BOOMING e =a 800 Series Truck js i 00 Ser ruck Cranes American Crane Corporation AMERICAN = Wilmington, North Carolina BOOM ASSEMBLY, DISASSEMBLY, AND LENGTH CHANGES This set of procedures {s organized according to the following outline: 1. Assembly and Boom Raising Procedures A. Essential Safety Precautions B. Boom Assembly with Service Crane-- On-Site Assembly (Method “A”) C. Boom Assembly with Service Crane-- Pre-Assembly Method (Method “B") D. Boom Assembly without Service Crane II. Disassembly and Boom Lowering Procedures A. Essential Safety Precautions B. Boom Disassembly with Service Crane C. Boom Disassembly without Service Crane III, Boom Shortening or Lengthening These procedures are intended for all standard booms (excluding only those booms used with a floating mast) which are approved for American Crane crawler, self- propelled and truck-mounted cranes. Requirements for locomotive and pedestal cranes are specialized and will vary somewhat from the recommended procedures given here. Depending--upon-the-type of -assist—equipnent—available—at~the job-site,—and- the specific task to be performed, any one of the working procedures iisted above may be called for at any given time. It is the responsibility of the crane owner and oper- ator to determine the adequacy of available service equipment, and the method of asseubly or disassembly to be used. Along with following the correct set of step-by- step procedures, it is vital that the appropriate general safety precautions (I-A. or II-A., above) are observed. To avoid senous imury never allow anyane fo snd on, in. or under Boom sections ducing assembly oF Gisassamply. Booms can fall when pena are removed if Not propery supported by Blocking, oF boom suspension ropes are not relocated as described in the operators manual. Consult ihe ‘operators manual Tor oroper assembly and disassembly procedures. In he absence of propat instructions consul your AMHOIST detier ote factory Se Tea ro7e04e, Figure 1 Printed in U.S.A. 1-4045 copper)BooMENG — 800 Series Truck Cranes American Crane Corpofation Wilmington, North Carolina —7 Assembly and Boom Raising Procedures I-A. Essential Safety Precautions for Assembly and Boom Raising A.l Before starting any procedure, make sure the crane and boom are standing level on a firm, uniformly supporting surface. Attempting to work over un~ even and unstable terrain can produce accidents. Sudden loss of support and unexpected weight shifts can cause injury to personnel and damage to compo- nents. If the operating surface is not level or adequately supporting, crane mats must be used. A.2 Keep the boom off the ground. Always rest the boom— or individual boom sections— on blocking rather than on the ground, to avoid damaging chords, sheaves, or load line. Never ride in or on the boom during any part of the assembly or raising procedure. A.3 Before assembling the boom, inspect all chords, lacing and splice connec~ tions for damaged or bent areas. Any cracks, deep scratches, gouges on the chords, or dented or deformed lacings will severely weaken the structural integrity of the boom. If damage is found, the boom section involved gust not be used until repairs are made. A.4 Damage to boom sections occurs most often during handling, either before or / after transport or during assembly. Take care when attaching slings. Never’ attach slings to light lacing members, only to chords or plated areas. Use synthetic web slings whenever possible to avoid cutting or scratching chords. If wire rope slings are used, protect the chords with softeners— for example, 2" x 4" wood splints placed between sling and boom. A.5 The A-frame must always be fully raised whenever the outer bail is pinned to the boom inner for handling boom sections or whenever the completed boom is raised for work. A.6 The force of the wind on individual boom sections can be dangerously unpre~ dictable, depending upon the direction and speed of the wind as well as on the individual length of the section and its angle to the wind. Postpone completing the boom assembly and erection procedure whenever wind gusts are creating hazardous conditions. A.7 Never stand underneath a boom section while driving pins in or out. Never remove any pin from between boom sections unless you are certain all boom sections are adequately supported and cannot fall, scissor or jerk when the pin is removed. Always stand well clear of boom pins being removed! When the boom is on the ground on blocking, ready for disassembly, there may still be some load on individual pin connections. Under pressure from the weight of one or both of the adjoining sections, pins may fly out of their bores as they are driven out, with explosive force. A.8 It is vital that, no matter which boom assembly procedure is used, the cor-* rect sequence of steps is followed, in the specified order, to prevent in- jury or death to personnel and damage to equipment. Amhoist cranes can self- erect all boom or boom-Jib combinations shown on the machine's Rating Chart, unless specifically stated otherwise. In general, the erection (or lowering) Printed in U.S.A. 1-4046BOOMING ot 800 Series Truck Cranes American Crane-Corporation AMERICAN ae Wilmington, North Carolina = ae! Ag A.10 Awl? I-B. of near maximum boom or boom-and-jib combinations can only be accomplished over the end of the crane's lower works. On crawler cranes the boom aust be erected (or lowered) directly over the idler end of the crawler lower with idler tumblers securely blocked. On rubber tired cranes the outriggers must be fully extended and set, and the boom erected or lowered directly over the tear of the carrier. Keep this in mind when laying out boom for assembly, and especially before lowering a boom for disassembly. Follow the boom-jib erection table and the boom-jib composition table on the crane's Rating Chart for maximum erection capability (and reduced capability of erection performed over the side), as well as the proper boom-jib sections to be used and their order of compostion. Erection or lowering boom over the side of the machine must only be performed with the crawler sidefranes fully ex- tended or with outriggers fully extended and set. NOTE: Near maximum erection capability on truck cranes may require bumper counterweight. Never attempt to raise an assembled boom from the ground when wind speeds exceed those listed in the boom combination/wind speed table on the last page of this procedure. Before a boom is raised, always look it over carefully to make sure no lines or pendants are hung up on the boom. Look at all boom and pendant pins to see that they're completely installed with keeper pins secured. Also look out for loose timbers or rigging hardware left on or in the boom. As the boom is raised these will fall and could tnjure or kill someone. When-raising-(or-lowering)—a—boom,—pay-out—load-line-so-that-the-load-block and any suspended tackle is on the ground whenever the boom is below the lowest boom angle shown on the crane's Rating Charts. Before lowering a boom, lay tackle and block to one side or the other to prevent interference with the boom when it is lowered down to blocking- The weight of accessories added in the field such as lights, cables or timbers fastened to the boom will reduce the crane's self-erection capabil~ ity. Consult Amhoist to determine the effect of such accessories. Boom Assembly With a Service Crane~ On-Site Assembly Method (Method Bel Make sure all safety precautions (Section I-A.) are observed before starting embly sequence. Use the service crane to pin the boom inner section to the machinery deck. Place enough blocking under the outer end of the section Printed in U.S.A. 1-4047BOOMING | 800 Series Truck Cranes American Crane Corporation AMERICAN. Wilmington, North Carolina ee to allow the next section to be pinned on without hitting the ground. Con~ nect the outer bail to the ears on the end of the inner section, using re- quired adapter links where necessary. Reeve the boom hoist line from the boom hoist drum through the inner and outer bails. d eae B.2 Using the service crane bring in the next adjoining section and pin it to the inner. Follow the boom composition table included with the cranes's Rat= ing Chart for the proper sequence of assembly. To allow upper pin connec~ tions to be ade more easily, place slings so that the boom section is tipped slightly. (Refer to the illustration above.) To assist in making the lower pin connection, after upper pins have been installed, release the service crane slightly, allowing boom section to pivot on the upper pins un till lower connection holes line up. Before setting the boom down, lift the connected sections up and move blocking out to the far end of the last in- stalled section. Repeat this