE TERMINAL TUBE COVER STR.

FIGURE 4. SWING GEAR UNIT INSTALLATION COPYRIGHT 2002

LeTourneau, Inc.

TAĆ8962ĆCG

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


PCMĆ350SS GANTRY ASSEMBLY The PCMĆ350SS Electric Deck Crane is equipped with a rigid steel pipe assembly that is pinned to the swing table structure. The Gantry Sheave Housing Assembly is pinned to the top of the Gantry Structure to give proper fleet angle. The Boom Positive Stop is pinned to the Gantry Structure to stop the boom at a minimum radius. Refer to Figure 5 for an illustration of the components of the Gantry Assembly.


b. Remove bolts, keeper plates and pins from the top of the Boom Stop Support. Remove bolts, keepers and pins from back of Boom Stop Assembly. Hoist Boom Stop Structure away. c. Remove bolts, keeper plates and pins for base of Boom Stop Support and hoist it away. d. With a suitable hoisting device secured to the top of the Front Gantry Structure, remove bolts, keeper plates and pins form the top and bottom of the Rear Gantry and pins from the top and bottom of the Rear Gantry Structure and hoist away. e. Remove bolts, keeper plates and pins from base of Front Gantry Structure and hoist away.

NOTE

INSPECTIONS UPON DISASSEMBLY a. Thoroughly clean all pins, nuts and bolts with a suitable solvent and allow to air dry. Any worn parts should be replaced.


NOTE

DISASSEMBLY

All shafts and gears must be magnetic particle tested.

a. With a suitable hoisting device, remove the Gantry Sheave Housing Assembly.

NOTE


Refer to GANTRY SHEAVE HOUSING ASĆ SEMBLY, page 18.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

To reassemble the Gantry Assembly, reverse the procedures in DISASSEMBLY, above.

COPYRIGHT 2002

LeTourneau, Inc.

17


PUBLICATION ROMĆ1

1 2 3

3

4

22

21 20 3

19 23 18

4 2

17 1 15 16 15 14

8 4

1 5 6 14

2 13 4 3

2

11 12

10 1 3

9 2 8

7

1

FIGURE 5. GANTRY ASSEMBLY 1ĆCGĆ1847, P10Ć53

18

TAĆ8970ĆCG

COPYRIGHT 2002

LeTourneau, Inc.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


GANTRY ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

BOLT KEEPER PLATE PIN PIN LOWER GANTRY STR. REAR GANTRY STR. LOWER GANTRY STR. FRONT GANTRY STR. GREASE FITTING BOLT RETAINER PLATE SHEAVE PIN BEARING SPACER BEARING SPACER SEAL BEARING SHEAVE SLEEVE PUSHER STRUCTURE BOOM STOP SPRING BOLT BOOM STOP STR. BOOM STOP SUPPORT STR.

COPYRIGHT 2002

LeTourneau, Inc.

19


20

COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


PCMĆ350SS GANTRY SHEAVE HOUSING ASSEMBLY NOTE

The Gantry Sheave Housing Assembly is made up of six (6) sheave wheels and seven (7) divider plates. Its function is to assist in the raising and lowering of the boom. Refer to Figure 5 for an illustration of the Gantry Sheave Housing Assembly.

Examine for burrs and nicks. With a hand grinder, remove any that are noted.

NOTE Sheaves and sheave wheel pins are to be magnetic particle tested.



NOTE

b. Insert bearing assembly and spacer into first wheel. Put wheel into position between spacers and slide sheave wheel pin through spacers, wheel bearing and wheel.


DISASSEMBLY a. With a suitable hoisting device attached, remove the three (3) capscrews from the end of the gantry hinge pins. Remove the two gantry hinge pins. This will allow the whole Gantry Sheave Housing Assembly to drop down. b. Remove the two 1/2Ćinch bolts that hold the sheave housing pin keeper plates. Remove sheave housing pin and six (6) spacers.

NOTE Only one sheave housing pin needs to be removed and if the back pin is removed a complete inspection of all wire ropes can be made.

CAUTION

In removing the sheave wheel pin, care should be taken not to drop or damage the sheave wheels, wheel bearings and spacers.

INSPECTIONS AND SERVICES a. Thoroughly clean all parts to the Gantry Sheave Housing Assembly. b. Inspect all pins, wheels, bearings and spacers. replace if damaged.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

d. Replace retainer plates with three (3) 1/2Ćinch bolts each side of sheave wheel pin. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque. e. Replace sheave housing pin and at the same time replace the six (6) spacer pipes, one between each sheave housing plate. replace keeper plates with 1/2Ćinch bolts, each side of sheave housing pins. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque.

NOTE

c. Remove retainer plates on sheave wheel pin. Remove pin with caution.

!

c. Repeat procedure b" until all wheels, bearing assemblies and spacers are in place and the sheave wheel pin is all the way through the sheave divider plates.

Make sure all wire ropes are in proper order. f. With a suitable hoisting device, raise gantry sheave housing unit up and connect back to top of gantry with the two gantry hinge pins. Replace keeper plates with three (3) 1/2Ćinch bolts in the end of each pin. Tighten capscrews. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque. g. Lubricate bearing assemblies through the grease fitting on the end of the sheave wheel pin as specified in Figure 1, PCM CRANE LUBRICATION SPECIFIĆ CATIONS, in Publication OSMĆ4, located in the OPERĆ ATING AND SERVICE MANUAL.

COPYRIGHT 2002

LeTourneau, Inc.

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22

COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


PCMĆ350SS BOOM ASSEMBLY The PCMĆ350SS Electric Deck Crane is equipped with a rigid steel boom made up of four sections. The lower structure is 43 feet 6 inches in length. There are two middle sections; one of 20 feet and one of 40 feet in length. With the Auxiliary Hoist System (optional), the top boom section has a length of 25 feet. Sections are connected using bolt plates, bolts and nuts. Each joint of the boom has a male and a female fit for additional safety. Refer to Figure 6 for an illustration of the Boom Assembly.

i. In succession, remove the capscrews and nuts that hold the upper, middle and lower boom sections together and remove each with a suitable hoisting device. j. Remove pin retainers, idler sheave pin, bearing and 30 inch sheave wheel from auxiliary hoist boom tip weldment. k. Remove cotter pin and sheave pin form guide sheave housing assembly. l. Remove bolts, lockwashers and lock plate from guide sheave housing assembly and drive out sheave housing pin. Remove the 22 inch sheave wheel. Remove bearing seal and bearing assembly.


NOTE

m. Remove bolts, retainer plates and sheave wheel pins from boom housings. Secure sheave in place and drive out sheave pins. Roll out the sheaves onto a prepared surface. remove all bearing seals, spacers and bearings.


BOOM DISASSEMBLY AND REMOVAL a. Hoist the Main Hoist and Auxiliary Hoist Hook (optional) and block assemblies close enough to the tip to prevent the wire ropes from fouling when the boom is lowered. b. Above a flat working surface, lower the boom until the tip almost touches.

!

h. Attach suitable hoisting device to boom structure and lower to a prepared work surface.

BOOM INSPECTIONS UPON DISASSEMBLY a. Thoroughly clean all bearings, bushings, spacers, nuts, pins and grease fittings in a solvent and allow to air dry. b. Inspect all components for excessive wear and/or damage. Replace or repair when necessary.

CAUTION

DO NOT lower the boom below a parallel with the base of the boom. Do not let the tip touch the deck surface because it might bend or damage the boom structure.

Replace ALL nuts and bolts for boom connections every 4 years of operation, also bolts and nuts are to be replaced if any boom sections must be replaced. Failure to comply with this instruction could result in serious injury or death and damage to the crane.

c. Remove the Main Hoist Hook and Block Assembly and the Auxiliary Hoist Hook and Block Assembly (optional).

NOTE

d. Spool Main Hook and Auxiliary Hook (optional) lines on to the drums.

ALL pins and critical welds are to be magnetic particle tested.

e. With a suitable lifting device, lower the floating sheave assembly on top of boom and secure. f. Remove boom wire rope dead end for gantry sheave assembly. g.

Spool boom wire rope onto the cable drum.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

BOOM REASSEMBLY To reassemble the Boom Assembly, reverse the proceĆ dures in BOOM DISASSEMBLY AND REMOVAL, above.

COPYRIGHT 2002

LeTourneau, Inc.

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COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

1

2

3

4

5

6

14 15 8 12

13

16

9

7

E

10

E

19 17

VIEW – A

VIEW – B

11

VIEW – C

20 21

14

SECTION E–E

18

A C B

1

1. 2. 3. 4. 5. 6. 7.

2

LOWER BOOM SECTION MID BOOM SECTION - 40' MID BOOM SECTION - 20' TOP BOOM SECTION BOOM TIP W/AUXILIARY HOIST BOOM TIP EXTENSION BRIDLE CABLE ASSEMBLY

3

8. 9. 10. 11. 12. 13. 14.

BOLT CAP PLATE GREASE FITTING LUFFING ATTACHMENT STR. BOLT NUT BOLT

4

15. 16. 17. 18. 19. 20. 21.

5

6

PIN RETAINER BUSHING, SELFĆALIGNING BUSHING, PIN GREASE FITTING HINGE PIN IDLER NUT

NOTE: REFER TO FIGURE 6, PARTS 2 AND 3, FOR ILLUSTRATIONS OF THE BOOM TIP ASSEMBLY. FIGURE 6. BOOM AND AUXILIARY HOIST (1 of 3) 1ĆCGĆ1848, Ldgr2Ć21

1-ROM 1.1, 350SS, FOĆ1 6/25/98

TAĆ8991ĆCG

COPYRIGHT 2002

LeTourneau, Inc.

25


26

COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

1ĆCGĆ1849, P10Ć54

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

LeTourneau, Inc.

COPYRIGHT 2002

6

5

4

11

12

3

14

13

16

12

6

5

4

11

FIGURE 6. BOOM AND AUXILIARY HOIST (2 of 3) 11

15

3

12

12

6

14

13

17

12

14

5

4

13

11

12

18

11

3

3

4

19

6

5

11

3

12

10

6

13

13

14

12

4

14

12

5

2

1

11

12 11

3

9

8

7

6

5

4

12 13

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

14 12 11

BOLT TOP PLATE PIN RETAINER BOLT GREASE FITTING BOLT CUFFING ATTACHMENT CAP PLATE BOLT GREASE FITTING BEARING SPACER BEARING SEAL BEARING ASSY. SHEAVE BOOM TIP EXTENSION STR. IDLER SHEAVE PIN SHEAVE PIN BOOM TIP STR. SHEAVE PIN

PUBLICATION ROMĆ1 PCM 350SS ELECTRIC DECK CRANE STRUCTURAL COMPONENTS

BOOM TIP INSTALLATION WITH AUXILIARY HOIST - PCM 350SS

TAĆ8993ĆCG

27


PUBLICATION ROMĆ1

2 1 3

10 7

6 4

5 5

6 9

7

8

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

BRIDLE LINE CABLE ASSY. WIRE ROPE ASSY., 550' SINGLE SHEAVE DYNAMOMETER MAIN HOOK LINE ASSY., 1" X 2225' ANTIĆTWO BLOCK SENSOR CLAMP, WIRE ROPE - 1" OPEN WEDGE SOCKET, 1" OVERHAUL BALL ASSY., 10T HOOK AND BLOCK ASSY. LINK LOADCELL BOOM GROUP WITH AUXILIARY HOIST FIGURE 6. BOOM AND AUXILIARY HOIST (3 of 3)

1ĆCGĆ1850, P10Ć55

28

TAĆ8989ĆCG

COPYRIGHT 2002

LeTourneau, Inc.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


PCMĆ350SS FLOATING SHEAVE HOUSING ASSEMBLY NOTE

The Floating Sheave Housing Assembly is a pulley made up of six (6) 30 inch sheave wheels. Its function is the raising and lowering of the crane's boom. Refer to Figure 7 for an illustration of the components of the Floating Sheave Housing Assembly.

Magnetic particle tests should be conducted on all critical welds and pins during disassembly or every four (4) years.

INSPECTIONS AND SERVICES a. Thoroughly clean all parts of the Floating Sheave Housing Assembly.


b. Inspect all pins, wheels, bearings and spacers. Replace if damaged or worn.

NOTE

NOTE

Examine for burrs and nicks. With a hand grinder, remove any that are noted.



DISASSEMBLY a. Lower the Floating Sheave Housing Assembly into the cradle provided on the top of the boom. Remove the three (3) 1/2Ćinch bolts on the end of the pin that holds the bridal connector structure in place. With proper hoisting device remove pin. b. Remove the two (2) 1/2Ćinch bolts and keeper plates on the end of sheave housing pins that holds the five (5) sheave divider plates together. remove pin and six (6) spacer pipes.

NOTE

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

d. Replace sheave housing pins and spacers, one between each sheave housing plate. replace keeper plates and 1/2Ćinch bolts and tighten to proper torque. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque.


c. Remove 1/2Ćinch bolts and retainer plates that hold the sheave wheel pin. Remove pin with caution.

In removing the sheave wheel pin care should be taken not to drop or damage the sheave wheels, wheel bearings and spacers.

c. Replace the retainer plates and 1/2Ćinch bolts. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque.

NOTE


NOTE

b. Insert bearing assemblies and spacers into sheave wheels. Put into position and slide sheave wheel pin through spacers, wheel bearings and sheave wheels.

e. Replace bridle connector and secure into place with bridal pin structure and cap plate with 1/2Ćinch bolts. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque. f. Lubricate bearing assemblies through the grease fitting on the end of sheave housing wheel pin as specified in Figure 1, PCM CRANE LUBRICATION SPECIFICATIONS, in Publication OSMĆ4, located in the OPERATING AND SERVICE MANUAL.

COPYRIGHT 2002

LeTourneau, Inc.

29


PUBLICATION ROMĆ1

1

3 18 2

17

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

16

15

3" PIPE SPACER 30" SHEAVE WHEEL 1Ć1/8" BEARING SPACER KEEPER PLATE 1/2" NC X 1" BOLT 5/8" O/S PLATE RETAINER PLATE 1/8" GREASE FITTING 1/2" NC X 1Ć1/4" BOLT SHEAVE HOUSING PIN SHEAVE WHEEL PIN CAP PLATE FLOATING HOUSING STR. BRIDLE CONN. STR. BRIDLE PIN STR. BEARING SEAL BEARING ASSY. 3/4" BEARING SPACER

4 5 6

7 8 9

14

13

12 5 11

10

FIGURE 7. FLOATING SHEAVE HOUSING ASSEMBLY

1ĆCGĆ1851, P10Ć55

30

TAĆ8934ĆCG

COPYRIGHT 2002

LeTourneau, Inc.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


PCMĆ350SS MAIN HOOK AND BLOCK ASSEMBLY The Hook and Block Assembly is in two parts. The Hook Assembly itself and the Sheave Housing Assembly. The Hook and Block Assembly is used for hoisting materials. Refer to Figure 8 for an illustration of the components of the Hook and Block Assembly.

DISASSEMBLY a. Lower the Hook and Block Assembly to a prepared working surface. b. The hook Assembly itself is disassembled by first removing the keeper plates that retain the swivel block.

measure the same as original, if not, discard the hook.

REASSEMBLY a. In reassembling the Sheave Housing Assembly, first reassemble an lubricate all bearing assemblies. b. Insert bearing assemblies and spacers into the first wheel. Put wheel into position between spacers, bearing seals, wheel bearings and sheave wheel.

NOTE

c. With a suitable hoisting device attached to the Hook Assembly, remove the tie bolts and tie pins that hold the Sheave Housing Assembly together.

Outside sheave plates are wider than the two divided plates, so the two wider bearings spacers must go to the outside.

d. Remove the bolts that hold the retainer plates on the sheave wheel pin. Remove the pin with caution.

c. Place Hook Assembly between sheave housing plates.

NOTE

d. Repeat procedure b" in this section until all wheels, bearing assemblies, spacers and seals are in place and the sheave wheel pin is all the way through sheave and divider plates.

In removing the sheave wheel pin, care should be taken not to drop or damage the sheave wheels, wheel bearings, spacers, seals and Hook Assembly. e. Remove Hook Assembly to a prepared working surface. f. Remove the cotter pin and 4Ćinch hook nut and carefully remove the hook itself so as not to damage the bearing assembly. g.

Remove the bearing assembly.

e. Replace sheave wheel pin retainer plates and bolts. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque. f. Replace sheave housing tie bolts and tie pins and at the same time replace the 3Ćinch spacer pipes. replace 1Ć1/2 inch nuts and keeper plates. Refer to the CAPSCREW TORQUE CHART in the appendix of this manual for the proper torque.

NOTE

INSPECTIONS AND SERVICES a. Thoroughly clean all parts of the Hook and Block Assembly. b. Inspect all pins, wheels, bearing assemblies, spacers and seals. Replace if damaged or worn.

NOTE Hook wheels and pins are to be Magnetic Particle Tested every four (4) years or if disassembled.

NOTE Check crane hooks for deformation or cracks. Hooks will be discarded where cracks exist or throat opening is 15 percent more than the original throat opening. Hooks will also be discarded where they are bent or twisted more than 10° from the plane of the original hook configuration. The shank of the hook shall 1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

Make sure all wire ropes are in proper order. g. Lubricate bearing assemblies through the grease fitting on the end of the sheave housing wheel pin as specified in Figure 1, PCM CRANE LUBRICATION SPECIFICATIONS, in Publication OSMĆ4, located in the OPERATING AND SERVICE MANUAL. h. Lubricate the hook thrust bearing located on the side of the swivel bearing block as specified in Figure 1, PCM CRANE LUBRICATION SPECIFICATIONS, in PubĆ lication OSMĆ4, located in the OPERATING AND SERĆ VICE MANUAL. i. Perform a No Load Test" prior to putting back in service.

NOTE The Auxiliary Hook Assembly is a vendor supplied item. Refer to the Parts Catalog for ordering information. COPYRIGHT 2002

LeTourneau, Inc.

31


PUBLICATION ROMĆ1

1 2 3

24

23

6

23

7 8

1

5 4 22 6 9 10

7 11 8 1

21 20 3

14 2

19 11 18 10

13 12

17

16

1. 2. 3. 4. 5. 6. 7. 8.

SPACER PIPE KEEPER PLATE CAPSCREW RETAINER ROD NUT RETAINER PLATE GREASE FITTING BOLT

15

9. 10. 11. 12. 13. 14. 15. 16.

SHEAVE WHEEL BEARING SPACER BEARING SPACER SEAL BEARING COTTER PIN SAFETY LATCH HOOK

17. 18. 19. 20. 21. 22. 23. 24.

SWIVEL BLOCK THRUST BEARING NUT TIE PIN MOUNT PLATE SHEAVE PIN SIDE PLATE DIVIDER PLATE

FIGURE 8. MAIN HOOK AND BLOCK - PCM 350SS (75ĆTON) 1ĆCGĆ1852, P10Ć56

32

TAĆ8964ĆCG

COPYRIGHT 2002

LeTourneau, Inc.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


CABLE DRUM LOCK PIN The cable drums for the main and auxiliary hooks and boom luffing are equipped with a safety lock pin mount structure to prevent the cable drum from turning if the brake is released for service or repair or if the DC drive motor must be removed. The pin for the applicable drum

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

should be installed anytime these operations or any other operation which requires the drum to remain stationary are being conducted. Refer to Figure 9 for illustrations of the lock pin mount structure.

COPYRIGHT 2002

LeTourneau, Inc.

33


PUBLICATION ROMĆ1

1

B

B

A

A 2 3

4

5

6

7

4 5

8 6 7

8 VIEW A-A

1. 2. 3. 4. 5. 6. 7. 8.

MACHINERY HOUSE KING PIN AND SWING TABLE STR. CABLE DRUM STR. LOCK PIN STR. BOLT LOCK PIN MOUNT STR BOLT PLATE

VIEW B-B

FIGURE 9. LOCK PIN MOUNT STRUCTURE INSTALLATION - PCM 350SS TAĆ8949ĆCG

1ĆNGOĆ1592, P10Ć31, 6/1/98

34

COPYRIGHT 2002

LeTourneau, Inc.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


PCMĆ350SS STRUCTURAL REPAIRS The following instructions pertain to structural repairs of the crane and welding procedures which relate to safety and integrity of the load bearing members.

BOOM DIAGONAL PIPES: 3" XĆHVY. X .300 wall thickness and are made from AĆ53 Gr.B or equal.

WELDING REQUIREMENTS

Before any structural repairs are made magnetic particle and dye penetrant tests shall be conducted.

Certain materials are manufactured exclusively by LeTourneau, Inc. Substitution of these materials is not to be attempted without prior approval by LeTourneau, Inc. due to the possible incompatibility of alternate materials. Should the owner desire, LeTourneau, Inc. will provide personnel and materials for repairs and/or replacements if requested. Instructions for welding of LeTourneau, Inc. structural steel are included in LeTourneau, Inc. Publication LeTĆ1, FIELD WELDING PROCEDURES, located in the back of Section 1, in the REPAIR AND OVERHAUL MANUAL. It is ESSENTIAL to review these procedures and contact both your distributor and LeTourneau, Inc. prior to attempting ANY structural repairs to this crane.

NOTE

STRUCTURAL REPAIR PROCEDURES

!

BEFORE proceeding with any structural repairs and/or replacements, BE SURE that there is no load on the crane and power has been disconnected from the crane.

!

CAUTION

It is essential to isolate the Load Moment Indicator system from the crane's electrical system prior to welding repairs or damage will result. The boom should be supported in either the boom rest or temporary supports.

NOTE

Anyone performing structural repairs to the crane shall meet the following qualifications: American Welding Society Specifications for Welding Machinery and Equipment ClassificaĆ tion and Application of Welded Joints for AWS D14.4 Ć 77.

No repairs and/or replacements shall be undertaken without prior approval from LeTourneau, Inc. and the certifying authority under which the crane is operating. Any repairs shall be witnessed by an attending surveyor of the certifying authority.

STRUCTURAL MATERIALS COLUMN PLATES: 1" thick and made from NĆ20 BHT MAIN BOOM PIPES: 6Ć5/8" O.D. LET. X .375 wall thickness and are made from high strength steel (70,000 minimum yield, 100,000 minimum tensile charpy of 20 lb. at -40).

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

CAUTION

If emergency repairs and/or replacements are necesĆ sary, the certifying authority shall be provided with a detailed description of the extent of the repair and/or replacement, materials and procedures used, plus any other pertinent data, at the earliest possible time. Arrangements shall also be made for an inspection by the certifying authority's representative.

COPYRIGHT 2002

LeTourneau, Inc.

35


36

COPYRIGHT 2002

LeTourneau, Inc.

PUBLICATION ROMĆ1

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


PCMĆ350SS/120SS ELECTRIC DECK CRANE PAINTING RECOMMENDATIONS These instructions cover surface preparation, coating system and inspection requirements to be used in the painting of LeTourneau, Inc. Electric Deck Cranes. The recommended two coat system with two part inorganic zinc silicate primer combats corrosion by the elimination of rust creep" or undercutting of all blasted steel surfaces including the crane's Machinery House, ColĆ umn, Gantry, Boom and other structural components. These instructions are minimal requirements for normal conditions. Local conditions and overall condition of the crane's painted surfaces may require additional meaĆ sures to ensure quality paint work.

NOTE

Paint Equipment: Devilbiss Air Spray Gun - Model MBC 510 with air cap AUĆ1239Ć704; 10 gallon Pressure Feed Tank with Air Motor Agitator Q.S.A. 503 or equivalent

NOTE Materials and equipment listed above are used successfully by LeTourneau, Inc. in the manufacturing process. Substitute items that meet specifications listed are acceptable.

SURFACE PREPARATION a. Securely seal the ventilator fan, access door and any other place blasting sand or paint overspray might enter the Machinery House or Operator's Cab (optionĆ al). Cover the glass and weatherstripping on the Operator's Cab (optional). Use masking tape or other suitable material to seal these areas.

Refer to paint manufacturer's specification sheets for physical properties, performance limitations, additional instructions for surface preparation, application and safety precauĆ tions specific to the application of their products. Specification sheets for the original equipment paint are provided at the end of this article.

!

Sandblast Equipment: Pangborn Blast System or equivalent

b. Cover or remove the wire rope as necessary to prevent contamination from blasting sand and paint. c. Cover and seal the swing gear and swing pinion to be sure no contamination from sand or paint occurs.

CAUTION

d. Protect any exposed electrical wiring or terminals from damage by sandblasting.

Surface preparation and painting requires working in close proximity with chemicals and vapors which can cause skin and respiratory injury. Read and follow all safety precautions mentioned in paint manufacturers specificaĆ tions.

e. Sandblast to a commercial blast clean finish (almost near white) per Steel Structures Paint Council, Surface Preparation Specification SSPCĆSPĆ10Ć63T. The grit size should be Mesh/U.S. Sieve Series and be clean, washed silica such as Lone Star #1 or equal. Nozzle velocity of the abrasive should not be less than 100 psi.

Also, follow these additional safety precauĆ tions: 1. Wear the appropriate respirators, eye protection and protective clothing to prevent injury. Do not use solvents or thinners to clean skin.

!

Use caution to not damage seals when sandblasting in close proximity to swing gearbox and drivers.

2. Do not smoke, eat or drink in the surface preparation and painting area. Also, keep sparks, heat and open flames away from the these areas.

NOTE Do not reuse blasting sand. Oil and grease should be removed by hosing or by wiping with a suitable solvent.

MATERIALS AND EQUIPMENT RECOMMENDATIONS a.

NOTE

MATERIALS RECOMMENDED

Sandblast Media: Lone Star #1 Bulk Blast Media or equivalent Paint and Primer: Refer to manufacturer's product information following this article. b.

EQUIPMENT RECOMMENDED

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

CAUTION

COPYRIGHT 2002

After sandblasting, ALL welds should be inspected by a qualified person and any that are suspected of being cracked are to be dye penetrant and magnetic particle tested. Refer to STRUCTURAL REPAIRS, and publication LeTĆ1, FIELD WELDING PROCEDURES, loĆ cated in Section 1 in the REPAIR AND

LeTourneau, Inc.

37


PUBLICATION ROMĆ1

OVERHAUL MANUAL before attempting ANY welding repairs to the structural components of the crane.

!

Care must be taken to minimize surface contamination from atmospheric pollution such as dust, industrial fallout etc.

f. All rough welds, burrs, weld splatter and other sharp surface projections should be ground smooth. Any grinding done after sandblasting should be reĆ blasted to obtain a surface like the remainder of the area to be painted. g. Sandblasting and painting operations should be scheduled so that they will not be in progress at the same time or so that blasting is not in progress while there is wet paint within the range of sandblasting contamination. The blast cleaned surface should be coated with one coat of primer as specified during the same day as blasted and also before any visible rust occurs. Sandblasted steel wet by rain or moisture prior to priming should be reĆblasted.

NOTE A color contrast has been purposely estabĆ lished between the primer and the finish coat. The color contrast is designed to act as an indicator to insure complete coverage with both primer and finish coat. The contrast is not to be so great as to markedly influence the appearance of the top coat.