procedure, one section at a time, all the way out to the boom tip. Always move the blocking to the far end of the boom be- fore adding the next section. B.3 After the tip section has been pinned to the rest of the boom, measure all pendants carefully to make sure the total length of both and the right and left side pendants will be equal. Connect the appropriate pendants between the outer bail and boom tip. Disconnect the bail from the inner when pend- ants have been connected. { B.4 Install boom stops. Before raising the boom to working position, read through the checklist of safety precautions (Section I-A, Items 1-12). TheBOOMING 800 Series Truck Cranes American-Crane Corporation Wilmington, North Carolina boom can be raised to working height when all safety precautions have been observed. Watch suspension ropes and pendants to make sure they don't catch on boom pins or cotter pins. @ WARNING ©) NEVER ATTEMPT TO RAISE THE WHOLE BOOM FROM OFF BLOCKING WHEN THE OUTER BAIL IS PINNED TO THE INNER. WHEN ADDING SECTIONS TO THE ASSEMBLED BOOM, ALWAYS MAKE UPPER PIN CONNECTIONS FIRST, THEN TIGHTEN BOOM SUSPENSION LINES ONLY AS FAR AS NECESSARY TO INSTALL THE LOWER PINS. I-C. Boom Assembly with a Service Crane-~ Pre-Assembly Method (Method “B") C.l If the crane is not at the same location as the boom, but is to arrive at the job site later, the boom may be pre-assembled on blocking ahead of tine, using an on-site service crane. This can also be done with longer com= binations, to avoid the need for moving blocking out to the end each tine another section is added (as in Method A). Except for the boom inner sec— tion, which is always pinned to the machinery deck before the pin connec- tions are made to the first.center section, the boom should be preassembled on blocking that is slightly higher out towards the tip section than it is near the first center section. The illustration below shows the approximate location where taller blocking (minimum recommended size 8" x 8", or 200mm x 200mm) should be placed. Blocking nearer the inner should be between 4" x 4" (100mm x 100mm) and 6” x 6” (150mm x 150mm). Follow the boom compo- sition table on the crane's Rating Chart for the proper sequence of boom sections to be assembled. NOTE: Tais end blocked slightly lower than tip end a C.2 Pin the boom inner section to the machinery deck of the crane. Lower the inner section down to blocking in front of the machine, so that the outer bail can be connected to the ears on the end of the inner section. Reeve the boom hoist line from the boom hoist drum through the inner and outer bails. BODO OOOO OK OX X KREIS Printed in U.S.A. 1-4049 10/85 4347BOOMING eet 800 Series Truck Cranes American Crane Core ed Wilmington, North Carolina — Witmington, North Caroling €.3 Move the crane forward and connect the two top pins of the inner section to the adjacent center section. The weight of the boom must be entirely sup- ported on blocking as the pins are installed. NOTE: Tt will be easier to make this connection 1f the blocking has been arranged as recommended in C.1, above; higher toward the tip and lower under the first center section. C.4 Raise the boom slightly, using the boom suspension lines, so that the bottom two splice pins can be inserted. ( WARNING © DO NOT ATTEMPT TO PICK THE COMPLETE BOOM OFF THE BLOCKING. THE WEIGHT OF THE BOOM SHOULD SAFELY PIVOT ON THE UPPER PIN CONNECTIONS AND THE TALLER BOOM BLOCKING NEAR ‘THE TIP SECTION. €.5 Lower the boom down on blocking until bail lines are slack, and the outer bail is laying flat supported on the bail rest. Repeat Steps B.3 and B.& from the previous procedure (I-B.) to install pendants and boom stops. I-D. Boom Assembly Without Service Crane D.1 When no service crane is available to assist with boom assembly, the crane can use its own inner section to unload and assemble the complete boom, sec- tion by section. The inner section must already be in place, the boom sus- pension line reeved and the outer bail pinned to the end of the inner sec- tion. To prevent pulling the inner section over backwards while raising and lowering, install crane boom stops before handling other boom sections. ) D.2 Remove the boom tip section from the transporting truck. This can be done either with the counterweight handling sheaves in the boom inner (if avail- able) or by pinning the tip directly to the boom inner. Move the tip to a clear area where the boom can be assembled and lay it on blocking. Unpin the tip from the inner 1f it was carried in that way. Printed in .8.A. qoun80,BOOME NG 800 Series Truck Cranes American Crane Corporation wee Wilmington, North Carolina D.3 When joining new sections to the tip, or to whatever length of boom has already been assembled on blocking, the blocking should be supporting the weight of the boom sections at all times. ( WARNING ©! NEVER ATTEMPT TO RAISE THE WHOLE BOOM FROM OFF BLOCKING WHEN THE OUTER BALL IS PINNED TO THE INNER. WHEN ADDING SECTIONS TO THE ASSEMBLED BOOM, ALWAYS MAKE UPPER PIN CONNECTIONS FIRST, THEN TIGHTEN BOOM SUSPENSION LINES ONLY AS FAR AS NECESSARY TO INSTALL THE LOWER PINS. D.4 Unload the next boom section (working back from the tip) by repeating which- ever procedure was used in the previous step. Follow the boom composition table_on the crane's rating chart for the. proper_sequence. and move the next specified adjacent section to the tip and pin the two together on blocking. If there are no counterweight handling sheaves in the inner section of the boom, careful disassembly is required each time the inner {s unpinned from the last assembled section. After lower pin connections are assembled to the boom sections on blocking, do not slack off on the boom suspension lines. Take a strain into the boom suspension lines to remove the load from the bottom pins on the end of the inner section. Take these pine out first, then disassemble the upper pin connections. Repeat this procedure with each succeeding boom section. Always lift the blocked sections only enough to assemble (or disassemble) lower pin connections. Printed in U.S.A. 1-4051 10/85 4467Booman 800 Series Truck Cranes ' gto American Crane Corporation AMERICA Wilmington, North Carolina Wilmington, North Carolina _ D.5 After the last section has been pinned in place, measure all pendants car- efully to make sure the total length of the right and left side pendants will be equal. Connect the appropriate pendants between the outer bail and the boom tip. Disconnect the bail from the boom inner. Before raising the boom to working position read through the checklist of safety precautions (Section I-A, Items 1-12). The boom can be raised to working height when all safety precautions have been observed. Watch suspension ropes and pendants to make sure they don't catch on boom pins or cotter pins. Il, Disassembly and Boom Lowering Procedures II-A. Essential Safety Precautions for Boom Lowering and Disassembly A.l When preparing to lower and disassenble the boom, observe all of the pre- cautions that apply to boom raising. Read through the list of safety pro~ cedures (Section I-A). In addition: A.2 Never attempt to lower near maximum boom or boom-jib combinations when wind speeds or gusts are approaching the limits shown for that boom combination / in the wind speed table (Columns "D" and “E"). Be especially careful when winds are blowing from behind the crane, in the same direction that the boom tip ts pointing. A.3 Never attempt to lower near the maximum amount of boom or boom-jib com- bination if there is a heavy accumulation of ice or snow on the boom. A.4 When lowering a boom past the longest radius on the crane's rating chart, reduce the boom lowering speed gradually to prevent a possible shock load on the boom or tipping. When lowering the boom on all models except 1200 Series Cranes and the Model 7000 Truck and Crawler cranes, boom lowering speed can be reduced by setting the main hoist brake and slightly engaging the main hotst clutch. This will slow the gear train and retard the boom speed, as the clutch tries to turn the drum with the brake set. Printed in U.S.A. roenenBOOMING 800 Series Truck Cranes American Crane Corporation =e Wilmington, North Carolina <= i. (@ WARNING ©) A.5 | NEVER REMOVE ANY PIN FROM A BOOM SECTION UNLESS YOU ARE ABSOLUTELY CERTAIN THE BOOM IS ADEQUATELY SUPPORTED AND CANNOT FALL, SCISSOR OR JERK WHEN THE PIN IS REMOVED. NEVER STAND UNDERNEATH A BOOM SECTION WHILE DRIVING PINS IN OR OUT. A or Wali V Y \ LAX A | fl Noh pe ¥ UR ‘WRONG 4-6 Always stand Well clear of boom pins being removed! When the boom is on the ground on blocking, ready for disassembly, there may still be some load on individual pin connections. Under pressure from the weight of one or both of the adjoining sections, pins may fly out of their bores as they are driven out, with explosive force. A.7 Disassembly of any pin-connected boom can be hazardous. Never remove upper or lower pins until boom is lowered to the ground on secure blocking and the outer bail has been pinned to the inner section. The illustrations below show what will happen if pin connections are broken in the wrong places. Printed in U.S.A. 1-4053 10/85 4347BOOMENG 800 Series Truck Cranes American Crane Corporation warren : Wilmington, North Carolina Ld II-B. Boom Disassembly with Service Crane NOTE: All boom disassembly procedures begin with the next tuo steps, II-B.1 and I1-B.2. Refer to these steps when disassembling the boom without a serv ice crane, or when lowering the boom to change composition. RR I B.l After making sure that all general safety precautions pertaining to boom disassembly have been observed, lower the boom onto blocking. There should be enough blocking available for completely supporting the boom— and individual boom sections— when the boom is lowered and disassembled. For lowering the boom, blocking will be adequate if the tip is just off the ground— the rest of the boom will then be safely above ground level, at ‘a good working height. With a few inches of clearance between the blocking and the boom chords just ( ahead of the faner section, there will be working room, if required, to take the load off the lower pin connections. BEAT TRE RRR RLY LETT 7 B.2 When the boom is completely down on blocking, slack the boom suspension lines completely and pin the outer bail to the boom inner section. Use ap- propriate links where necessary. Remove all boom pendants. TDD I 8 B.3 With the boom tip supported on blocking, take a strain into the boom sus~ pension line which is attached to the boom inner. This will remove the load from the bottom pins between the inner and the first center section. Remove the bottom pins between the inner and the first center section and allow the center sections to lower onto the prepared blocking. Printed tn U.S.A. TauBOOMING | 800 Series Truck Cranes American Crane Corporation Serre Wilmington, North Carolina ~~ ( WARNING {! DO NOT ATTEMPT TO RAISE THE WHOLE BOOM OFF THE BLOCKING WITH THE BAIL PINNED TO THE INNER SECTION. Remove the top pins between the inner and the first center section and back the crane away from the remainder of the assembled boom. Use the service crane to disassemble the boom center sections and tip. The service crane can then remove the inner section from the crane after the bail has been un— reeveds II-C. Boom Disassembly without Service Crane Cal c.2 The boom lowering procedure and blocking requirements are the same whether or not a service crane is available to assist with boom disassembly. Begin this procedure by following Steps 1 and 2 in the previous section (II-B.1 and II-B.2). With the boom tip supported on blocking, take a strain into the boom sus- pension line which is attached to the boom inner. This will remove the load from the bottom pins between the first two center sections. Remove the bottom pins and lower the boom down on prepared blocking. c.3 OOOO RE > @ WARNING ©! DO NOT ATTEMPT TO RAISE THE WHOLE BOOM OFF THE BLOCKING WITH THE BAIL PINNED TO THE INNER SECTION. When there are no counterweight handling sheaves on the inner, lower the boom all the way down on blocking and remove the upper pins between the first two center sections. Carry the first center section avay pinned to the inner and unload it for transport by unpinning it from the inner. (This is the reverse of the Procedure for Assembly without a Service Crane.) NOTE: If the boom can be disassembled using the counterweight handling sheaves in the boom inner, then repeat the first three steps of the previous Procedure and disassemble the lower pin connection between the inner and the first center section. Lower the boom all the way down on blocking and remove the upper pins. Proceed with disassembly using the counterweight handling sheaves on the inner section. Py S a LY OY Coy Printed in U.S.A. 1-4055,BOOMING 800 Series Truck Cranes ' ot American Crane Corporation AMERICAN, Wilmington, North Carolina Wilmington, Mor ee C.4 Return with the crane and re-pin the top pins of the inner to the next cen ter section. Take a strain into the boom suspension until the bottom pin holes are aligned and the bottom pins can be installed, then remove the bottom (and after them the top pins) between the first two center sections to remove the boom section. Carry the boom section to the unloading point and repeat the process until all boom sections have been disassembled. WRONG ( WARNING © UNDER NO CIRCUMSTANCES SHOULD MORE THAN TWO CENTER SECTIONS BE CANTILEVERED BEYOND THE BOOM INNER AT ANY ONE TIME. NEVER TRY TO LIFT THE ENTIRE BOOM WITH THE OUTER BAIL PINNED TO THE INNER SECTION. III. Boom Shortening or Lengthening TII.1 The boom must be fully lowered down to solid blocking every time boom com- position is changed, to add or remove sections. The boom lowering procedure and blocking requirements are the same whether the boom is being lowered for disassembly or to change composition. Begin this procedure by following steps 1 and 2 for Disassembly with Service Crane (IL Bel and II B.2). IIL.2 With the boom tip supported on blocking just above ground level, take a strain in the boom suspension line to remove some of the load in the boom bottom pins. x (3 WARNING © DO NOT ATTEMPT TO RAISE THE WHOLE BOOM OFF THE BLOCKING WITH THE BAIL PINNED TO THE INNER SECTION. Printed in U.S.A. T4056BOOMING 800 Series Truck Cranes ' 7 — American Crane Corporation AMERICAN Wilmington, North Carolina —_—” ——— III.3 Follow the boom composition chart to make sure of the sequence of new boom assembly and to identity the splice points at which pin connections must be disassembled to add or remove sections. Unpin one pair of lower pins first, then remove the pins above them after the boom is all the way dow on blocking. Wmenever possible, change composition by adding or removing sections immediately ahead of the boom inner. 1x Dou obxonna =o ( WARNING © The proper way to disassemble pin-connected booms is with the outer bail = connected to the inner sections...With. the, bail.ia- this. positian.the. boomia supported only on one end (or cantilevered). Maximum boom lifting capability is reduced to at most the boom inner section and the next two center sec- tion: TII.4 Use an assist crane for changing boom composition if available. If no assist crane is available to perform this function, the crane must use its own inner section to change boom composition as required. IIL.5 After changes are made, travel the crane back and pin the upper pins to the boom sections still on the ground. Take a strain on the boom suspension so that bottom pins can be inserted and then add or remove pendants as needed. The bail can then be unpinned from the boom inner section. The boom can now be raised following the procedures outlined in Section I for safe doom assenbly and raising. ( WARNING &) ALWAYS OBSERVE THE WIND SPEED LIMITATIONS SHOWN IN THE TABLE ON THE FOL LOWING PAGE WHEN PERFORMING ANY BOOM ASSEMBLY OR DISASSEMBLY PROCEDURE. Printed in U.S.A. 1-4057 10/85 4347American Crane Corporation i North Carolina 800 Series Truck Cranes HIND SPEED LIMETATIONS A 8 ce ° € No operation. Boo Siz | Boom or Boon| Operation | Lover Boom to Lover or Plus Jib 50-60 degrees. secure Position rear boom of crane into wind. 0-140" 0-30 mph 30-50 mph Over 50 mph (0-42.32) | (0-13.4 mps) | (13.4-22.4 mps) | (22.4 mps) (0748.3 kph) | (48.3-80.5 kph) | (80-5 kph) 4 Over 140" 0-20 sph 20-30 uph Over 30 aph (423m) | (0-89 aps) | (8.9-13.4mps) 13.4 aps) (032.2 kph) | (32.2-48.3 kph) | (48.3 kph) 0-170" 0-30 aph 30-50 apt Over 50 aph (518m) | (0-13.4 ape) | (13.4-22.4 pe) | (22.4 mps) (0-48.3 kph) | (48.3-80.5 kph) | (80-5 kph) 4 over 170" 0-20 mph 20-30 mph over 30 mph (51.88) | (0-8-9 ps) | (8.9-13.4 (1364 apa) (0-32.2 kph) | (32.2-48.3 kph) | (48.3 kph) 0-220" 0-30 mph 30-50 aph over 50 mph (0-67.1m) | (0-13.4 wpa) | (13. (22.4 ps) (o-48.3 ka) | (48. (80.5 kph) over 220" 0-20 ePh 20-30 aph Over 30 aph (67.1) | (0-8.9 aps) | (8.9-13.4 aps) | (13.4 mps) (0-32.2 kph). | (382-48 Bikph>. |. + GBs 3-kph= 0-290" 0-30 ph 30-50 mph over 50 aph 88.40) | -9-13.4 mps) | (13.4-22.4 mp8) | (22.4 aps) Y948.3 kph) | (48.3-80.5 kph) | (80.5 kph) Ger Bo" cad eon | 2030 ann | over 30 apn (884m) | (0-8-9 wpe) | (8.9-13.6 aps) | (13.4 mps) (0-32.2 kph) | (32.2-48.3 kph) | (48.3 kph) 92"-94"=118" 0-360" 0-30 mph > 30-50 aph Over 50 aph (0-109.8m) | (O-13.4 mps) | (13.4-22.4 a (0-48.3 kph) | (48.3-60.5 kph) (22.4 aps) (80.5 kph) 92°-947-118" | over 360° 0-20 mph. (109-8m) | (0-8.9 mp) (0- 262 kph) | (326 (8.9-13.4mps) 1-483 kph) 20-30 mph Over 30 mph (13.4 mpa) (48.3 kph) 130" 0-400" 0-30 mph (0-48.3 kph ) | €48.3-80.5 kph) 30-50 mph Over 50 sph (0-120) | (0-13.4 mps) | (13.4-22.4 mps) (22.6 aps) (80.5 kph) Printed in U.S.A. 10/85 4347 over 400" 0-20 mph 20-30 ph (122m) (0-8.9 apa) | (8.9-13.4 aps) (0-32.2 kph) | (32. 