POST PAINTING INSPECTION AND SERVICES Post painting inspection and servicing should be conducted by a qualified person to be sure the requirements listed the paint manufacturer's specificaĆ tions are met and that no damage to crane components by contamination from sandblasting and painting will occur. The following inspections and services should be performed:

NOTE Surfaces which do not require painting should be masked or otherwise protected during the painting of adjacent work. Also, be aware of possible damage to surrounding rig compoĆ nents from overspray and take appropriate measures to protect them.

a. Inspect the paint to be sure that a film thickness as listed in Figure 10 is met. Measurement should be made by Dry FilmĆMikrotest or equivalent gauge.

PAINT APPLICATION a. Primer and paint used should be the original used in the manufacturing process or equivalent, conform to the paint manufacturers specifications and be applied listed in Figure 10. b. Painting should be done in a neat and workmanĆ like manner and all joints and crevices should be filled where necessary and thoroughly painted. Paint should be applied only on surfaces that are completely dry. c. Painting should only be permitted within a range of temperature and humidity recommended by the paint manufacturer as published in specifications for the particular product.

38

CAUTION

b. Inspect Machinery House, control panels, motors, wiring, and terminals for contamination from sandblastĆ ing and painting. Vacuum out any contamination. c. Inspect the slewing bearing, gear, gearbox pinion and lubricant to be sure no contamination from sandblasting and painting is present. Clean and lubricate as required. d. Inspect the wire rope to be sure no contamination from sandblasting and painting is present. Clean and lubricate as required. e. Inspect pins and bushings for contamination from sandblasting and painting and clean as required.

COPYRIGHT 2002

LeTourneau, Inc.

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

PUBLICATION ROMĆ1


Component

Metal Prep

Outer Column and Gear Str. (PC 350); Inner Column and Gear Str. (PC 120) Swing Table, Gantry Boom (except tip), Machine House Exterior, Other crane structures

Near white shot or sand blast SSPCĆ10

Primer

Tie Coat

One coat inorganic One coat red zinc primer 2Ć1/2 expoxy 1 MIL DFT to 3 MLS DFT

One Coat Grey HiĆSol expoxy 4-6 MILS DFT One Coat Yellow HiĆSolids epoxy 4-6 MILS DFT One Coat Orange HiĆSolids epoxy 4-6 MILS DFT

Boom Tip

Machine House Interior

Wire brush to remove rust and loose scale. Wash to remove oil, grease and foreign matter.

Welded Hand Railjoints

YELLOW

One coat epoxy primer 4 MILS DFT

None

One Coat Whle Polyurethane 1.5 to 2 MILS DFT

None

None

Two coats cold galv. compound, 2-3 MILS total DFT

ORANGE

FIGURE 10. PCM CRANE PAINT REQUIREMENTS 1ĆCGĆ1565, P10Ć33

1ĆROM 1.1, 350SS 6/25/98 (Rev 8/31/01)

Top Coat

COPYRIGHT 2002

LeTourneau, Inc.

TAĆ8941ĆCG

39

FIELD WELDING PROCEDURE

PUBLICATION LeT-1

NOTES ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________

2

COPYRIGHT 2001

LeTourneau, Inc.

7-LeT-1.3 GEN. EQUIP. (MSWord) 11-29-01

PUBLICATION LeT-1


WARNINGS AND CAUTIONS !

To ensure that no damage occurs to solidstate components, the welding ground clamp should be as close as possible to the area to be welded.

Place a DO NOT OPERATE sign on the controls while welding, maintenance or repair work is being completed. Serious injury or death is possible if the machine is started or moved while maintenance or repair operations are being conducted. For the welder’s safety, always disconnect the battery ground near the battery box to prevent the machine from being started while the welder is working.

!

CAUTION

Under NO circumstances should a bearing or movable joint be between the grounding point and the area to be welded.

!

CAUTION

Isolate ALL DDEC components before beginning welding procedures. Damage to components could otherwise result.

If inspecting the welds of making welding repairs on the elevated structures of a Jib Crane, Straddle Hoist, or Marine Crane NEVER proceed beyond existing platforms. Moving beyond the safety of hand-railed platforms could cause injury or loss of life. Wear a hard hat when performing any inspections, maintenance operations or welding repairs on a Jib Crane, Straddle Hoist or Marine Crane. Be sure all power is turned off before touching any electrical connections or terminal. Only qualified and experienced personnel should enter the electrical control room of a Jib Crane or Marine Crane.

NOTE Machines with Detroit Diesel engines equipped with the DDEC system (instead of the governor system) are also equipped with an electronic battery equalizer. To avoid reverse polarity damage when disconnecting battery terminals, always remove the equalizer ground terminal first and replace the equalizer ground terminal last. 1. For machines with an articulating joint, make certain that the ground strap in the pivot area is left firmly connected because this cable electrically “ties” the two frame sections together. 2. If the welding unit is connected to commercial power such as in a shop area, the machine must be isolated from all other contacts to ground other than the welding ground clamp if possible. Machine attachments must not contact any steel wear rails in the floor. If an overhead crane is used to support any part of the machine, a nonconductive sling should be used.

BEFORE working in the pivot or “pinch” area of an articulated machine, securely attach the frame lock or steering locking pin to prevent the machine from turning. Enter this area only when necessary. Before operating, be sure steering locking pin is disconnected and properly stowed.

3. Do not disconnect the neutral from ground in the master junction box. Machines fitted with the optional ground fault system have this connection at the fault current limiting resistors.

NEVER, under any circumstances, weld or use a cutting torch on a wheel with an inflated tire. This could cause a tire explosion resulting in serious injury or loss of life.


CAUTION

COPYRIGHT 2001

LeTourneau, Inc.

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PUBLICATION LeT-1

NOTES ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________

4

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1


GENERAL WELDING PRACTICES PREHEAT AND INTERPASS TEMPERATURES Preheat and interpass temperature controls are crucial elements in making a quality weld. Preheat is defined as the temperature of the base metal in the surrounding area of the starting point of welding immediately before welding begins. Preheat is to be applied using an oxy-fuel torch with a rosebud attachment. The minimum preheat temperature shall be maintained within 3” of the welding area. To determine the proper minimum preheat temperature and the maximum interpass temperature, follow the information on. Where possible, preheat on opposite side of the area in which welding is being done to insure that the temperature has soaked through the part. Temperature of the part shall be checked with temperature crayons to ensure correct preheat. Interpass temperature is defined as the temperature of the weld between weld passes. The interpass temperature shall be checked between each successive weld pass with temperature crayons. The start of another weld pass shall not begin until the temperature of the part is below the maximum interpass temperature at the arc initiation site.

ELECTRODE STORAGE AND HANDLING All SMAW electrodes shall be removed from a fresh hermetically sealed canister or from baking or storage ovens. Electrodes shall be issued and held in quivers or other small open containers by the welder until used. After hermetically sealed containers are opened or after electrodes are removed from baking or storage ovens, the electrode exposure to the atmosphere shall not exceed the values shown in Figure 1. Electrodes exposed to the atmosphere for periods less than those permitted by Figure 4 may be returned to a holding oven maintained at 250°F minimum for a minimum hold time of four hours. Electrodes exposed to the atmosphere for periods greater than those permitted in Figure 4 shall be re-baked as follows: · All electrodes having low-hydrogen coverings conforming to ANSI/AWS A5.1 shall be baked for at least two hours between 500°F and 800°F. · All electrodes having low-hydrogen coverings conforming to ANSI/AWS A5.5 shall be baked for at least one hour at temperatures between 700°F and 800°F.


After the electrodes have been re-baked, they may be re-issued. Electrodes shall be re-baked no more than once. Electrodes that have been wet shall not be used.

CERTIFIED WELDERS AND APPROVED WPS All welding done shall be performed by a certified welder following an approved Welding Procedure Specification (WPS). The WPS and welder must be qualified according to AWS D 1.1 Structural Welding Code - Steel or other recognized governing code requirements.

WELDING TECHNIQUES For multiple pass welds, starts and stops should stagger for each weld pass. All starts and stops should occur before or after the corner of a structure. No slug welding will be permitted. Where possible, use run-off tabs. All stops and starts should be on the tabs. Remove all tabs by oxy-fuel cutting or arc gouging and grind flush. No weave welding is allowed.

CLEANING REQUIREMENT Prior to welding, all lose scale, cutting dross, grease, oil, water, paint, rust, dirt and other contaminants are to be removed at least 2” from the edge of the joint. During welding, all individual passes are to be cleaned. No slag welding is allowed. After welding, remove slag and spatter from the weld and welding area by appropriate means. Excessive grinding should be avoided, but blend grind all repairs.

WELDING DEFECTS The following discontinuities will cause the weld to be deemed defective and will require for the discontinuity and/or the defective weld to be removed. · Porosity (Pinholes) - any cavity type discontinuity. · Overlap (Cold lap) - protrusion of weld metal beyond the weld toe or weld root. · Crack - a fracture of the weld metal and/or the base metal characterized by a sharp tip and high length to width ratio. · Undercut - Removal of parent material at the toes of the weld.

COPYRIGHT 2001

LeTourneau, Inc.

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PUBLICATION LeT-1

d. Prepare the joint as defined by engineering. Repair all excessive gouges and nicks up to 3/16” by blending the metal by grinding. All discontinuities about 3/16” are to be restored to the original joint profile using the approved WPS for the structure. e. Clean the joint as defined above. f. Preheat the joint using guidelines defined in Figure 1, Figure 2 and Figure 3. g. Weld using requirements and techniques as described above. h. Visually inspect the weld during and after welding. If a defect is noted, refer to FIELD REPAIR OF A DEFECTIVE WELD to make the repair.

PROPER ELECTRODE SELECTION (refer to Figure 1 to determine class) Class

Electrode

1

E7018-1

2

E7018-1

3

E8018C3

4

E9018-M

5

E9018-M

FIELD WELDING Defined as any welding done outside of the original fabrication environment in which an item is being welded to the structure for the first time. a. Check with the engineering print to ensure dimensional accuracy. b. Determine the base metals being joined to determine the proper preheat and interpass temperatures (refer to Figure 1, Figure 2, Figure 3). c. Preheat the weld joint. d. Weld using described above.

requirements

and

techniques

e. Visually inspect the weld during and after welding. If a defect is noted, refer to FIELD REPAIR OF A DEFECTIVE WELD to make the repair.

FIELD REPLACEMENT WELD Defined as any welding done outside of me original fabrication environment in which an item is being welded to the structure to replace a worn or defective item. a. Before removing the old item, make any dimensional markings as needed. b. Preheat the area to be gouged to 250°F. c. Use Air Carbon Arc Gouging to remove the old item. Be sure not to damage the permanent items in the structure.

6

FIELD REPAIR OF A DEFECTIVE WELD Defined as any welding done outside of me original fabrication environment in which a structure is being welded on to repair a defective weld or base material. a. Determine the extent of the defect by using NonDestructive Examinations (NDE) such as Magnetic Particle Inspection (MT) or Liquid Penetrant Testing (PT). b. Preheat the area of the defect to be removed to 250°F. c. Use Air Carbon Arc Gouging to remove the defect. If the defect is a crack, remove the crack plus one inch past the termination of the crack. d. MT or PT the area to ensure the defect has been removed. e. Clean the weld joint as defined above. f. Preheat the joint using guidelines defined in Figure 1, Figure 2 and Figure 3. g. Weld using requirements and techniques described above. h. MT or PT and visually inspect the completed weld. If a defect is still detected, repeat Steps “a” through “h”.

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1


Class 1

Class 2

Class 3

Class 4

Class 5

A-36 EH36 A-106-B A500 1026 C1010 CMS10 Mild .33 Max Carbon

C23M (1506) NC23M (1517) C1035 A572 Gr-50

4820H N20 Cl-1 (1518) N20 Cl-2 (1518) N20 Cl-3 (1518) N20 Cl-5 (1518) M&M Class 2 (1512) M&M A/R (1512) A516-70 8720-H 4130

8630M NN30 (1508) N20 HS (1503) NN-20HS (1503) N20 Hi Moly (1504) N20 HMRB (1505) NN25 (1507) M&M Class 3 (1512) M&M Tubing (1511) N-20 Cl-6 (1518) A710 Class 1 A710 Class 3

N40 FSC (1510) A514-Q N30 FSC (1508) N30 LVR (1508) N30 HN (1509) N25HN HTF S1 (1516) 4340

Figure 1. MATERIAL WELDABILITY GROUPING

Material Thickness

Class 1

Class 2

Class 3

Class 4

Class 5

< or = 3/4”

100°F

100°F

125°F

175°F

200°F

>3/4” to 1-1/2”

125°F

150°F

225°F

225°F

250°F

>1-1/2” to 2-1/2”

150°F

225°F

250°F

275°F

300°F

>2-1/2”

225°F

300°F

300°F

325°F

350°F

Figure 2. PREHEAT REQUIREMENTS

Material Thickness

Class 1

Class 2

Class 3

Class 4

Class 5

< OR = 3/4”

500°F

500°F

500°F

450°F

450°

>3/4” to 1-1/2”

500°F

500°F

500°F

450°F

450°F

>1-1/2” to 2-1/2”

500°F

500°F

500°F

450°F

450°F

>2-1/2”

500°F

500°F

500°F

450°F

450°F

Figure 3. INTERPASS MAXIMUM

A5.1

Electrode

Maximum Exposure Time (hours)

Electrode

Maximum Exposure Time (hours)

E70XX

4

E70XX-X

4

E70XXR

9

E80XX-X

2

E70XXHXR

9

E90XX-X

1

E7018M

9

E100XX-X

1/2

E110XX-X

1/2

A5.2

Figure 4. MAXIMUM EXPOSURE TIME


COPYRIGHT 2001

LeTourneau, Inc.