2-48.3 kph) Over 30 aph (13.4 mps) (48-3 kph)Oo PO. Box 91447 RMC “IZ Abuquerquo, NM 87199 = (505) 345-0008 ERAT CONTRACTOR (505) 345-0111 FAX HOIST ROPE 1020 FEET 1" 6 X 25 FW, RRL, IWRC, EIPS 103,400 LB MINIMUM BREAKING STRENGTH BOOM ROPE 783FEET 3/4" 6 X 26, WS, FW, LAL, IWRC, EIPS 58,800 LB MINIMUM BREAKING STRENGTHO PO. Box 91447 RMCI s Albuquerque, NM 87199 = (505) 345-0008 ‘GENERAL CONTRACTOR (505) 345-0111 FAX 30" BUTT SECTION 20" TRANSITION SECTION 20' BOOM SECTION 50' BOOM SECTION 50' BOOM SECTION 50' BOOM SECTION 30' TAPER TIP SECTION 60" 16HL JIB (1) HAMMER HEAD TIP SECTION (2) 8,130 # COUNTERWEIGHTS (1) 21,840 # COUNTERWEIGHT (1) 18,600 # COUNTERWEIGHT (1) 30,540 # COUNTERWEIGHT (1) MCKISSICK 3-SHEAVE LOAD BLOCK (SERIAL # 7025)(WEIGHT 1,480 LBS) (4) MILLER HEADACHE BALL (WEIGHT 600 LBS)(5 TON CAPACITY) CRANE SMART LMI SYSTEMOQ PO. Box 91447 RMCI 2 Albuquerque, NM 87198 = (608) 348-0008 ‘GENERAL CONTRACTOR (605) 345-0111 FAX 1974 AMERICAN 8460 CRANE SERIAL NUMBER GS17256 CARRIER ENGINE MODEL # 8V71N CARRIER ENGINE SERIAL # 8VA261867 HOURS SHOWING 5 UPPER ENGINE MODEL # 8V71N UPPER ENGINE SERIAL # 8VA423763 REBUILD ENGINE INSTALLED IN UPPER ON 12-23-2009 HOURS SHOWING 11,588 REBUILT REAR DIFFERENTIAL OCTOBER 2010 REBUILT SWING MOTOR NOVEMBER 2009 REPLACED SWING PUMP DECEMBER 2010 REBUILT HOIST PUMP DECEMBER 2010 REBUILT BOOM PUMP DECEMBER 2010Sf American Crane Corporation Wilmington, North Carolina ot AMERICAN OPERATION 800 Series Truck Crane : INTRODUCTION : Proper operation and maintenance is a prime factor in the reduction of costly down time. This manual contains suggested procedures for operation, ger eral inspection and safety precautions that should bs employed to maintain the machine in proper working order. This manual, however, cannot take inio account all the variables the serviceman or operator will encounter in the field, therefore, agen- erally applicable rule is offered here: approach your machine, and every new working situation, with respect and a safety first attitude. NOTE All information, illustrations, and speciti- cations contained in this manual are based on the latest product information available at the time of publication. Rights to alter and substitute specifications and methods at any time are reserved. Printed in U.S.A. 3/80 ‘Tm 0000050 Liabitity for any personal injury or property damage occasioned by the use of this ‘manual in effecting maintenance, opera- tion, or repair of your American Crane unit is in no way assumed by American Crane Corporation, Accordingly, anyone using a procedure not recommended by American Crane should first completely satisfy himselt that his personal safety and the machines integrity will not be jeopardized by the method selected. WARNING Avoid serious bodily injury or property damage. Do not attempt to start or oper- ate this machine without thoroughly read- ing and understanding the instructions provided in this operator's manual. 8-0001American Crane Corporation Wilmington, North Carolina — AMERICAN OPERATION Alll Series Cranes ACCIDENT PREVENTION SIGNS GENERAL INFORMATION: Accident prevention signs are found in several locations on American cranes. They are color and format coded to convey 5 different types of messages. The first two of these five designs will be found on every American product that has been issued with accident prevention signs. The latter 3 types may or may not be found on a given machine, depending upon the safety requirements for that product. If any sign is lost or damaged, a replacement may be ordered from the Parts Book supplied with your machine. The correct mounting location for each sign can be found on a separate drawing in the Parts Book which is included for reference, so that the crane owner may be assured that all required safety information is properly posted at all times. Accident prevention signs on your machine should be read, understood and complied with. 1. Signs marked "DANGER" are posted to wam anyone in the vicinity of the machine of an immediate hazard or peril capable of causing serious injuries or severe equipment damage. This sign may also be used to prohibit any activity or practice which is hazardous. The right half of each sign carries a graphic symbol inside a red circle identifying the type of hazard or prohibiting a specific activity. The sign shown in Figure 1, for example, wars of the danger present during assembly or disassembly of boom sections. A falling boom can cause serious injury to anyone standing on, in, or under a boom section. Booms can fall when pins are removed, if not properly supported by blocking, or if boom suspension ropes are not relocated as described in the operator's manual. Figure 1 Printed in U.S.A. (CONTINUED) Page 102 2/84 (R2-11/93) ‘7H0150017American Crane Corporation Wilmington, North Carolina eet AMERICAN OPERATION All Series Cranes ACCIDENT PREVENTION SIGNS (CONTINUED) COLORS: BLACK YELLOW oS os . . Tworsco%7-2 Figure 2 I. Signs marked “CAUTION” are used to call attention to specific potential dangers or hazards which could Cause serious but not irreversible damage or injury. Thi8 Sign may also be used to warn against practices or hazards in a more broadly general way, where no immediate danger is apparent, as in Figure 2 which recommends reading the manual before operating the crane. ll, = V. Three other types of signs may also be used: green and white “GENERAL SAFETY" signs (I!) {indicating rules relating to health, first aid, house- keeping, or general safety precautions), red and white “FIRE” or “EMERGENCY” signs (IV) (indicating fire hose or fire extinguisher location, or access informa- tion), and blue and white "NOTICE" signs (V) (relating to location of equipment or information helpful to operation). Pontec m USA 288 ‘worso017 Page 103OPERATION a BO American Crane Corporation ee ae Wilmington, North Carolina CARRIER CAB CONTROLS 4203 4 6 6 78 94 1 219 4 35 ; + , iLd2 orees ee eae fee — ee 2 Ee ueercimnomer * Serenata ae 2 Somer Se pet ¢ Soeeoriee raced ois ee VAL um pace Bers He ao ices ae Rae Peres ieee 8 Bees ele ae ST renee eee teiece § ces, 2 Srivimrce, Sete 72 SE, Ea eno Se aa Printed in U.S.A. TM 0000081 B-2001 3/80OPERATION American Crane Corporation rors} 800 Series Truck Crane Wilmington, North Carolina | OUTRIGGER CONTROLS The outrigger controls are located on the left and right side of the carrier sideframe, The following illustration shows the controls on the left side ‘OUTRIGGER OPERATION BEAR EaoNT CYC.DOWN BEAM OUT || BEAM OUT CYC. DOWN Pull PULL PULL PULL cyc.up —seawin |] aeamiN cc. uP | Bush ‘BUSH PUSH BUSH a a hy O O 0 a Outrigger Controts Printed in US.A. ‘Tm 000082 B-3001 3/80la } American Crane Corporation Wilmington, North Carolina OPERATION AMERICAN 800 Series Truck Crane TRUCK CRANE TRAVEL RESTRICTIONS Around the Job Site The crane may be traveled over the job site provided you observe the following: 1. Do not exceed 5 mph (8 km/hr) travel speed 2. Travel with no load or with loads shown in the ratings chart under “ON RUBBER". 3. Travel on firm, level ground only. 4, Travel with boom over rear only (full coun- terweight may be on, but bumper counterweight, if used, must be removed). 5. Cartier engine speed is governed in Lo-Lo. Over the Road The crane may be traveled over the road in different configurations, depending on weight restrictions. The following must be observed: 1. If the counterweight is on, it must be firmly blocked to prevent the crane from rocking on its swing bearing. 2. When the boom inner and outer sections are on, travel with the boom over the rear of the car= rier with all load devices off. 3. When only the boom inner section is on, sus- pend the boom a few inches above the carrier saddle and lash it inthat position. Do not allowthe boom to ride in contact with the saddle, Printed in U.S.A, 4. Allltruck crane carriers are governed to travel at only certain maximum speeds. Do not attempt to exceed this speed. 5. Set the swing brake and engage the swing lock (if your crane has swing jock). 6. Lower the gantry to allow bridge and under- pass clearance. 7. The crane may be traveled with 80 feet to 90 feet (24.38m to 27.43m) of boom over the rear with the A-Frame fully retracted. With a 100 foot (30.48m) boom, the gantry must bein its partially up intermediate position so the boom and pendants do not interfere with each other. Travel with more than 100 feet (30.48m) of boom is not recommended. CAUTION Traveling the crane at higher than gov- ‘ered speeds may result in serious struc- tural damage to the equipment. Never allow the carrier to freewheel. (Over) 3/80 ‘rw 0000134 B-3301American Crane Corporation Wilmington, North Carolina OPERATION — 800 Series Truck Crane Clearance for Normal Operation Clearance During Transit Normal Operation Minimum Required Normal Voltage Minimum Required (Phase to Phase) Clearance (Phase to Phase) Clearance to S0KV 10 t( 3.05) to 75KV 4 (122m) sot 200 KY 181( 480m) 75t0 “S0KV 81 (183m) 20010 360 KV 20:8( 6.10m) 50% 345 KV 10 8 (305m) 36010 S00 KV 25 (782m) 3450750 KV 16487) 50010750 KV 35 11 (087m) 750 to 1,000 KV 201 (6.10m) 750 to 3,000 KV 451 (13:72m) Clearance for Normal Operation DANGER ZONE SEE TABLE FOR REQUIRED CLEARANCE Danger Zone Around Power Linas 8-3302 7m 9900194 Clearance During Transit 1M 0000124 Cm Printed in U.S.A. 3/80a] 4 American Crane Corporation Wilmington, North Carolina OPERATION eet 800 Series Truck Crane AMERICAN Travel Weights The crane's tandem load weights must not exceed the maximum recommendations given in the follow- ing tables. Use the tables along with the Traveling Weight Charts that follow to determine what must be removed to reach the correct weight at a particular speed. Because of the possible contamination of the hydraulic system during travel, do not bleed hydrau- lic lines to reach maximum travel weights. NOTE These recommendations apply to Stand- ard tires supplied with this machine. Before using other tires, contact the American Crane Service Department for recommendations, Travel only with boom rearward, Static & Up to 1-5 mph 5-45 mph Travel Speeds | 1 mph (1.61km/hr) | (1.61-8.05km/hr) | (8.08-72.41km/:u; Recommended Total 110.000 ibs 73,200 ibs 144,000 tbs Front Bogie Load (49,8964) (95:925ka) (19.958k9) Recommended Total 220,000 Ibs 158,400 ibs 88,000 tos Rear Bogie Load (99,792kg) (71,850k9) (38.8179) Tire Pressure 140 psi 130 psi 100 psi (2.83%9/em*) (214kg/er) (7.03kg/ em?) ‘Speed and Traveling Weight Relationships (Michelin G26Y 14:00 x 24 4 Stee! Ply) Static & Up To 3-40 mph Travel Speeds —} -3 mph (0-4.83km/hr)- | (4.83-64.36km/hr) Recommended Total 115,750 Ibs 50582 tos Front Bogie Load (52,504.20kg) (22844.00ka) Recommended Total 231,500 ibs 101,164 ibs Rear Bogie Load (108.008.4049) (45,888,009) Tire Pressure 130 pl 130 psi (9.14kg/em®) (9:14kg/em®) ‘Speed and Traveling Weight Relationships (Michelin 14:00 x 24 x RB Three Star) Printed in U.S.A. 3/80 rm a000194 (over) B-3303OPERATION | A et 800 Series Truck Crane American Crane Corporation Saeneae Wilmington, North Carolina Taper Outer Front | Rear | Front | Rear | Gross Tip Boom Inner | Counter-] Out- | Out- | Tandem | Tandem | Weight Folded | Block | Hammerhead | Boom | Weight | Rigger | Rigger | Ibs tbs tbs sesio_| 120880 | 213500 97.060] 174400] 211.490 106.960 —|— 100.990" 207. 960 21,960] _123.040_| 145.000 28.410_| 116,580 | 142.990 '96.310_| 103,160 [139.460 14250 [119.940 | 73a.190 [ t 78.710 [113.490 [132.200 [ 28,510_| 100,050 128.660 25.050 [109.140] 134,190. 29.510 102.680 132.200 39.410_| 88,250] 128 660. 17,380_| 106,040 [123.390 i810 [99,580 121.400 31,700 [86.150 | 177,850 112.870 | —_90;340_| 203.810 42,220 [93,080] 135.310 24520_[ 99,990 |124.510_—] “ 145.320 79,100 | 124510 37.620 76080_[ 113710 720.540_|74070|_194.610 49.890_| 76.200 | 126.110 42.190] 73.100 118 310 52.980 62320 [115 310 45.280 | $9220 | 104510 fofo}o]a}olofolofo}fofo»lolo|»olofxfoo}xfofo ofofofolalofofojofo}ofaf-fofo}xfo}ol»jofolxlolo] ofolofofo}ala}ofofo}o} |» o} | >q]o}x|x}ofa<]] nn nf af] fa ff ee alololo}>o}ofofolxfolo}ola|olalolofofo}olo| |] > of fo}a}>e]o} of} x] |] 0 of off] > >> ofoo}r<|><]><]0] of eff fo} oo] of of of nf xf a nf All weights per ander are shown with he boom fot facing the cer ofthe carr. in place 0 = Reroved Traveling Weight Chart (US. Measure) XX Printed in U.S.A, B-3304 11 9000524 3/80OPERATION American Crane Corporation Paeeeen 800 Series Truck Crane Wilmington, North Carolina Taper Outer Front | Rear | Front | Rear | Gross Tip Boom Inner | Counter-] Out- | Out- Tandem | Weight Folded | Block | Hammerhead | Boom | Weight | Rigger| Rigger | kg kg kg ° x x x x x x_| 42008 | sess6_| s6.eee © Cc) x x x x X44 008 | “51.905 | as.sa0 x o o x x x x [aesi7 | —a5809 | ga.s06 o x x x a x x 9961_[ssait_| 65772 | S65 x ee [enema ree x 0 3. x 0 x x [16.470 [46 769] 63.259 o x x x o 2 x 5.464 | 54.405 | 60.869 | ° °. £3 5 0 © x 3.487 | 51,479 59.366 | x © o i o 2 x [2.976] 45383 s8.360 | o x x x © x o7 [11363 | 49.506 [60869 0 o x x a x ‘oO |13.386| 48.580 | 59.066 | cg oO 2 x io] x o 17,876 49.484 | 58.360 | o x x x © 3. 0 77048100] “$5370 | 0 o x x 0 o. 0 9883 [_ 45.174 [55067 = 3. 0 x 3. 6 ‘O | “1437e | ~30.078 [52457 o o ° x x x Xx [51.198 [41250 92.445 o o o x 3. x x [ig151 [22386161377 Fy o 0 o x © 0 X__[15658_| “aso | sea7e ) o 0 o x 6 x O__| 20557 | “35.521 | seare o. 0 o x 0 o Oo [ 17.064 | “3514 [51.579 °. o 0 © x x X__| 867733598 | -e8275 | 0 o. o 0 © x X__[ 22690 _| 34573 $7204 | 0 O. © 3. 0 o x__|“19.137_[ “33.167 [52.305 i 0 o. 0 3. o x ‘Oo | 24,036 | 28258 [52.306 | 0 ol 0 © o ©: (Oo ] -20.544~ [2662] =47 406 {All weights per tandem are shown withthe boom fot 19 the rear ofthe carrer | x=Inplace (0 = Removes 7 Traveling Weight Chart | (Metric) | | | a Printed in U.S.A. eee 3/80 TM 0000134 B-3305American Crane Corporation Wilmington, North Carolina oe AMERICAN OPERATION 800 Series Truck Crane 8-3306 [Tort [_effect Per item | weight Front Rear Front Rear Gross | Adjustment | Tandem | Tandem | Tandem | Tandem | Weight item | tbs tka) | tbs (ka) | tbs (ka) | tbs (kg) | bs (kg) | tos tka) counterweight | 2200 170 760 aaseo_ | sso | 102260 Beams ciorisy) | 666.72) _|_caea.7a) | (1987675) | c2est7a6) | (46.996-21) Tapgings and a7 7430 SHO —[-a2560-—] S12 37510 apes zieaer | 4ass). | 1151502) | (19.228.10) | (2500240) | (442005 Ravractable 3700 700 330 ERED a a Gant 2iaise) | 846.15) | (205.77) | 17361.95) | (24,716.66) | (42.0086) 174 Ful Foal 200 730 70 38,190 | ~Se400- | sai “rank (s072) wss97)_| 17) _| 1732298) | cageasty | 4200780) Engine Coorg 730 30 3 35100] Baa80_—-[—saa60 Water (8.04) wosey | 2722) _| 17282:16) | (24.657 70) | cai s0988) Operators 750 7 750 36100 | S310] sen10 Cab (204,129 (0) 042) | 7282.6) | (24.4550) | (4179574 TourernaiAT Beam Rolers 150 90 60 aero | sagso | o1aso ‘and Pins (e304 soa) | 2722) | 7241.94) | (24.426) | (41.867 70) Additional Weight Reduction Chart C Printed in U.S.A, 3/80American Crane Corporation Wilmington, North Carolina TRAVEL WEIGHTS ‘The crane’s tandem load weights must not exceed the maximum recommendations given in the following tables. Use the tables along with the Travelling Weight Charts and Bumper Counterweight Travel Restrictions to determine what must be removed to reach the correct weight for a particular speed. Because of the Possible contamination of the hydraulic system during travel, do not drain hydraulic lines to reach maximum allowed travel weights. Refer to the additional Weight Reduction Table on 8-3310. OPERATION 800 Series Truck Crane bors} 8470 Chart under document with other travelling weight charts, NOTE: These recommendations apply to Standard tires supplied with this machine. Before using other tires, contact the American Crane Service Department for recommendations. Travel only with boom rearward. FREE RATING JOBSITE TRAVEL HIGHWAY TRAVEL Travel Speeds Static & Up to 1-5 mph 5-45 mph ‘Lmph (1.6k mit) (16-81 rvhe) (81-724 kmvne) Recommended Total 116.000 Ibs 74,000 tbs. 146,000 los Front Bogie Load (52618 kg) ($3,566 ko) (20,966 kg) | Recommended Tatar 2330007 {280001 ~ 32,000 Tbs ——] Rear Bogie Load (105.235 kg) (67.13 ka) (41,731 kg) | Tire Pressure 715 pal 700 pst | (796 kPa) (600 kPa) (690 kPa) ‘Speed and Travelling Weight Relationships (Michelin 14:00 x 24 XVC) - Standard Duty Rims Printed in USA. 8.3307 ss (CONTINUED) "70030020OPERATION American Crane Corporation rer | sao ae Wilmington, North Carolina TRAVELLING WEIGHT CHART - LBS. BOOM REARWARD : oe mr oe ae “Faced | vormereas [ack | Seon | Sogn |ouiaue| owas | “tan | te” | “GS” ° x x x | x x x aaio | 144,580 | 217.800 x fof fo fe | x | eo] na | seem x fo fo] | fox | x | erso|rime | rare G x fx fx fo | x |e | memo] sense | taeo eo} x fo] «x | o | « | x | mmol naz | wan eae | cee | ee es oe of «x fx | x | o | o | x | eso} eras | coun ee en er ee | ee asta eee x {© fo] x | o | o | x | zo] wer | ease of} «x fx |x | o | « | © | esol mm | raw ° x ° x ° x ° 200 | 104190 | 195000 x ° ° x ° x ° sas20| 90200 | 10180 of} x |x | x fo | o | o, | eee] za | rum eo} «x fo} x} o | o | o | mmol mun | sono x | 0 fo] x | o | o | o | seo] rau | rane o{ c jofx| «|x ara arn | eso eo] o jo] x | o] « cea | sro | ras ° ° ° x ° ° « area] s20s0 | res210 eo | o fo] «| o | x | o | eeo| om seo E eo one ee oe of 0 fo je} x | x | x | | sss | a eee ele cre | alee posi ° ° ° ol o ° x | sas90 on ie o ° ° ° o x | ° sssoo} 63310 | 116810 ° eo fefol| o | o | o | use| ms | mao Printed in USA, oes NOTE: All weights per tandem are shown with the boom facing the rear of the carrier. Travel with the boom forwardis not recommended. X= IN PLACE = REMOVED CAUTION Do not swing over the side of the machine when the rear deck counterweight has been extended backward, and the carrier outriggers have not been extended and set. Retract the counter- weight in order to swing or raise the carrier up on outrlggers. (CONTINUED) ‘Tooséa0 58-3308OPERATION 800 Series Truck Crane American Crane Corporation remot 8470 Wilmington, North Carolina Printed in USA, roe TRAVELLING WEIGHT CHART METRIC BOOM REARWARD raters eartoet = | ae feat che || tee |e] Se Teal [ esos | | Se | oe [oboe] WS] Ter Ss a re of oe fof a] x | x | x |e | cae | ane x foe fol] a] a | x | cm] ene | one ° x fx x ° x x 809s | saees | 67.700 of oe fof] of | x | sm) sm | cow x foo fof e| o|] «| x | oe] om | can ef x |efale]o sa | me | ee eo | x folx} elo va | sae | aan x foe fof] o | o | x | am] ane | aun of oe feta to] x | o | cen | am | am of» fe} sz] o| x | 6 [us| a | ae x] oe fof x] of] 2 | o |r| am | sae o fe fa} x] of o | o | sm| sm | wes of x fel] o] ©} o | al aan | am x foe fefx] of} o | | stow] me | se of o feof] «|x | x [um ase [am of e fel] of} «| x fam|am| ave 0} 0 fol x] o | o | x | an| am | ame ofc fel a] of x | o |am|oum | me o |e fej oe} co] 6 |e || son_| sn ° o ° ° * x x [areas | aneas | 29540 - e | o jefe] eo x | sae sem | tes of ce fof o] of] o | x |e] sw | sen of o fof o | o| x | o |aa| ans | aan ofc Jojo] of] 6 | o | am| am | om NOTE: All weights per tandem are shown with the boom foot facing the rear of the carrier. Travel with the boom forward is not recommended. X= IN PLACE = REMOVED CAUTION Do net wing over th sie of the machine when the reer deck Countrwaigh he beon extanod back on te eta. outagurs have ot Deon extensosunaec Remsttneccania, woh ronda fo sing or take th carr apes eae B-3309 “Ton50020OPERATION 800 Series Truck Crane American Crane Corporation 8450-8460-8470 Wilmington, North Carolina ; ————ee OPERATOR CAB CONTROLS CRANE Lever Stand atom 29 La eS [Od |. Throttle 13, Main Drum Hoist Contro! Lever . Swing Charge Pregsure Gauge "14, Main Drum Tum indicator . Hoist Supercharge Pressure Gauge 15. Main Drum Parking Brake Lever . Air Pressure Gauge 18. Auxillary Drum Hoist Control Lever ‘Swing Control Lever “17. Auxiliary Drum Tum Indicator . Hand Hoist Pump Control 19. Boom Dog Lever . Hom Button 20. Boom Hoist Contro! Lever |. Swing Parking Brake Lever 21. Hydraulic Pump Foot Control ‘Swing Lock Lever 22. Auxdiary Drum Brake Pedal Third Drum Hoist Control *23. Third Drum Brake Pedal Third Drum Parking Brake Lever 24. Main Drum Brake Pedal '25._ Main Drum Single Lever Control Selector *26.* Auxiliary Single Lever Control Selector 1m 0000125 Printed in U.S.A. 3/60 Revised 3/50 : 8-4001OPERATION American Crane Corporation et 800 Series Truck Crane Wilmington, North Carolina — 8470 ADDITIONAL WEIGHT REDUCTION TABLE - 8470 Total Effect Per iter Total with al Preceding items Removed Weight Front Fear Front “Rear “Gross Item Adjustment | Tandem |, Tandem | tandem | Tanc Weight Ibs (ka) | tbs (ka) | tbs tka) | tbs ko) | tbs (ks) | tbs (kg) H| Counterweight and 2.380 1,560 820 42.740 58,790 101,530 Beams. Rollers & Pins 1080 (708) (72) (19365) | (26665)_| (46.055) T]Lagaings and Ropes, 4770 1,450) 40} 45370 250 36785 —] Main Hoist Ropes. reser) | (eaaesy | cusis0z) | (18740 | 25.150) | (43.890) T [Retractable ‘4700 4070 “83 ‘37240 3a Gantry 33192) | (a46.15) | (28577) | (16.890) | (24865) | (41.760) 7a Ful Foar 200 730 70 “S710 34750 31360 Tank (20.72) (58.97) crs | igeas)_| (24835) | (41.670) T [Operators 70 y a0 “3770 ‘54280 31,350 —] ‘Cab 213) o 213) (16895) | (24.820) | (a1.455) ‘Carrier with outriggers and swing bearing ~ less upper 28008 Bru 79.499 (12.715) | 23138) | (98,080) ‘Carrier with swing bearing - less upper and outriggers 22,301 32,198 54.500 Goris) | 14605) | (24.720) a Printed in USA. 8.3310 10788 “Tw00s0020OPERATION + + T Wilmington, North Carolina Zz Side Console (Latest Machines) | view Ak | (ROTATED 90% weed | a ) Coye Cin] e | CID] e i CID] e ] Ci }e e Cip |e Cap) e seme [IL] @ 78 Tm 0000796 1, Engine Water Temperature Gauge 2. Engine Oil Pressure Gauge | 3. Tachometer 4, Fuel Level Gauge 5. Transmission Oil Temperature Gauge 6. Engine Start Key Switen 7. Generator Light 8. Engine Stop + 9 Heater Switch 10. Shift Control Indicating Light | 11. High/Low Hoist Shift Control | 32. Blank 13. Transmission Fllter Light 14. Blank 15. Blank 16. Boom Hoist Control Pushbutton | “17. Cab Lighting a 18. Swing Drag Brake 19. Engine Cluten Control "20. Windshield Wipers. "21. Crane Level 22. Boom Override Pushbutton 23. Fuse Pai "24. Horn Fuse “Option NOTE: Controls and location of Controls may vary. Printed in US.A, 3/80 rmonoens B-4101Nw OPERATION 800 Series Truck Crane American Crane Corporation hoe] Wilmington, North Carolina Side Console (Early Machines) VIEW "AA" (noTaTeD 1" Sx srr For] ©) oat 10 = fedeer| 14 7™ 9000137 1. Engine Oil Pressure Gauge 2. Engine Water Temperature Gauge 3. Tachometer 4.--Fuel Level Gauge. 8, Transmission Oil Temperature Gauge 6 7. a. Engine Stop Pushbutton Engine Start Key Switch Generator Light 98, High/Low Hoist Shift Controt 10. Blank 11. Shift Control Indicating Light 12. Transmission Filter Light "13. High Water Temperature Light "14. Low Oil Pressure Light "18. Heater 16 Boom Control (Depress To Activate Boom Hoist After Each Startup) "17, Cab Lighting 18 Swing Drag Brake 18. Engine Clutch Control "20. Windshield Wipers "21. Crane Level 22. Boom Override Pushbutton 23. Fuse Panel *26. Horn Fus “Options NOTE: Controls and location of Controls may vary Printed in U.S.A. 3/80 rm 0000137 B-4301American Crane Corporation Wilmington, North Carolina OPERATION eo 800 Series Truck Crane MACHINERY CAB CONTROLS Engine Control Panel ‘The engine control panel is mounted at the left front ofthe diesel engine. Refer to paragraphs titled Start- ing Diesel Engine - Below 40°F (4°C) for procedures on using the contro! panel. ELAPSED TIME METER, ENGINE START PUSHBUTTON EMERGENCY ‘STOP. TACHOMETER WATER - TEMPERATURE om ‘TEMPERATURE AMMETER Engine Control Panel rm 0000138 Printed in U.S.A CAUTION The Emergency Stop should not be used exceptin an emergency. Use of the Emer- gency Stop can cause oil to be sucked past the oil seals and into the blower housing. 3/80 rm 0000198 8-5001OPERATION 800 Series Truck Crane i American Crane Corporation hoax} Wilmington, North Carolina Counterweight and Gantry Controls (GS-18488 and Up) The levers for extending or retracting the counter- weight and raising or lowering the gantry are located on the left rear of the machinery deck, ‘COUNTERWEIGHT PUSHTO | PUSH TO extend | EXTEND LEFT SIDE | RIGHT SIDE Putt To | PULL TO RETRACT GANTRY PusHTO | PUSH TO Raise | RAISE LEFT SIDE | RIGHT SiDE PULLTO | PULL TO Lower | Lower Gs-18488 and Up 17m 0000138 Printed in U.S.A, 3/80 ‘7M o000139 B-5401mane OPERATION American Crane Corporation AMERICAN 800 Series Truck Crane Wilmington, North Carolina Counterweight and Gantry Controls (GS-17250 Through GS-18028) The levers for extending or retracting the counter- on the left rear of the machinery deck. See the fol- weight and raising or lowering the gantry are located lowing illustrations for the controls on your machine, COUNTERWEIGHT PUSHTO | PUSHTO EXTEND | EXTEND LEFT SIDE | RIGHT SIDE. PULLTO | PULL TO RETRACT GANTRY PusHTo | PusH To RAIse | RAISE LEFT SIDE | aIGHT sioe| PULLTO | PULL TO tower | Lower GS-17250 Through GS-18028 (Machines Without Gantry Unioader) Tm aceor40 GS-17250 Through GS-18028 (Machines With Gantry Unioader) rm soverse-1 Printed in U.S.A, 3/80 TM 0000140 B-5501) 2 American Crane Corporation Wilmington, North Carolina OPERATION 800 Series Truck Crane Counterweight and Gantry Controls (GS-17111 and Lower) ‘The levers for extending or retracting the counter- weight and raising or lowering the gantry are located on the left rear of the machinery deck, GANTAY PUSH TO | PUSH TO Raise | RAISE LEFT SIDE | AIGHT SIDE PuLTo | PULLTO. tower | Lowen PUSH TO EXTEND. PULL TO RETRACT GS-17111 and Lower Number Printed in U.S.A, 3/80 TM 0000148 ‘COUNTERWEIGHT PUSH TO EXTEND LEFT SIDE |aIGHT SIDE PULL TO RETRACT, Tm 0000143 B-5601OPERATION ed 800 Series Truck Crane American Crane Corporation AMERICAN Pa Wilmington, North Carolina OPERATION Pre-Start Inspection Counterweights | This inspection is to be done by the operator of the crane to make sure hes receiving the crane in goo condition. Itis in addition to the daily inspection ang lubrication requirements described in the Lubrica- | tion section. (If the operator also maintains the crane, this procedure and the one in the Lubrication section may be combined. Refer to the Lubrication section for detailed inspeo- | tion procedures, if necessary, and proceed as follows: Booming 1. Check chords and lacing for damage. 