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PUBLICATION LeT-1

NOTES ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________

8

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1


STRUCTURAL WELDING OF HIGH STRESS JOINTS The following procedure is provided as a generic procedure for the repair of cracks that may appear in the load bearing components of LeTourneau, Inc. Material Handling Equipment.

NOTE This procedure applies only to crack repairs. Replacement of a ball or socket should be done in accordance with the Lower Ball, Pivot Ball and Pivot Ball Socket Field Replacement Procedures.

Figure 5. GRINDERS

PREPARATION a. Steam clean the area to remove all contamination on weld joints. b. Clean the area to be welded of all rust, paint, oil, grease, dirt and/or mill scale.

ELECTRODE

c. Before any cutting or air carbon arc gouging is performed, ensure the area is dry.

GREATER THAN 3X DIAMETER WEAVE

d. Preheat the area around the crack to at least 250°F (121°C).

NOTE

NOT ACCEPTABLE FOR STRUCTURAL REPAIRS WEAVE WELD

1-NGO-2859, P03-53

If the crack is in a casting or a weld attached to a casting, the preheat is 350°F (177°C). The preheat area should extend 3” from the crack. Maintain the preheat temperature during the repair procedure.

Figure 6. WEAVE WELD

e. Use air carbon gouging to remove the crack. f. Test the area after arc air has been completed with die penetrant or mag particle to assure that the entire crack has been removed. Continue to air carbon arc gouge until the crack has been removed. g. Grind the entire gouged area (100%) so that the steel is free of any slag and carbon deposits. Shiny steel material should be visible in all parts. This can be done with either air powered or electric powered grinders as shown in Figure 5.

d. Bake previously opened packages of electrodes in a ventilated oven at 500°F (260°C) for two hours before using. e. Electrodes taken from cardboard boxes or a nonairtight container should also be baked at 500°F (260°C) for two hours in a ventilated oven. Then they should be placed immediately in a ventilated holding oven set at 225°F (107°C). f. Any electrode exposed to the air for more than four hours should be re-baked per the instructions above. g. Preheat the area to be welded with a heat blanket or torch to a temperature of 250°F (121°C).

WELDING a. Use AWS Class E7018-1 low hydrogen electrodes for the repair. These electrodes must be clean and dry. b. Control the moisture in low hydrogen electrodes by purchasing electrodes in 10 pound (4.5 kg) sealed packages. c. Remove only one hour’s supply of electrodes at a time. Keep the remainder in a ventilated holding oven at 225°F (107°C).


TA-10310

NOTE If the crack is in a casting or a weld attached to a casting, the preheat is 350°F (177°C). The preheat area should extend 3” from the crack. Check periodically and maintain the preheat temperature during the repair procedure. The temperature should be checked using heat crayons or heat sticks.

COPYRIGHT 2001

LeTourneau, Inc.

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PUBLICATION LeT-1

h. When welding use stringer beads. The bead width must be no wider than 3 times the rod diameter. Refer to Figure 7.

ELECTRODE

WELD BEADS

ELECTRODE

STRINGER BEAD WIDTH MAXIMUM 3X ELECTRODE DIAMETER BACKUP STRIP

MAX 3X

ROOT PASS BEAD STRINGER BEADS

ELECTRODE GREATER THAN 3X DIAMETER WEAVE WELD BEADS

STRINGER BEAD WIDTH OF BEAD = MAXIMUM 3X ELECTRODE DIAMETER 1-NGO-2860, P03-53

TA-10309

Figure 7. STRINGER BEAD

THIS WELD IS UNACCEPTABLE 1-NGO-2861, P03-53

i.

No weave welds are permitted. Refer to Figure 6.

TA-10311

Figure 8. BACKUP STRIP

j. Use a backup strip made from 1/4” thick mild steel (when practical) if the crack penetrates completely through the plate. Refer to Figure 8. k. Weld the root pass bead for the complete length of the bottom of the crack area. l. Remove the slag from the root pass with an air scaler or air chisel. m. To ensure that the root pass has no cracks, visually check the root pass weld. Use die penetrant or mag particle if a crack is suspected. If cracks are found, the root should be gouged out, edges ground smooth with a grinder and re-welded.

EACH PASS MUST BE COMPLETED FOR THE FULL LENGTH OF THE REPAIR AREA PRIOR TO BEGINNING THE NEXT PASS.

NOTE If there are problems with cracks in the root pass using the 7018 electrode, then it is permissible to use either 6013 or 6011 electrodes to make the root pass. n. Continue the bead for a full pass the length of the weld prior to beginning a second pass. Refer to Figure 9. o. Interpass temperature (temperature in the base material 1” away from the weld) should not exceed

10

1-NGO-2862, P03-

TA-10312

Figure 9. FULL PASS WELD 450°F (232°C). Use heat crayons or heat sticks adjacent to the weld to check temperatures. Refer to Figure 10. p. Starts and stops on each pass should each be in different locations from the previous passes. Refer to Figure 11.

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1

HEAT CRAYON OR HEAT STICK

FIELD WELDING PROCEDURE INTERPASS TEMPERATURE 1" AWAY FROM THE WELD

GRINDER

GRINDING TO BE ACROSS THE WELD DIRECTION

SMOOTH FINISH NO GRINDING MARKS 1-NGO-2863, P03-53

TA-10313

Figure 10. INTERPASS TEMPERATURE

1-NGO-2866, P03-53

TA-10316

Figure 13. WELD FINISHING

STARTS AND STOPS FOR EACH BEAD ARE STAGGERED IN DIFFERENT LOCATIONS 1-NGO-2864, P03-53

TA-10314

Figure 11. WELD STARTS AND STOPS q. Remove the slag after each pass with an air powered needle scaler or chipper. Refer to Figure 12. GRINDING DIRECTION ACROSS THE WELD MUST BE SMOOTH POLISH FINISH AFTER COMPLETION 1-NGO-2867, P03-53

TA-10317

Figure 14. WELD POLISHING r. Peen each bead, except for the root and cap passes, with the scaler or chipper to reduce stress concentrations. s. Grind the weld-repaired area to blend in with the adjacent base material. No undercut is allowed. Grind feed marks should not be visible when the grinding is finished. If necessary, polish with an emery wheel or disk. Refer to Figure 13 and Figure 14.

1-NGO-2865, P03-53

TA-10315

t. If surrounding air is above 40°F (5°C), post-heating after welding is NOT necessary. If surrounding air is below 40°F (5°C), post-heat the entire repaired area uniformly at 350°-400°F (177°-204°C) then air cool.

Figure 12. NEEDLE SCALER KIT, SCALERS


COPYRIGHT 2001

LeTourneau, Inc.

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PUBLICATION LeT-1

NOTES ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________

12

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1


UPPER BALL FIELD REPLACEMENT PROCEDURE accomplished by laying a straight edge on the ball base and measuring out from the side plate ring to the straight edge (refer to Detail “1”, Figure 15).

For upper ball field replacement, perform the following procedures: a. Before removing the damaged ball, a locating dimension must be established so that the new ball can be located properly. This dimension is taken from the shoulder of the ball base, across the weld joint, to the face of the side plate ring. Make three or four measurements around the ball (refer to View “A”, Figure 15). The shoulder of the ball base may have its corners beveled, as shown in Detail “1”. Make sure the locating dimension is taken from the original shoulder corner and not from the beveled corner. This can be

b. Scribe a mark around the weld joint 1/4” out from the side plate ring. This scribe mark is to be used when cutting off the ball base (refer to View “A”, Figure 15). c. Scribe a mark around the base of the ball 1-3/4” in from the outer diameter of the ball base. This scribe mark is to be used when cutting off the ball base (refer to View “A”).

SCRIBE LINE STEP "b" DO NOT CUT PAST THIS LINE WHILE CUTTING BASE OFF

REMOVE THIS SECTION WITH AIR ARC 1/4"

STEP "e"

TUBE BALL BASE SHIMMING DIMENSION

ORIGINAL WELD AREA

1-3/4"

STEP "h" DETAIL 2

B 1/4" SCRIBE LINE GRIND THE END OF THE TUBE CLEAN

STEP "c"

ADDITIONAL WELD WILL BE REQUIRED TO FILL THE ID OF TUBE WHERE AIR ARC UNDER CUT THE TUBE CUT

VIEW C

B

STEP "d" CUTS FOR

LOCATING DIMENSION

AREA REMOVED

STEP "f" & "I"

STEP "a"

LOCATION DIMENSION

STEP "e"

VIEW A

VIEW D AREA CUT

1-3/4" SCRIBE LINE

STEP "d"

BALL BASE

16,965

VIEW B

1/8" RADIUS - BOTH ENDS ORIGINAL SHOULDER CORNER

TOOL DRAWING

GAGE ROD - MAT. 1/4" ROUND HEIGHT OF

6 TO 8 FT. LOCATING DIMENSION

NEW BALL + 2" LIFTING LUG 1/2" PLATE

STEP "a" SIDE PLAE RING DETAIL 1 1" DIA. ROD

BALL INSTALLATION TOOL

1-NGO-1281, P08-24

1/4"

1" DRILL 7/16" DIA. HOLE MUST BE IN THE SAME PLANE AS THE LIFTING LUG. INSERT 3/8" x 2" BOLT FROM THIS SIDE

LOCATION FOR 1" FLAT WASHER TA6075CG

Figure 15. UPPER BALL FIELD REPLACEMENT


COPYRIGHT 2001

LeTourneau, Inc.

13


PUBLICATION LeT-1

2. Place the ball in liquid nitrogen and freeze for 30 to 40 minutes. Watch the position of the lifting lug on the ball installation tool so that the 3/8” X 2” bolt does not fall out.

d. Use air-arc to cut the ball off at the neck, as shown in View “A”. e. Use air-arc to cut the ball weld joint out. The intersection of the 1/4” and 1-3/4” scribe marks is used to locate the approximate root of the weld joint. Do not undercut past the 1/4” scribe mark (refer to View “A”, Figure 15). f. Make two air-arc cuts 90° from each other as shown in View “B”. Be careful not to cut into the tube. g. Remove the pie shaped section of the ball base. h. Before cutting and removing the other ball base section, determine the dimension between the bottom of the ball and the machined recess in the tube (refer to Detail “2”). A shim of this dimension will be used when installing the new ball. This dimension should be approximately 0.125”. i. Cut and remove the rest of the ball base section (refer to View “B”, Figure 15). j.

TUBE WELDING PREPARATION: 1. The end of the tube is to be replaced by grinding clean and welding up any air-arc undercut of the tube below the 1/4” scribe line. Preheat the weld area to 300° F (149°C) and weld with material listed in Step “o”, 1 (refer to View “C”). 2. Grind the end of the tube and, if necessary, grind the I.D. as the machine surface of the tube (refer to View “C”). 3. Install a shim, of your making, in the bottom of the machined recess in the tube. The thickness for this shim was determined in Step “h”.

k. INSTALLATION TOOL FABRICATION: 1. Fabricate the ball installation tool, as shown in tool drawings on Figure 15. 2. Make gage rod tool, as shown in tool drawing on Figure 15. l.

14

BALL FREEZING PROCEDURE: 1. Insert the installation tool through the new ball. Place a 1” flatwasher over the 1” rod and put a 3/8” X 2” bolt through the 7/16” hole. Do not put a nut on the 3/8” bolt.

m. TUBE EXPANSION: 1. Heat is required to enlarge the tube bore. The five-inch slab around the tube is to be heated first to about 300°F (149°C), and then the tube can be heated to 300°F (149°C). 2. Use the gage rod to check expansion of the tube. If gage rod will not go into tube, then increase slab and tube temperature by 25°F (4°C) and recheck with gage rod. n. BALL INSTALLATION PROCEDURE: 1. Be sure the shim install in Step “j”, 3 is still in place. Hoist the frozen ball into position and insert into the heated tube. You will have three to four minutes to locate the ball. The ball should bottom against the shim. Check the locating dimension obtained in Step “a”. This should be checked in three or four places around the ball. Reposition, as necessary, to hold this dimension until the ball temperature increases to the point that the ball is held snugly in place within the tube. This dimension must be held for proper ball location (refer to View “D” of Figure 15). 2. Allow the ball and tube to return to room temperature. 3. Rotate the ball installation tool until the 3/8” X 2” bolt falls out. Remove the installation tool. o. BALL WELDING PROCEDURE: 1. Preheat the weld area to 300°F (149°C) and maintain this temperature while welding out the joint. Arc weld with 1/8” diameter E-8018C1 electrodes or MIG weld with TriMark TM-911N2 flux cored wire. The electrodes must have been stored in a sealed container and heated in a 250°F (121°C) oven for 30 minutes before welding. Do not weave weld. 2. The cap passes must be blended smooth. If not, they must be ground smooth. 3. Paint the repair area.

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1


LOWER BALL FIELD REPLACEMENT PROCEDURE The following procedure is set forth for the field replacement of the lower ball structure. a. Before removing the damaged ball, a locating dimension must first be established so that the new ball can be located. This dimension is taken from the edge of the side plate ring to the shoulder of the base ball. b. Scribe a mark around the weld joint one inch out from the side plate ring. Do not cut past this line when cutting the ball off. See View “A”, Figure 16. c. Scribe a mark around the base of the ball 1-13/16” in from the outer diameter of the ball base. d. Use air-arc to cut the ball weld joint out. Do not cut past the one-inch reference line at the surface. The 113/16” reference line and the 2-9/16” depth dimension can be used to locate the root of the weld joint. e. The end of the tube is to be repaired by grinding clean and welding up the air-arc undercut with E-8018C1 electrodes. Preheat to 300°F (149°C) before welding. Do not over weld I.D. or it will have be ground by hand.

f. Grind the end of the tube clean and if necessary grind the I.D. of the tube to the same I.D. as the machined surface of the tube. See View “B”, Figure 16. g. Install spacer ring in the tube bore to provide positive stop when installing ball. h. Install new ball. It should be loose fit into the tube. If heat is required to enlarge the tube bore, the side plate is to be heated first to about 300°F (149°C) and then the tube can be heated to 300°F (149°C). i. Use the dimension obtained in Step “a” to locate the new ball in the end of the tube. Tack weld in place four places. See View “C”, Figure 16. j. Preheat the area to 300°F (149°C) and maintain this temperature while welding out the joint. k. Use 1/8” diameter E-8018C1 electrodes that have been stored in a sealed container and heated in a 250°F (121°C) oven for 30 minutes to weld the joint. Do not weave the electrode more than 1-1/2” times the diameter of the rod. l. The cap passes must be blended smooth. If not, they must be ground smooth. m. Paint the repair area.