2. Check that all boom section connecting pins fe. and cotter pins are in place. 3. Check all ropes for fraying, kinking or other damage, 4. Check sheaves, blocks and hooks for exces- sive wear and damage. Outriggers 1. Check to see if outriggers are retracted or extended. If extended check that all tires are 1 to2 inches (3 to § cm) above the ground. Gantry and Back Legs 1. Check to see if gantry is raised or lowered and that all connecting pins and cotter pins are in place. 3 go Printed in U.S.A, 3/80 Tu oo0ot42 1. Check to see if counterweight is extended or retracted with owt pins in place. 2. Check to see if bumper counterweight is in place (if used) Crane Engine and Drive Train 1. Check engine oil level. 2. Check oil level in pump tower. 3. Check engine coolant level (check only when engine is cool). 4. Check for engine coolant leakage. Hydraulle System 1. Check hydraulic oil level in reservoir. 2. Check high pressure hoses on main hoist and boom hoist for leakage, 3. Check machinery deck tor hydraulic oil leakage. Alr System 1. Make sure drain valves on air reservoir and air filter are closed. Crane Operators Cab 1. Check engine diesel fuel level 2. Check instrument gauges and lights for damage. 8-701a) oe American Crane Corporation Wilmington, North Carolina OPERATION eet 800 Series Truck Crane Starting Diesel Engine WARNING WHEN STARTING OR OPERATING THE MACHINE CHECK TO MAKE CERTAIN THAT NO UNAUTHORIZED PERSON- NEL ARE IN THE ENGINE COMPART- MENT OR NEAR THE MACHINE. GIVE WARNING BEFORE STARTING THE ENGINE. Before starting the engine each day, make a pre- start inspection of the crane and proceed as follows: Above 40°F (4°C) 1. Close the ENGINE circuit breaker and the SHIFT CONTROL circuit breaker. A continuous buzzer should sound indicating that the engine clutch is disengaged, 2. Insert the start key in the ENGINE START switch. Turn the key clockwise and push it down. When the engine starts, release the key immediately. 3. With the engine running, check the following: a. Check the AIR PRESSURE gauge. Correct, air pressure is 110 to 130 psi (7.73 to 9.14 kg/cm) b. Check the CHARGE PRESSURE gauge. Correct pressure is 200 to 350 psi (14.06 to 24.61 kg/em*). The gauge should read 250 psi (17.58 kg/em*) minimum at 800 RPM engine speed. c. Check the AUXILIARY PRESSURE gauge. Do not operate below 100 psi (7.03 kg/em*) Pressure is raised by increasing engine RPM. d. Check the GENERATOR light. The red light should be off. e. Check the ENGINE OIL PRESSURE gauge. If there is no pressure indicated within 10 to 15 seconds, stop the engine and check the lubri- cating oil system. Printed in U.S.A. 3/80 TM 0004s 1, Check engine RPM on the TACHOMETER. Engine speed should not be allowed to fall below 550 RPM or exceed 2250 RPM. NOTE Aun the engine at part throttle and no load for about five minutes, allowing it to warm up before applying a load. Avoid unnecessary engine idling. When prolonged engine idling is necessary, ‘maintain at least 800 RPM. 9. Check the ENGINE WATER TEMPERA- TURE gauge. With engine at operating tempera- ture, the gauge should indicate 160°F to 180°F (719C to 82°C). Never operate engine above 200°F (93°C) fh. Check the TRANSMISSION TEMPERA- TURE gauge. In cold weather, warm the hydraulic olf to a minimum of 30°F (-19C) before beginning work. This may be done by running the crane functions at low load and speed to warm the oil. Cold weather oil may be used, in which case work may begin with the oil temperature at 0°F (-18°C), NOTE The hydraulic oi will warm up with the engine clutch disengaged because the charge pump is directly coupled to the engine. Engaging the engine clutch cou- ples the main hydraulic pumps to the engine. Oil temperature in the reservoir must not exceed 170°F (77°C) with summer weight oil or 145°F (63°C) with winter weight off (see Oil Recommendations table in the Lubrication Section). B-7101OPERATION tet . American Crane Corporation AMERICAN 800 Series Truck Crane Wilmington, North Carolina 4. Asthe engine warms up, the ENGINE CLUTCH CAUTION control may be movad to the IN position. The buzzer will stopwhen the engine cluten is engaged Operation with the tilter restricted will allow untittered oil tobe circulated through CAUTION out the hydraulic system. Engage the engine clutch at low engine 7. The crane is now ready tor operation. speeds only. Below 40°F (4°C) 5. Press the BOOM HOIST pushbutton. This button must be pressed after each start-up to 1. Make sure the engine is in normal shutdown actuate the boom hoist system or if clutch is dis- condition. Ma 2. Close the ENGINE circuit breaker and the 8. Check the TRANSMISSION FILTER tight SHIFT CONTROL circuit breaker. A continuous The light should be off, buzzer should sound indicating that the engine clutch is disengaged. ele 3. _Atthe engine control panel in the machinery The TRANSMISSION FILTER light, when cab, proceed as follows: on, indicates that the oil filter is restricted. The light may also.come on when the oil is a. Push Quick Start contro! knob in and hold cold at start-up, because the cold oil res- it in for three seconds to fill the valve. Release / ists flowing through the filter. When the the valve and allow three seconds to discharge oil ls cold enough for this to happen, keep the ether into the diesel blower box. the engine speed low and gradually raise the engine speed as the oll temperature b. Press ENGINE START pushbutton. As the raises. Do not continue operation if the engine starts, use additional ether to keep the light does not go off after a reasonable engine running it necessary. length of time. : ©. Check Ammeter and Oil Pressure gauge Ifthe light comes on under normal operat- for proper indications, ing conditions (warm oil and full throttle), shut down immediately and change the 4. Return to the operators cab and follow the filter element, normal engine start checkout procedure, Printed in U.S.A. B-7102 rH o000143 3/80American Crane Corporation Wilmington, North Carolina OPERATION 800 Series Truck Crane a Sa aaeea—— Stopping Diesel Engine Normal Shutdown 1. Lower the load to the ground. 2. Place BOOM DOG lever in IN position. 3._ Place MAIN DRUM, AUXILIARY ORUM, THIRD DRUM, and SWING PARKING BRAKES to SET position, 4, Place THROTTLE lever in Idle position. 5. Place ENGINE CLUTCH in OUT position, 6. Depress ENGINE STOP pushbutton (fuel rack will shift shutting off fuel to engine). 7. Open SHIFT CONTROL and ENGINE circuit breakers. 8. Open drain valves on the air tanks to bleed off air pressure and water. Be sure to close them before starting engine. Printed in U.S.A, 3/80 Emergency Shutdown If the engine does not stop attér using the normal engine shutdown procedure, pull the EMERGENCY. STOP knob on the Engine Control panel in the machinery cab. This control cuts off the air to the engine. DO NOT try to restart the engine until the cause for the malfunction has been found and corrected. CAUTION The emergency shutdown system should never be used except in an emergency. Use of the emergency shutdown can cause oll to be sucked past the oil seals and into the blower housing. The air shut-off valve, located on the blower air inlet housing, must be reset by hand and the EMERGENCY STOP knob pushed in before the engine is ready to start again, 8-7103American Crane Corporation Wilmington, North Carolina Crane Operating Instructions Two Speed Hoisting Feature The crane has a two speed hoisting feature, Rated Single Line Pull (SLP) is available with the LOW range, and one half the rated SLP is available with the HIGH range. The two speed hoisting feature is used in the operation of the main hoist, auxiliary hoist, ang the third drum. See the following table. Excessive Load Warning ‘There is a warning device on the crane to sound a buzzer if an attempt is made to lift too heavy aload. This warning device may be tested in the following manner: 1. With the engine at idle, place the ENGINE CLUTCH control on the side console to the IN position, - 2. Advance the THROTTLE to 1000 RPM engine speed. a OPERATION 800 Series Truck Crane eet AMERICAN 8450-8460 3. Close SHIFT CONTROL circuit breaker. CAUTION Do not shift the operating range unless all hoisting machinery is motionless. 4. Place SHIFT CONTROL to HIGH position The amber light will come on. 5. Place MAIN and AUXILIARY DRUM PARK- ING BRAKE levers on the front console to SET Position, 6. Position MAIN DRUM HOIST and AUXIL~ }ARY DRUM HOIST control levers to the HOIST position. Depress the HYDRAULIC PUMP CON- TROL foot lever. The overload buzzer should sound. 