Figure 16. LOWER BALL FIELD REPLACEMENT


COPYRIGHT 2001

LeTourneau, Inc.

15


PUBLICATION LeT-1

NOTES ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________

16

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1


PIVOT BALL FIELD REPLACEMENT PROCEDURE For replacement of the pivot ball, perform the following procedures: a. Separate the pivot ball from the pivot socket as described in the FRONT FRAME REMOVAL, in Section 1, STRUCTURAL, in the REPAIR AND OVERHAUL MANUAL. b. Clean the repair area free of dirt and grease. c. Preheat cross-member to 200°F (93°C) and cut off old ball. d. Repair any gouges or cracks in the slab while it is still hot, using dry E-8018C electrodes. (If E-8018C electrodes are not available, E-70l8 electrodes are acceptable, but only for slab repairs.

first three root passes. Finish the weld by completing each layer all the way around the ball before starting on the next layer. (Rod size is not important after the first three passes). Tri-Mark TM-911N2 gas shielded flux cored wire may be used for all welding. i. Do not exceed 400°F (204°C) in the neck area of the ball at any time and never contact the carburized area with the torch. Do not allow the heat transference to cause the temperature of the ball to exceed 300°F (149° C). j. Extend the weld out from the edge of the ball 1-3/8” and blend smooth the slab by grinding.

e. Grind cross-member surface smooth.

k. Wrap the ball and cross-member to extend the cool down time. Ball must cool down to at least 100°F (38°C) before reassembling.

f. Place a 1/16” diameter copper wire around the ball base. Space wire away from the edge of the ball base so the wire does not melt into the weld. Refer to Figure 17.

l. Follow the PIVOT BALL SOCKET REPLACEMENT PROCEDURE. One socket must be removed and reinstalled to insure correct alignment and preload with the new ball.

g. Preheat the slab around the perimeter of the ball base until the ball base temperature is 300°F (149°C). Do not exceed this temperature.

m. Clean and paint the repaired area.

h. Weld the ball base to the cross-member using dry E-8018C electrodes. Use a 1/8” diameter rod for the

n. Follow the re-assembly procedures outlined in Section 1, STRUCTURAL, in the REPAIR AND OVERHAUL MANUAL.

BEVEL AROUND BALL BASE

3/8 in. MINIMUM

PILOT STUD

1-NGO-1284, P08-25

1/16 in. DIA. WIRE WIRE PART #151-0182

TA8246CG

Figure 17. PIVOT BALL REPLACEMENT


COPYRIGHT 2001

LeTourneau, Inc.

17


PUBLICATION LeT-1

NOTES ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________

18

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1


PIVOT BALL SOCKET FIELD REPLACEMENT PROCEDURE To replace the pivot ball socket, perform the following procedures: a. Separate the front and rear halves of the machine as described in FRONT FRAME REMOVAL, in Section 1, STRUCTURAL, in the REPAIR AND OVERHAUL MANUAL. If the pivot ball is also being replaced, replace the pivot ball first. Refer to PIVOT BALL FIELD REPLACEMENT PROCEDURE. b. Clean the repair area free of dirt and grease. c. Preheat the cross member to 200°F (93°C). Cut the weld from around the socket using air-arc. Refer to Figure 18 and dimensions of the new socket for depth and angle of cut in cross-member. d. Bevel slab as shown in Figure 18. e. Repair cracks and gouges in slab while it is still hot, using dry E-8018C1 electrodes. (If E-8018C1 electrodes are not available, E-7018 electrodes are acceptable). f.

Clean up notch in slab for re-welding.

g. Measure and record the dimension between the upper and lower cross-members that the pivot balls mount to. The measurement should be as close to ball centerline as possible. The measurement must be .001 inch.

k. Heat the socket and cross-member area adjacent to the socket to 250°-350°F (121°-177°C) and tack firmly into place using dry E–8018C1 electrodes or TriMark TM-911N2 gas-shielded flux cored wire. l. E-8018C1 electrodes, 1/8” diameter, should be used to make the first three root passes. Finish each root pass by completing each pass all the way around the socket before starting the next pass. Rod size may be increased after the first three root passes are completed. Welds are to be stringer beads, not weave welds. Tri-Mark TM-911N2 gas-shielded flux cored wire may also be used for all welding. m. Wrap the cross-member and the socket to extend the cool-down time. Allow to cool to at least 100°F (38°C) before proceeding further. n. Disassemble the ball cap and socket to install shims. Follow the re-assembly procedure outlined in ASSEMBLY OF REAR FRAME TO FRONT FRAME AND BALL CAP SHIMMING PROCEDURES, located in Section 1, STRUCTURAL, in the REPAIR AND OVERHAUL MANUAL. Be sure to check the steering pivot ball cap shim tolerance as indicated in this section.

h. Hoist the ball cap and socket up to the ball base and install around ball base using new liners. Omit the spacer and shims between the ball cap and socket, and snug up the capscrews. i. Join the machine halves together allowing the socket to seat firmly against the rear of the notch in the slab. j. Using a jack underneath the lower ball and socket, push until the cross-member deflects to .010-inch minimum and .015 inch maximum. Reference dimensions in Step “g”.

Figure 18. PIVOT BALL SOCKET REPLACEMENT


COPYRIGHT 2001

LeTourneau, Inc.

19


PUBLICATION LeT-1

NOTES ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ 20

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1


JC-40SS A-FRAME TIE PLATE INSTALLATION The following procedure is for installing tie plates to repair loose A-frame pin bores on JC-40SS Cranes.

NOTE Before beginning these repairs, review WARNINGS AND CAUTIONS. All weld and heat treat procedures used in these repairs should be per the welding instructions, located in STRUCTURAL WELDING OF HIGH STRESS JOINTS. Use 7018 electrodes.

INSTALLATION OF A-FRAME TIE PLATES a. Move trolley to the outer end of the boom. This places the counterweight boom cables in tension and places the A-frame pins in a partially loaded configuration. 1. After positioning trolley, lock out control systems to prevent accidental crane operation. 2. Position ground leads close to repair area to prevent possible damage to crane electronics. 3. Inspect A-frame ears and I-beam areas for any cracks to be repaired before proceeding. Use non-destructive test methods. b. Install two tie plates, P/N 413-9717 (inside) and 413-4779 (outside) on each A-frame leg. Refer to Figure 19.

NOTE

1. The tie plate slots (1-5/8”) may require trimming to fit the ears of the base beam. After trimming, grind smooth all torch marks and bevel edges as required. Refer to Figure 19. Ensure plates are installed on the correct sides of A-frame legs. 2. Weld tie plates on the counterweight boom side according to welding installation procedures shown in Figure 20, Figure 21 and Figure 22. 3. The weld areas in the center of the plate should be free of flaws and imperfections. Grind if necessary.

!

CAUTION

DO NOT WELD TO THE TOP FLANGE OF THE BASE BEAM. 4. Grind smooth all repaired areas and check for cracks. 5. Paint all repaired areas. 6. Inspect at P.M. intervals.

NOTE Although not expected to be required, the same procedure applies to the boom side A– frame pin configurations.

USE SINGLE WELD PASS ONLY. DO NOT USE WEAVE WELDS.

NOTES ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________


COPYRIGHT 2001

LeTourneau, Inc.

21


PUBLICATION LeT-1

A-Frame

Boom

A-Frame Pin Locations

Counterweight Boom

1-NGO-2070, P10-94 TA-9347-CG

Figure 19. A-FRAME PIN LOCATIONS

22

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION LeT-1


The 1-5/8" slot will be fitted to the crane. Grind smooth any torch marks. Prepare a 3/4" bevel for weld.

P/N 413-9717 Tie Plate, Inside A-Frame

The 1-5/8" slot will be fitted to the crane. Grind smooth any torch marks. Pepare a 3/4" bevel for weld.

P/N 413-4779 Tie Plate, Outside A-Frame

1-CG-2071, P10-94 TA-9348-CG

Figure 20. A-FRAME TIE PLATES


COPYRIGHT 2001

LeTourneau, Inc.

23

PUBLICATION LeT-1 LETOURNEAU, INC. FIELD WELDING PROCEDURE MATERIAL HANDLING EQUIPMENT LIST OF ILLUSTRATIONS

TABLE OF CONTENTS PAGE

PAGE

SCOPE OF THIS PUBLICATION.................................................. 1

Figure 1.

MATERIAL WELDABILITY GROUPING ..................7

WARNINGS AND CAUTIONS ...................................................... 3

Figure 2.

PREHEAT REQUIREMENTS ..................................7

GENERAL WELDING PRACTICES.............................................. 5

Figure 3.

INTERPASS MAXIMUM ..........................................7

Figure 4.

MAXIMUM EXPOSURE TIME .................................7

Figure 5.

GRINDERS .............................................................9

Figure 6.

WEAVE WELD ........................................................9

PREHEAT AND INTERPASS TEMPERATURES...................... 5 ELECTRODE STORAGE AND HANDLING .............................. 5 CERTIFIED WELDERS AND APPROVED WPS....................... 5 WELDING TECHNIQUES......................................................... 5 CLEANING REQUIREMENT .................................................... 5 WELDING DEFECTS ............................................................... 5

Figure 7.

STRINGER BEAD ................................................. 10

Figure 8.

BACKUP STRIP .................................................... 10

Figure 9.

FULL PASS WELD................................................ 10

FIELD WELDING...................................................................... 6

Figure 10.

INTERPASS TEMPERATURE............................... 11

FIELD REPLACEMENT WELD................................................. 6

Figure 11.

WELD STARTS AND STOPS................................ 11

PROPER ELECTRODE SELECTION ....................................... 6

FIELD REPAIR OF A DEFECTIVE WELD ................................ 6

Figure 12.

NEEDLE SCALER KIT, SCALERS ........................ 11

STRUCTURAL WELDING OF HIGH STRESS JOINTS................ 9

Figure 13.

WELD FINISHING ................................................. 11

PREPARATION ........................................................................ 9

Figure 14.

WELD POLISHING................................................ 11

WELDING................................................................................. 9

Figure 15.

UPPER BALL FIELD REPLACEMENT .................. 13

UPPER BALL FIELD REPLACEMENT PROCEDURE ............... 13

Figure 16.

LOWER BALL FIELD REPLACEMENT ................. 15

Figure 17.

PIVOT BALL REPLACEMENT............................... 17

Figure 18.

PIVOT BALL SOCKET REPLACEMENT .............. 19

Figure 19.

A-FRAME PIN LOCATIONS .................................. 22

JC-40SS A-FRAME TIE PLATE INSTALLATION....................... 21

Figure 20.

A-FRAME TIE PLATES ......................................... 23

INSTALLATION OF A-FRAME TIE PLATES........................... 21

Figure 21.

WELDING INSTALLATION.................................... 24

Figure 22.

WELDING INSTALLATIONS ................................. 24

LOWER BALL FIELD REPLACEMENT PROCEDURE ............. 15 PIVOT BALL FIELD REPLACEMENT PROCEDURE................. 17 PIVOT BALL SOCKET FIELD REPLACEMENT PROCEDURE ............................................................................. 19

SCOPE OF THIS PUBLICATION Publication LeT-1, FIELD WELDING PROCEDURES, provides instructions for welding structural components on all LeTourneau, Inc. Log Stackers, Straddle Hoists, Side Porters, Jib Cranes, Marine Cranes and Letro-Pik Aircraft Cranes. To avoid personal injury or damage to machine components, it is essential to follow the instructions in this publication.


COPYRIGHT 2001

LeTourneau, Inc.

1


PUBLICATION LeT-1

A-Frame Structure

Tie Plate P/N 413-9717 Tie Plate P/N 413-4779

Weld Areas (both sides of eye) Typ

I Beam 1-NGO-2072, P10-94

TA-9349-CG

Figure 21. WELDING INSTALLATION

A-FRAME TYP

413-4779 TIE PLATE

413-9717 TIE PLATE

TYP NO WELD TYP

1-NGO-2073, P10-94 TA-9350-CG

Figure 22. WELDING INSTALLATIONS

24

COPYRIGHT 2001

LeTourneau, Inc.


PUBLICATION ROMĆ6


AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS) DESCRIPTION OF OPERATION The purpose of the Automatic Overload Protection System (AOPS) is to automatically (no operator interĆ vention required) relieve hoist line tension in the event of a sensed gross overload on the hook. If the crane experiences an overload of 140% (user adjustable) or more of maximum rated load, the Wylie loadĆmoment system termination unit board will signal the Gross Overload Sense card (mounted on the upper rightĆhand side wall of the cab relay box) to apply 24V to wire GOL. Wire GOL applies 24V to the hoist controller, which turns on the Gross Overload Light and causes the hoist motor to automatically come to a stop (if moving), regardless of operator control inputs. The hoist controlĆ ler then energizes CR44, which energizes SOL1 (Brake Master Solenoid) and SOL8. The hoist controller also energizes CR44A, which energizes SOL9. SOL8 and SOL9 route hydraulic pressure away from the top brake canisters of the main and auxiliary hoist motors respectively and to the proportional relief valve soleĆ noids, SOL3 and SOL5 (see machine hydraulic scheĆ matic). Since no current is sent to energize SOL3 or SOL5 (these are only energized during Power Loss Lowering System (PLLS) events), all hydraulic pressure to the top canisters is bypassed to tank through SOL3 and SOL5, and the top canisters remain fully set. At the same time, the hoist controller will also energize CR43, which energizes either SOL2 if the main hoist is selected, or SOL4 if the auxiliary hoist is selected, This applies full hydraulic pressure to the selected motor's bottom brake canister, releasing it fully. The end result is that when the AOPS is triggered by the Wylie system, the top brake canister of the selected hoist motor will be fully set, and the bottom brake canister will be fully released, resulting in a holding force of approximately 150% of maximum rated load. If a true gross overload exists, the load will pull through the one brake canister without causing structural damage to the crane.

4ĆROM 6.2e, Gorilla 9/25/01

This system is required by Norwegian Petroleum Directorate (NPD) regulations for North Sea operations, and may be disabled for other operations by positioning the Overload Protection switch to Reset, and positionĆ ing the rightmost circuit breaker in the cab junction box (CB28) to the open (down) position. OVERLOAD PROTECTION SWITCH - Leave in Reset (AOPS disabled) unless told otherwise. If told otherwise: • Overload Protection Switch ................................ON • Overload Protection Active Light (Green) ...........ON To Reset the AOPS after an Activation: • Overload Protection Switch ..................Reset • Gross Overload Light............................OFF • Overload Protection Active Light ...........OFF • Overload Protection Switch ...................ON • Overload Protection Active Light.............ON NOTES: a. A flashing Gross Overload Light indicates that the AOPS has malfunctioned and has disabled itself. Clear the malfunction indication by taking the Overload Protection Switch to Reset and back to On. b. A flashing Hoist Brakes Light indicates that a brake is dragging. This indication is generated by pressure switches mounted on each hoist brake canister. Stop hoisting until proper release of both hoist brake canisters has been verified. c. The AOPS needs to be tested every six months. Refer to Publication OSMĆ4 (Preventive Maintenance Requirements and Recommendations) in the Operating and Service Manual. The AOPS needs to be recaliĆ brated if the Wylie loadĆmoment system is recalibrated. See AOPS TEST AND CALIBRATION PROCEDURE of this document.

COPYRIGHT 2002

LeTourneau, Inc.

83

PUBLICATION ROMĆ6


AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS) TEST AND CALIBRATION PROCEDURE TEST PROCEDURE To fully operationally test the AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS) would require actually grossly overloading the crane, which is not a desirable situation. The best alternative is to simulate a gross overload and confirm that the proper system response take place. a. Position the hooks to a safe area. Remove the cover from the Wylie load moment box in the cab. Position the hook select switch to MAIN. Connect a potentiometer (5k ohm ideal) or decade resistance box across terminals T2 and T6 on the Wylie circuit board. Varing the resistance across these terminals will artificially cause the load readout on the Wylie display to change. Turn the Overload Protection Switch and the Master Switch to ON. Adjust the resistance until the Gross Overload Light comes on (approximately 2.8k ohms, start with high resistance and work down). This should happen at approximate 140% of maximum rated load (210,000 lbs. on the display for the PCM350 (maximum rated load = 150,000 lbs.); 140,000 lbs. for the PCM120 (maximum rated load = 100,000 lbs)). Visually check that the top canister of the main hoist motor brake remains set, that the bottom canister releases fully, and that LED 3 on the hoist controller (GOL Veac Disable, visible through the window in the hoist controller front cover) illuminates. The external cab mounted alarm and the machinery house mounted alarm, which should already be sounding from an overload greater than 100%, will change from their normal tones to a pulsating tone, indicating an AOPS activation. Clear the alarms with the Acknowledge Horn Button, remove the added resistance, switch to Aux Hoist, and take the Overload Protection Switch to RESET and then back to ON. b. To test the AOPS on the Auxiliary hook, connect the resistance across terminals T8 and T6 on the Wylie circuit board. Increase the displayed load by varing the

4ĆROM 6.2e, Gorilla 9/25/01

resistance until the Gross Overload Light comes on (approximately 900 ohms, start with high resistance and work down). This should happen at approximately 140% of maximum rated load (28,000 lbs. on the display for both the PCM350 and PCM120 (maximum rated load = 20,000 lbs)). Visually check that the top canister of the aux hoist motor brake remains set, that the bottom canister releases fully, and that LED 3 on the hoist controller (GOL Veac Disable, visible through the window in the hoist controller front cover) illuminates. The external cab mounted alarm and the machinery house mounted alarm, which should already be soundĆ ing from an overload greater than 100%, will change from their normal tones to a pulsating tone, indicating an AOPS activation. Clear the alarms with the AcknowlĆ edge Horn Button, remove the added resistance, and take the Overload Protection Switch to RESET. CALIBRATION PROCEDURE If necessary, the gross overload trip point for each hook can be adjusted by pots on the Gross Overload Sense Card (P/N 422Ć7381). This card is mounted on the inside rightĆhand wall of the cab junction box; bottom pot calibrates the main hook, top pot calibrates the aux hook. Adjusting a pot CW raises the trip point, CCW lowers the trip point. To calibrate the AOPS trip point for a given hook, turn the appropriate pot on the Gross Overload Sense Card fully CW (maximum trip point). Adjust the appropriate load readout with a variable resistor as described in the test procedure above to the desired gross overload trip level (factory recommendation is 140% of maximum rated load). Adjust the Gross Overload Sense Card pot CCW until the Gross Overload Light comes on and the Gross Overload alarms sound. The AOPS for this hook is now calibrated. Reset the AOPS, and test the calibration for accuracy as deĆ scribed in the test procedure above.

COPYRIGHT 2002

LeTourneau, Inc.

85

14

ON

SS8

BLK

WARNING

BLK PB3

HORN

BLK PB9

ACKNOWLEDGE

LEFT

SWING

LT9 POWER ON

BAT SS1

BLK

OFF

1ĆCGĆ2458, P02Ć22

LeTourneau, Inc.

COPYRIGHT 2002

6

5

MASTER

RIGHT

LT3

GREEN

ON

DRIVE SYSTEM FAIL

RUN

RED LT4 SWING BRAKE ENGAGE

LT8

WARNING

BOOM LOWER LIMIT OVERRIDE

POWER LOSS HOIST LOWER

SPEED/TEMP

RED PB8

RED

LT3

AMB

2

RED

LIGHTS

OFF

1

7

LT1

SET

SS3 BRAKE

LT34

RED LT23 SS2

LT7

AUX

BOOM

SLACK WIRE ROPE

LT5

LIMIT SWITCHES

HOIST SELECT

MAIN

RAISE

LOWER

LT24

AMB

LT6

AMB

4

HOIST BRAKE HYD. PRESS.

GREEN

AUX

EMERGENCY HOOK RELEASE

ENABLE

RED

RUN

HOIST

GREEN

MAIN

SS7

ON

RED ONCONSTANT TENSION

OFF

SS6 OFF

BAT

3

RUN

EMERGENCY STOP

PB2

RED

LT2

GREEN

9

8

ELECTRIC DECK CRANE SAFETY INSTRUCTIONS PUBLICATION OSMĆ2

FIGURE 1. IDENTIFICATION GROUP (Sheet 1 of 7)

TAĆ9580Ć6

1ĆOSM 2.2a, 120SS Gorilla 7/13/99

ELECTRIC DECK CRANE SAFETY INSTRUCTIONS

11

10

WALL “M”

WALL “G”

12

13

14

PUBLICATION OSMĆ2

FIGURE 1. IDENTIFICATION GROUP (Sheet 2 of 7) 1ĆCGĆ2459, P02Ć22


TAĆ9734Ć6 COPYRIGHT 2002

LeTourneau, Inc.

15

14 15

14

8

É É

16

18

WALL “B”

19

17

18

19

PUBLICATION OSMĆ2

18



16


LeTourneau, Inc.


14

10

20

21

10

18

22

22

23 9ĆCGĆ2454-1, Ldgr2Ć39Ć1

9ĆOSM 2.2 (FOĆ1) 120SS Gorilla 09/20/01

FIGURE 1. IDENTIFICATION GROUP-120SS (4 of 7)

COPYRIGHT 2002

LeTourneau, Inc.

TAĆ9739Ć6

17

23

23

23 23

FIGURE 1. IDENTIFICATION GROUP (5 of 7) 1ĆCGĆ2462, LdgrĆ40

9ĆOSM 2.2, FOĆ2, 120SS Gorilla 09/20/01

TAĆ9738Ć6

COPYRIGHT 2002

LeTourneau, Inc.

19

PUBLICATION OSMĆ2

1


CONSTANT TENSION OPERATION

2

WARNING

POWER LOSS HOIST LOWER OPERATION

For use during crane power loss situations to lower load at a constant speed. Emergency Hoist Release Switch: OFF Before activating : Constant Tension Switch: OFF (1) Inspect Power Loss Lowering Card, thermocouples Master Switch: BAT and temperature transmitters as per OSM-4. FLASHING Power On Light: (2)Place a man in the machinery house to monitor Brake Switch: ENABLE Power Loss Hoist Lower Button: PRESS and HOLDthe brakes and notify the operator to stop if brakes begin overheating. Hoist Joystick: LOWER

For use (AUX HOIST ONLY) when a load is on the deck of a vessel that is pitching up and down due to wave motion. NORMAL

Emergency Hoist Release Switch: Master Switch: Power On Light: Hoist Select Switch: Brake Switch: Constant Tension Switch: Constant Tension Light:

OFF ON ON AUX ENABLE ON ON

POWER LOSS OFF BAT FLASHING AUX ENABLE BAT ON

DO NOT USE THE BOOM LOWER LIMIT OVERRIDE BUTTON WITH LOAD IN THE HOOK(S)

6

!

7

BEFORE OPERATING MACHINE, STUDY THE OPERATING AND SERVICE MANUALS. READ ALL SAFETY SIGNS ON MACHINE. CLEAR THE AREA OF THE OTHER PERSONS. LEARN AND PRACTICE SAFE USE OF CONTROLS BEFORE OPERATING.

EMERGENCY HOIST RELEASE 3

OPERATION For use if the hook becomes entangled in a vessel that is moving away from the crane. POWER NORMAL LOSS Master Switch: Power On Light: Emergency Hoist Release Switch: Emergency Hoist Release Light:

4

ON ON ON ON

It is the operator’s responsibility to understand and follow the manufacturer’s instructions on machine operation, service and to observe pertinent laws and regulations. Maintenance Manuals and Operating & Service manuals, may be obtained through your equipment dealer. LeTourneau, Inc. P/N 422–1605

BAT FLASHING ON ON

8

KG KIPS 45359.7 100

NEUTRAL BUS (BLOCK) IS NOT USED WITH TWO–POLE BREAKERS

40823.7 90 36287.7 80

120VAC 31751.7 70

22679.8 50

LeTourneau, Inc P/N 622–8869 CAPACITY

27215.8 60

18143.8 40

9

13607.9 30 9071.9 20 4535.9 10

0 REACH FEET REACH CM

20 30 40 50 60 70 80 90 100 110 103108 762.0 914.4 1219.2 1524.0 1828.8 2133.6 2438.4 2743.2 3048.0 3352.8

10 MAIN HOIST (4)(2)(1) LINE LIFT MIN– REACH 22.0 FT MAX SWL 98,400 LBS.

LeTOURNEAU PCM–120 CRANE

5

W/100 FOOT BOOM

BOOM ANGLE

REACH FEET

SWL (LBS.) 4 PART LINE



___

____

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_____

_____

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_____

___

____

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____

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___

____

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_____

___

____

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_____

_____

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____

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_____

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___

____

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_____

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___

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_____

_____

_____

___

____

_____

_____

_____

ELECTRICAL EQUIPMENT AUTHORIZED PERSONNEL ONLY

11

EQUIPMENT OPERATED BY REMOTE CONTROL




LeTourneau, Inc.

21


PUBLICATION OSMĆ2

! API SPEC 2C

12

FIFTH EDITION 1995

DATE MANUFACTURED

18 MANUFACTURER’S MODEL NO. DESIGN SERVICE TEMPERATURE

DEG.C.

MANUFACTURER SERIAL NUMBER MANUFACTURED BY

P.O. BOX 2307 LONGVIEW,TEXAS 75606

ADDRESS

HAZARDOUS VOLTAGE Can shock, burn, or cause death. Turn power off before servicing motor.

!

Hazardous A.C. voltage can be at terminals when motor is stopped.

13

LeTourneau, Inc.

HAZARDOUS VOLTAGE

P/N 414–9157

CAN CAUSE SHOCK, BURN OR DEATH

!

OPEN 600 VOLT DRIVE MOTOR FEEDER CIRCUIT BREAKERS IN POWER DISTRIBUTION PANEL

19

BRAKE DISC ON ELECTRIC MOTORS MAY BE HOT. BRAKE DISC WILL ROTATE IF MOTOR IS ENGAGED

LeTourneau, Inc P/N 422–8870


14 20

600 VOLTS LeTourneau, Inc P/N 423–4939

21 15

THIS EQUIPMENT IS SUPPLIED BY MORE THAN ONE POWER SOURCE

CRANE SN PC1 SWL 7.43 T 6.7° SWL 49.20 T 80.3° MANUFACTURED BY: LeTourneau, Inc. DATE PC 120 SN SWL REACH TONS FEET 49.20 22 7.43 103

BOOM ANGLE 80.3° 6.7°

22

LOW HEADROOM

16

DO NOT OPERATE CRANE WITH HATCH CLOSED

LeTourneau, Inc.

P/N 423–7045

LeTournean, Inc P/N 422–8868

23

! 17

HIGHLY LOADED SPRING INSIDE THIS HOUSING CAN CAUSE SERIOUS PHYSICAL INJURY OR DEATH DO NOT REMOVE SCREWS

! LADDERS: FALLING HAZARD Can cause serious injury or death. WATCH YOUR STEP. WATCH FOR WIND GUSTS.


ALWAYS face ladder when climbing up or down. Keep one hand firmly on ladder or handhold at all times. Keep ladder rungs, steps and platforms clean – free of grease, oil, etc. LeTourneau, Inc.

P/N 421–7858


22


LeTourneau, Inc.


PUBLICATION OSMĆ2


CRITICAL COMPONENTS The following is a list of components of the crane which should be considered as critical components." These components are ones which affect the safety of the crane from a structural and load hoisting standpoint. These components should be of prime concern to the deck operators supervisor, operator and maintenance personnel with regards to certification, inspection, maintenance and prompt repair per the appropriate guidelines. Instructions for the maintenance and repair of these components are included in the OPERATING AND SERVICE MANUAL and the REPAIR AND OVERĆ HAUL MANUAL for the crane.

D Electric drive motors for hoist, boom, and swing

CRITICAL STRUCTURAL COMPONENTS D Boom chord members D Boom section connection components D Boom foot pins D Primary load members of gantries, masts and AĆframes D Load transfer members of the rotating upper strucĆ ture D Pedestal and swing circle transition pieces

CRITICAL MECHANICAL COMPONENTS D All linkage between the brake control element and the component to be controlled. D Hoist, boom and swing brake systems D Drums, shafts, and gears of hoisting and swing systems

CRITICAL RIGGING COMPONENTS D All running wire ropes in hoist system D All standing wire rope in load restraint and support system D Hook block assembly

D Slewing or swing bearing and gear

D Wire rope deadĆend connection devices

D Wire rope sheaves and sheave shafts

D Floating harness or bridle assemblies

NOTES


COPYRIGHT 2002

LeTourneau, Inc.

13

PUBLICATION OSMĆ2


FORM H" LOAD DIAGRAM SEE CERTIFICATE NO. _____________________________ FOR THE APPROVED CONDITIONS FROM THE ATTACHED LOAD CHART, WHICH HAVE BEEN SURVEYED AND TESTED AS A UNIT AFTER INSTALLATION ONBOARD THE _____________________________. AUX. HOIST SB 1 INCH WIRE ROPE 57.5 TONS BREAKING STR. DYFORM 18 HSLR ROTATION RESISTANT SINGLE SHEAVE

BRIDLE PENDANTS 1Ć3/4 INCH WIRE ROPE 6 X 26 IWRC EIPS 168 TONS BREAKING STR. TWO SHEAVES

LUFFING 1 INCH WIRE ROPE 62.5 TONS BREAKING STR. CONSTRUCTEX

THREE SHEAVES T.B., SWL

SINGLE SHEAVE

R D.B. S.W.L. TWO SHEAVES

THREE SHEAVES

HOOK LOAD 20,000 LB UNDER HOOK

SINGLE SHEAVE SINGLE SHEAVE

Lw

HOOK LOAD 98,400 LB. UNDER HOOK MAIN HOIST DB, 1 INCH WIRE ROPE 70.03 B.S., DYFORM 34 LR, GR 2160 ROTATION RESISTANT

Lw Lw (1)

The attached load chart indicates the approved hook safe working loads and the approved rigging arrangements which may be certificated under the requirements of the American Bureau of Shipping.

(2)

Where sheaves are built into the structure they shall be treated as structural parts and need not be tested and certificated as loose gear.

(3)

The S.W.L. to be marked on the blocks should be indicated on this diagram.

(4)

S.W.L. = SAFE WORKING LOAD S.B. = SINGLE BLOCK D.B. = DOUBLE BLOCK T.B. = TRIPLE BLOCK R = RESULTANT LOAD Lw = LINE PULL TO THE WINCH HOOK AND BLOCK WT OF 1600 LB HAS BEEN DEDUCTED FROM THE MAIN HOIST HOOK LOAD.

PCM 120SS CRANE TAĆ8878ĆCG

1ĆCGĆ1585, P10Ć30, 5/8/00

9ĆOSMĆ2.2b.1, 120SS Gorilla 8/21/01

COPYRIGHT 2001

LeTourneau, Inc.

InsertĆ1


Insert -2

PUBLICATION OSM-2

COPYRIGHT 2002

LeTourneau, Inc.

7-OSM-2.2b.1, 120SS Gorilla (MSWord) REVISION: 05-01-02

PUBLICATION OSMĆ2



COPYRIGHT 2001

LeTourneau, Inc.

InsertĆ3


PUBLICATION OSMĆ2



HOOK SHEAVE WHEELS

HOOK CABLE DRUM

PCM 120SS CRANE MAIN HOOK CABLE REEVING SCHEMATIC TAĆ8926ĆCG

1ĆCGĆ1586, P10Ć30, 5/4/00

COPYRIGHT 2001

InsertĆ4

LeTourneau, Inc.


PUBLICATION OSMĆ2


6

FLOATING SHEAVE HOUSING

4

2

5

DEAD END 3 1” WIRE ROPE (9 x 40 CONSTRUCTEX) 460” LONG, 62.5 TONS B.S. 1

GANTRY SHEAVE HOUSING

BOOM UP CABLE DRUM

PCMĆ120SS CRANE BOOM UP CABLE REEVING SCHEMATIC

TAĆ8928ĆCG

1ĆNGOĆ1588, P10Ć30, 5/8/00


COPYRIGHT 2001

LeTourneau, Inc.

InsertĆ5


PUBLICATION OSMĆ2

GUIDE SHEAVE WHEEL JIB BOOM SHEAVE WHEEL

1” WIRE ROPE (19 X 19) 550’ LONG, 57.5 TONS B.S.

10 TON HOOK

AUX. HOOK CABLE DRUM

PCM 120SS CRANE AUXILIARY HOOK CABLE REEVING SCHEMATIC

1ĆCGĆ2465, P10Ć30


InsertĆ6

LeTourneau, Inc.


WORKING RADIUS (FT.)

BOOM ANGLE (DEG.)

22.0

STATIC AND DYNAMIC SAFE WORKING LOAD IN KIPS

PERSONNEL SAFE WORKING LOAD IN KIPS

4ĆPART LINE DYNAMIC 2.00

2ĆPART LINE STATIC 1.33




4ĆPART LINE

2ĆPART LINE

1ĆPART LINE

80.3

98.40a

65.06h

48.40a

48.40a

23.40a

23.40a

32.32f

23.60a

11.00a

25.0

78.5

94.24f

62.29f

48.40a

48.40a

23.40a

23.40a

30.34f

23.60a

11.00a

30.0

75.6

79.10g

52.20g

48.40a

48.40a

23.40a

23.40a

25.30g

23.60a

11.00a

35.0

72.6

67.46g

44.44g

48.40a

48.40a

23.40a

23.40a

21.42g

23.41g

11.00a

69.5

58.95g

38.77g

48.40a

41.72g

23.40a

23.40a

18.58g

20.06g

11.00a

45.0

66.4

52.38g

34.39g

48.40a

36.66g

23.40a

23.40a

16.39g

17.53g

11.00a

50.0

63.2

47.08g

30.85g

48.40a

32.49c

23.40a

23.40a

14.63g

15.45c

11.00a

55.0

59.9

42.67g

27.91g

44.36c

29.04c

23.40a

23.40a

13.16g

13.72c

11.00a

60.0

56.5

38.88g

25.39g

40.05c

26.16c

23.40a

23.40a

11.89g

12.28c

11.00a

53.0

35.56g

23.19g

36.39c

23.73c

23.40a

23.40a

10.79g

11.06c

11.00a

70.0

49.2

32.58g

21.19g

33.26c

21.64c

23.40a

21.64c

9.79g

10.02c

11.02c

75.0

45.3

29.85g

19.36g

30.54c

19.83c

23.40a

19.83c

8.88g

9.11c

9.11c

80.0

41.0

27.29g

17.66g

28.13g

18.22g

23.40a

18.24c

8.03g

8.31g

8.32c

24.84g

16.02g

25.53g

16.49g

23.40a

16.85c

7.21g

7.44g

7.62c

31.0

22.41g

14.41g

22.97g

14.78g

23.40a

15.57g

6.40g

6.59g

6.99g

95.0

24.7

19.89g

12.73g

20.32g

13.01g

21.24g

13.62g

5.56g

5.71g

6.01g

100.0

16.1

16.94g

10.76g

17.25g

10.96g

17.89g

11.39g

4.58g

4.68g

4.90g

103.0

6.7

14.07d

8.90g

14.27d

9.04g

14.69d

9.32g

3.65g

3.72g

3.86g

40.0

COPYRIGHT 2001

LeTourneau, Inc.

65.0

85.0 90.0

36.3

NOTES D D D D

InsertĆ7

This load chart meets API Spec. 2C (Fifth Edition, 1995) Safe Working Load (SWL) - Load which may be carried below the hook. API Static Rated Load = SWL plus 1.6 kip hook block. A 1600Ćlb. maintenance hook and block weight has been deducted from the total allowable loads on the 4Ćpart, 2Ćpart and 1Ćpart lines. D The design capacity of the crane is based on 50 tons at a 22Ćft. working radius. D Main Hoist Line - 1" Bridon Dyform 34 LR GR 2160, rotation resistant, B.S. = 70.03 tons D Aux. Hoist Line - 1" Bridon Dyform 18 HSLR, rotation resistant, B.S. = 57.5 tons

D Bridle Line - 1Ć3/4", 6 x 26 Class, IWRC, EIPS, B.S. = 168 tons D BoomĆup Line - 1", Bridon CONSTRUCTEX = 62.5 tons D Ratings followed by a" are limited by the hoist line limit. D Ratings followed by c" are limited by the foundation limit. D Ratings followed by "d"are limited by the luffing line limit. D Ratings followed by f" are limited by the boom axial load limit. D Ratings followed by g" are limited by luffing system on gantry limit. D Ratings followed by h" are limited by lifted load limit. D This chart is to be used for mild sea conditions only.



PUBLICATION OSMĆ2


LeTOURNEAU PCMĆ120SS MAIN HOIST CAPACITY CHART-100 FT. BOOM

WORKING RADIUS (FT.)

BOOM ANGLE (DEG.)

25.0

STATIC AND DYNAMIC SAFE WORKING LOAD IN KIPS

PERSONNEL SAFE WORKING LOAD IN KIPS




SINGLE LINE STATIC 1.33

SINGLE LINE DYNAMIC 2.00

4ĆPART LINE

2ĆPART LINE

SINGLE LINE

80.4

98.40a

57.13

48.40a

48.40

23.40a

23.40

32.30f

23.40e

11.00e

30.0

78.0

84.40c

46.42

48.40a

48.40

23.40a

23.40

29.40f

23.40e

11.00e

35.0

75.6

70.15c

39.25

48.40a

42.74

23.40a

23.40

27.09f

23.40e

11.00e

73.1

59.45c

34.06

48.40a

36.65

23.40a

23.40

25.19f

23.40e

11.00e

45.0

70.5

51.14c

30.1

48.40a

32.09

23.40a

23.40

23.58f

22.24f

11.00e

50.0

68.0

44.48c

26.95

44.48c

28.53

23.40a

23.40

22.20f

20.97f

11.00e

65.4

39.03c

24.36

39.03c

25.65

23.40a

23.40

20.99f

19.85f

11.00e

60.0

62.7

34.49c

22.18

34.49c

23.24

23.40a

23.40

19.91f

18.86f

11.00e

65.0

59.9

30.65c

20.29

30.65c

21.19

23.40a

23.00

18.94f

17.95f

11.00e

57.1

27.36c

18.64

27.36c

19.39

23.40a

20.91

18.04f

17.13f

11.00e

75.0

54.2

24.50c

17.16

24.50c

17.80

23.40a

19.10

17.22f

16.35f

11.00e

80.0

51.2

22.00c

15.81

22.00c

16.36

22.00c

17.52

16.44f

15.63f

11.00e

85.0

48.0

19.80c

14.57

19.80c

15.04

19.80c

16.05

15.69f

14.93f

11.00e

90.0

44.7

17.83c

13.41

17.83c

13.81

17.83c

14.67

14.97f

14.26f

11.00e

95.0

41.1

16.08c

12.31

16.08c

12.64

16.08c

13.37

14.26f

13.59f

11.00e

100.0

37.2

14.49c

11.24

14.49c

11.52

14.49c

12.13

13.55f

12.93f

11.00e

105.0

33.0

13.06c

10.19

13.06c

10.42

13.06c

10.93

12.83f

12.24f

11.00e

110.0

28.2

11.75c

9.11

11.75c

9.30

11.75c

9.71

11.75c

11.51f

10.55f

115.0

22.5

10.56c

7.96

10.56c

8.11

10.56c

8.43

10.56c

10.56c

9.80f

120.0

14.7

9.46c

6.58

9.46c

6.69

9.46c

6.91

9.46c

9.46c

8.84f

6.1

8.33d

5.23

8.33d

5.30

8.33d

5.45

8.33g

8.33g

7.80f

40.0

LeTourneau, Inc.

55.0

COPYRIGHT 2001

70.0

123.0

NOTES D D D D

InsertĆ9

This load chart meets API Spec. 2C (Fifth Edition, 1995) Safe Working Load (SWL) - Load which may be carried below the hook. API Static Rated Load = SWL plus 1.6 kip hook block. A 1600Ćlb. maintenance hook and block weight has been deducted from the total allowable loads on the 4Ćpart, 2Ćpart and 1Ćpart lines. D The design capacity of the crane is based on 50 tons at a 22Ćft. working radius. D Main Hoist Line - 1" Bridon Dyform 34 LR GR 2160, rotation resistant, B.S. = 70.03 tons D Aux. Hoist Line - 1" Bridon Dyform 18 HSLR, rotation resistant, B.S. = 57.5 tons

D D D D D D D D D

Bridle Line - 1Ć3/4", 6 x 26 Class, IWRC, EIPS, B.S. = 168 tons BoomĆup Line - 1", Bridon CONSTRUCTEX = 62.5 tons Ratings followed by a" are limited by the hoist line limit. Ratings followed by c" are limited by the foundation limit. Ratings followed by "d"are limited by the luffing line limit. Ratings followed by e" are limited by the hoist line limit. Ratings followed by f" are limited by the boom limit. Ratings followed by g" are limited by the luffing line limit. This chart is to be used for mild sea conditions only.



PUBLICATION OSMĆ2


LeTOURNEAU PCMĆ120SS MAIN HOIST CAPACITY CHART-120 FT. BOOM


PUBLICATION OSMĆ2

LeTOURNEAU, INC. PCM 120SS CRANE W/120' BOOM AUXILIARY HOIST SYSTEM DYNAMIC, STATIC AND PERSONNEL LOAD RATING CHART, SINGLE LINE LIFT API Spec 2C, Fifth Edition (1995) WORKING RADIUS (FT.)

BOOM ANGLE (DEG.)

STATIC LIFT SWL (KIPS) 1.33

DYNAMIC SWL (KIPS) 2.00

PERSONNEL LIFT SWL (KIPS)

30.0

79.9

20.00a

13.33

9.80e

35.0

77.5

20.00a

13.33

9.80e

40.0

75.2

20.00a

13.33

9.80e

45.0

72.8

20.00a

13.33

9.80e

50.0

70.3

20.00a

13.33

9.80e

55.0

67.8

20.00a

13.33

9.80e

60.0

65.3

20.00a

13.33

9.80e

65.0

62.7

20.00a

13.33

9.80e

70.0

60.1

20.00a

13.33

9.80e

75.0

57.4

20.00a

13.33

9.80e

80.0

54.5

20.00a

13.33

9.80e

85.0

51.6

20.00a

13.33

9.80e

90.0

48.5

19.28c

13.33

9.80e

95.0

45.3

17.49c

13.33

9.80e

100.0

41.8

15.87c

13.33

9.80e

105.0

38.1

14.41c

13.23

9.80e

110.0

34.1

13.08c

12.15

9.80e

115.0

29.5

11.85c

10.96

9.80e

120.0

24.0

10.72c

9.70

9.80e

125.0

16.7

9.66c

8.23

9.63f

128.0

9.6

9.04c

6.93

8.81f

NOTES D This load chart meets API Spec. 2L, Fifth Edition (1995). Safe Working Load (SWL) = Load which may be carried below the hook. API Static Rated Load = SWL plus 500 lb. overhaul ball. D Ratings followed by a" are limited by the auxiliary hoist line limit. D Ratings followed by c" are limited by the foundation limit. D Ratings followed by e" are limited by the auxiliary hoist line limit. D Ratings followed by f" are limited by the boom limit. D Main Hoist Line - 1" dia. Bridon Dyform 34 LR, GR 2160, rotation resistant. B.S. = 70.03 tons. D Aux. Hoist Line - 1" dia. Bridon Dyform 18 HSLR rotation resistant. B.S. = 57.5 tons. D Bridle Line - 1Ć3/4" dia., 6 x 26 Class, IWRC, EEIPS, B.S. = 168 tons. D BoomĆUp Line - 1" dia., Bridon CONSTRUCTEX = 62.5 tons

COPYRIGHT 2001

InsertĆ10

LeTourneau, Inc.


PUBLICATION OSMĆ2


CRITICAL COMPONENTS The following is a list of components of the crane which should be considered as critical components." These components are ones which affect the safety of the crane from a structural and load hoisting standpoint. These components should be of prime concern to the deck operators supervisor, operator and maintenance personnel with regards to certification, inspection, maintenance and prompt repair per the appropriate guidelines. Instructions for the maintenance and repair of these components are included in the OPERATING AND SERVICE MANUAL and the REPAIR AND OVERĆ HAUL MANUAL for the crane.

D Electric drive motors for hoist, boom, and swing

CRITICAL STRUCTURAL COMPONENTS Boom chord members D Boom foot pins D Boom section connection components D Primary load members of gantries, masts and AĆframes D Load transfer members of the rotating upper strucĆ ture D Pedestal and swing circle transition pieces

CRITICAL MECHANICAL COMPONENTS D All linkage between the brake control element and the component to be controlled. D Hoist, boom and swing brake systems D Drums, shafts, and gears of hoisting and swing systems

CRITICAL RIGGING COMPONENTS D All running wire ropes in hoist system D All standing wire rope in load restraint and support system D Hook block assembly

D Slewing or swing bearing and gear

D Wire rope deadĆend connection devices

D Wire rope sheaves and sheave shafts

D Floating harness or bridle assemblies

NOTES


COPYRIGHT 2002

LeTourneau, Inc.

13

14

ON

SS8

BLK

WARNING

BLK PB3

HORN

BLK PB9

ACKNOWLEDGE

LEFT

SWING

LT9 POWER ON

BAT SS1

BLK

OFF

1ĆCGĆ2458, P02Ć22

LeTourneau, Inc.

COPYRIGHT 2002

6

5

MASTER

RIGHT

LT3

GREEN

ON

DRIVE SYSTEM FAIL

RUN

RED LT4 SWING BRAKE ENGAGE

LT8

WARNING

BOOM LOWER LIMIT OVERRIDE

POWER LOSS HOIST LOWER

SPEED/TEMP

RED PB8

RED

LT3

AMB

2

RED

LIGHTS

OFF

1

7

LT1

SET

SS3 BRAKE

LT34

RED LT23 SS2

LT7

AUX

BOOM

SLACK WIRE ROPE

LT5

LIMIT SWITCHES

HOIST SELECT

MAIN

RAISE

LOWER

LT24

AMB

LT6

AMB

4

HOIST BRAKE HYD. PRESS.

GREEN

AUX

EMERGENCY HOOK RELEASE

ENABLE

RED

RUN

HOIST

GREEN

MAIN

SS7

ON

RED ONCONSTANT TENSION

OFF

SS6 OFF

BAT

3

RUN

EMERGENCY STOP

PB2

RED

LT2

GREEN

9

8

ELECTRIC DECK CRANE SAFETY INSTRUCTIONS PUBLICATION OSMĆ2

FIGURE 1. IDENTIFICATION GROUP (Sheet 1 of 7)

TAĆ9580Ć6



11

10

WALL “M”

WALL “G”

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13

14

PUBLICATION OSMĆ2




LeTourneau, Inc.

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14 15

14

8

É É

16

18

WALL “B”

19

17

18

19

PUBLICATION OSMĆ2

18



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LeTourneau, Inc.


10 14

18

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46

10

46

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FIGURE 1. IDENTIFICATION GROUP-350SS (4 of 7) 9ĆCGĆ9869-1, LdgrĆ40-1

9ĆOSM 2.3, (FOĆ1) 350SS Gorilla 09/20/01

TAĆ9869Ć6

COPYRIGHT 2002

LeTourneau, Inc.

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23

23

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FIGURE 1. IDENTIFICATION GROUP-350SS (5 of 7) 1ĆCGĆ2462Ć1, LdgrĆ40-1

9ĆOSM 2.3, FOĆ2, 350SS Gorilla 09/20/01

TAĆ9870Ć6

COPYRIGHT 2002

LeTourneau, Inc.

19

PUBLICATION OSMĆ2

1


CONSTANT TENSION OPERATION

2

WARNING

POWER LOSS HOIST LOWER OPERATION

For use during crane power loss situations to lower load at a constant speed. Emergency Hoist Release Switch: OFF Before activating : Constant Tension Switch: OFF (1) Inspect Power Loss Lowering Card, thermocouples Master Switch: BAT and temperature transmitters as per OSM-4. FLASHING Power On Light: (2)Place a man in the machinery house to monitor Brake Switch: ENABLE Power Loss Hoist Lower Button: PRESS and HOLDthe brakes and notify the operator to stop if brakes begin overheating. Hoist Joystick: LOWER

POWER LOSS

For use (AUX HOIST ONLY) when a load is on the deck of a vessel that is pitching up and down due to wave motion. NORMAL

Emergency Hoist Release Switch: Master Switch: Power On Light: Hoist Select Switch: Brake Switch: Constant Tension Switch: Constant Tension Light:

OFF ON ON AUX ENABLE ON ON

OFF BAT FLASHING AUX ENABLE BAT ON

6

DO NOT USE THE BOOM LOWER LIMIT OVERRIDE BUTTON WITH LOAD IN THE HOOK(S)

!

7

BEFORE OPERATING MACHINE, STUDY THE OPERATING AND SERVICE MANUALS. READ ALL SAFETY SIGNS ON MACHINE. CLEAR THE AREA OF THE OTHER PERSONS. LEARN AND PRACTICE SAFE USE OF CONTROLS BEFORE OPERATING.

EMERGENCY HOIST RELEASE 3

OPERATION For use if the hook becomes entangled in a vessel that is moving away from the crane. POWER NORMAL LOSS Master Switch: Power On Light: Emergency Hoist Release Switch: Emergency Hoist Release Light:

ON ON ON ON

It is the operator’s responsibility to understand and follow the manufacturer’s instructions on machine operation, service and to observe pertinent laws and regulations. Maintenance Manuals and Operating & Service manuals, may be obtained through your equipment dealer. LeTourneau, Inc. P/N 422–1605

BAT FLASHING ON ON

8 4 KG KIPS 68039.5 150 63503.5 140

NEUTRAL BUS (BLOCK) IS NOT USED WITH TWO–POLE BREAKERS

58967.6 130

120VAC

54431.6 120

CAPACITY

49895.6 110


45823.7 100 40823.7

90

36287.7

80

31751.7

70

27215.8

60

22679.8

50

18143.8

40

13607.9

30

9071.9

20

9

VENDOR: 4535.9 10 VENDOR: VENDOR: FEET 30 35 40 CM

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60

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90

100

110

120

130135

914.4 1219.2 1524.0 1828.8 2133.6 2438.4 2743.2 3048.0 3352.8 3657.6 3962.4 4114.8 REACH

10

5 LETOURNEAU PCM–350 CRANE WITH 123.5 FT. BOOM

BOOM ANGLE

REACH FEET


MIN– REACH 30.0 FT MAX SWL 146800 LBS.


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1ĆCGĆ2463Ć1, P02Ć22Ć1


ELECTRICAL EQUIPMENT AUTHORIZED PERSONNEL ONLY


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EQUIPMENT OPERATED BY REMOTE CONTROL

FIGURE 1. IDENTIFICATION GROUP-350SS (Sheet 6 of 7) COPYRIGHT 2002

LeTourneau, Inc.

TAĆ9868Ć6

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PUBLICATION OSMĆ2

! 12

API SPEC 2C FIFTH EDITION 1995

DATE MANUFACTURED

18 MANUFACTURER’S MODEL NO. DESIGN SERVICE TEMPERATURE

DEG.C.

MANUFACTURER SERIAL NUMBER MANUFACTURED BY

P.O. BOX 2307 LONGVIEW,TEXAS 75606

ADDRESS

HAZARDOUS VOLTAGE Can shock, burn, or cause death. Turn power off before servicing motor.

!

Hazardous A.C. voltage can be at terminals when motor is stopped.

13 LeTourneau, Inc.

HAZARDOUS VOLTAGE

P/N 414–9157

CAN CAUSE SHOCK, BURN OR DEATH

!

OPEN 600 VOLT DRIVE MOTOR FEEDER CIRCUIT BREAKERS IN POWER DISTRIBUTION PANEL

19

BRAKE DISC ON ELECTRIC MOTORS MAY BE HOT. BRAKE DISC WILL ROTATE IF MOTOR IS ENGAGED



14 20

600 VOLTS LeTourneau, Inc P/N 423–4939

21 15

THIS EQUIPMENT IS SUPPLIED BY MORE THAN ONE POWER SOURCE

CRANE SN PC3 SWL 17.95 T 0.0° SWL 73.40 T 79.5° MANUFACTURED BY: LeTourneau, Inc. DATE PC 350 SN SWL REACH TONS FEET 73.40 30 17.95 129

BOOM ANGLE 79.5° 0.0°

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LOW HEADROOM

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DO NOT OPERATE CRANE WITH HATCH CLOSED

LeTourneau, Inc.

P/N 423–7045

LeTournean, Inc P/N 422–8868

23

! 17

HIGHLY LOADED SPRING INSIDE THIS HOUSING CAN CAUSE SERIOUS PHYSICAL INJURY OR DEATH DO NOT REMOVE SCREWS

! LADDERS: FALLING HAZARD Can cause serious injury or death. WATCH YOUR STEP. WATCH FOR WIND GUSTS.


ALWAYS face ladder when climbing up or down. Keep one hand firmly on ladder or handhold at all times. Keep ladder rungs, steps and platforms clean – free of grease, oil, etc. LeTourneau, Inc.

P/N 421–7858

FIGURE 1. IDENTIFICATION GROUP-350SS (Sheet 7 of 7) 1ĆCGĆ2464Ć1, P02Ć22Ć1

22


LeTourneau, Inc.


Crane Inspection

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