7. If the amber light or the buzzer fail to work, find the cause before attempting e lift. Single Line Pull ‘Auxiliary or Nominal | High Speed Main Hoist Drum ist Layer 45.000 ibs 22,500 tbs {20.412 kg} (10.206 kg) ath Layer 30,000 tos 16.000 os (13608 kg) (6804 xg) Third Drum tstLayer 37.000 ios 18.650 bs (16783 45) | (648049) Sth Layer 29.600 Ios 14,800 oe [caer | 673.9 (OVER) Printed in U.S.A 3/80 ‘Tw 0000144 B-7301American Crane Corporation Wilmington, North Carolina Main Drum Hoist Operation 1. Select the hoist speed range, NOTE Release parking brake and hold load by using the main drum brake pedal. 2. Raise load by pulling MAIN DRUM hoist con- trol lever rearward to engage drum clutch. Release the main drum brake pedal and then depress foot pump control to start drum moving NOTE The foot pedal is graduated. Control speed with pedal or hand control. 3. Lower load by moving MAIN DRUM hoist control lever forward to engage drum clutch and then depress foot pump control. CAUTION The main and auxiliary hoist drums may be used at the same time, however, the combined pull must not exceed the capacity of a single drum pull, 4, To allow the load to free fall, center the MAIN DRUM hoist control lever to release the drum clutch and then release the main drum brake pedal. Auxiliary Drum Hoist Operation 1. Select the hoist speed range. NOTE Release parking brake and hold load by using auxiliary drum brake pedal. 2. Raise load by pulling AUXILIARY DRUM hoist control lever rearward to engage drum clutch. Release auxiliary drum brake pedal and then depress foot pump control to start drum moving, NOTE The foot pedal is graduated. Controlspeed with pedal or hand control. 8-7302 oe AMERICAN OPERATION 800 Series Truck Crane 8450-8460 3. Lower load by pushing AUXILIARY ORUM hoist control lever forward to engage drum clutch, then depress foot pump control to start drum moving, NOTE The foot pedal is graduated, Control speed with pedal or hand control. CAUTION The main and auxiliary hoist drums may be used at the same time, however, the combined pull must not exceed the capacity of a single drum pull. 4, To allow the load to free fall, center the AUX- ILIARY DRUM hoist control lever to release the drum clutch and then release the auxiliary drum brake pedal. Third Drum Holst Operation (Option) ¢ 1. Select the hoist speed range. NOTE Release parking brake and hold load by using the third drum brake pedal. 2. Raise load by pulling THIRD DRUM hoist control lever rearward to engage drum clutch. Release the brake pedal and then depress foot pump control to start drum moving. NOTE The foot pedal is graduated. Control speed with pedal or hand control. 3. Lower load by pushing THIRD DRUM hoist control lever forward to engage drum clutch, then depress foot pump control to start drum moving, 4._ Toallow the load to frée fall, center the THIRD DRUM hoist control lever to release the crum clutch and then release the third drum brake pedal ( Printed in U.S.A. ra cooot4e 3/80American Crane Corporation Wilmington, North Carolina OPERATION 800 Series Truck Crane PoE] 8450-8460 Boom Hoist Operation The BOOM HOIST pushbutton must be pressed each time the master clutch is engaged or engine started with clutch in. To hoist the boom proceed as follows: Place BOOM DOG lever in OUT position. 2. Pull BOOM HOIST contro! lever rearward to raise the boom. NOTE Litting speed will depend on both engine speed and how far back the BOOM HOIST control lever is pulled. This lifting speed will also depend on whether aload is being raised or lowered. (See descrip tion of Power Sharing in this section.) 3. To hold the boom in position, place BOOM DOG lever to IN position. 4. To lower the boom, pull the BOOM HOIST control lever rearward slightly to release tension on boom hoist dog, then. position BOOM DOG. lever to OUT position. 5. Lower the boom by pushing the BOOM HOIST control lever to the left and forward. When a long boom or a heavy load is lowered, side action on the BOOM HOIST control lever will lower the boom. This graduated side action is used for inching the boom or for very precise lowering. At high reservoir temperatures, a light boom will also operate with this side action. + “Printed in USA. 3/80 Hm 000014 Power Sharing When the main hoist and boom hoist functions are being used at the same time (when near 2/3 capa- city), the boom hoist speed will be slowed down by about 60%. This feature is to preventthecrane engine trom lugging down below 1800 RPM. This control prevents lugging when the swing function is also used. Hydrostatic Swing 1. Place SWING PARKING BRAKE in RELEASED position, 2. If the crane is equipped with a swing lock, place SWING LOCK lever in OUT position. 3. Move the SWING control lever forward forleft swing and rearward for right swing. 4. Swing braking may be done in the following ways: a, If swinging left place SWING control lever in neutral and then move it to the right. b. Move SWING control lever in the direction opposite that of boom motion, When the machine stops, center the SWING CONTROL, fever. c. Use the SWING DRAG BRAKE control on the side console to drag or brake the swing, 5. After the machine has stopped, place SWING PARKING BRAKE to SET. 6. If crane is equipped with a swing lock, place SWING LOCK lever in IN position B-7303American Crane Corporation Wilmington, North Carolina OPERATION ot 800 Series Truck Crane AMERICAN Counterweight Removal and Installation (Early Machines) For operations calling for the craneto be swung over the side of the carrier, check ratings charts for backward stability. A zero rating on the chart indi- cates that the outriggers must be extended before swinging to the side. Boom Setup for Counterweight Removal See the following illustration for boom setup. No other boom sections are to be attached to the boom inner section Refer to the following procedure for counterweight removal. BOOM INNER SHEAVES: ARRANGEMENT COUNTERWEIGHT DEAD END, = 2 PARTS OF LINE STATIC LINE PULL |____ 5009 Las (2268 KG) MAXIMUM, OUTRIGGER REMOVAL ‘DEAD END ONLY COUNTERWEIGHT Boom Setup for Counterweight Removal TM 0000145 Printed in US.A. 3/80 ‘Tw co00r4s B-7401A American Crane Corporation Wilmington, North Carolina Counterweight Removal (Four Piece) 1. Swing crane to side, remove two bolts (A), and open doors (F) in carrier. 2. Swing crane into line with carrier with coun= terweight over carrier. 3. Remove two pins (H) and move two pins (@) to outboard position. 4. Pull counterweight ramps (4) and (5) onto carrier deck and put ends into brackets (J), secure with pin (kK). 5. Activate hydraulic system and push counter- weight out onto ramps, keeping travel even on each side, CAUTION INSERT SAFETY STOPS IN RAMP TO PREVENT COUNTERWEIGHT FROM SLIDING OFF RAMPS. 6 Remove four bolts (B). 7. Retract counterweight supports (3), put pin (G) in inboard position, and replace pin (H) in ‘counterweight. 8. Swing crane around and off-load individual counterweight blocks with crane. Tel OPERATION —— 800 Series Truck Crane Counterweight Installation (Four Plece) 1. Pull ramps (4) and (5) onto carrier deck and ut into brackets (J), secure with pin (K). Leave doors (F) open, 2. Stack counterweight sections onto ramps (4) and (5), being sure that the front edge centers over marker strips on carrier. 3. Install and tighten four bolts (8), 4. Remove pins (H) from counterweight, move pins (G) to outboard position, and extend coun- terweight supports (3) full travel 5. Putpins (H) into lower holes in counterweight. 6. Retract counterweight supports (3), pulling counterweight off ramps, and keeping both sides even. 7. Remove pins (H) from lower hole and place in upper hole in counterweight. Put pins (G) in inboard position, slide ramps (4) and (5) into wells in carrier. 8. Swing crane to side, close doors (F), and install and tighten bolts (A). APPLY OIL OR CAUTION: DO NoT GREASE TO SHIMS LUBRICATE RAMPS (0)TO case (43) OPERATION AGA ; 4. i | 5S F Counterweight Removal (One Piece) Printed in U.S.A, 3/80 TM 0000148 1M 0000168 B-7403American Crane Corporation Wilmington, North Carolina OPERATION a 800 Series Truck Crane Counterweight Removal (One Piece) 1. Swing crane to side and open doors (F) in carrier. 2. Swing crane into line with carrier with coun- terweight over carrier. 3, Remove two pins (H) and move two pins (G) to outboard position. 4. Pull counterweight ramps (4) and (5).onto carrier deck and put ends into brackets (J), secure with pin (K). 5. Activate hydraulic system and push counter- weight out onto ramps, keeping travel even on each side. 6. Retract counterweight supports (3), put (G) in inboard position, and replace pin (H) in counterweight. CAUTION Lift counterweight from top center slab only. Use a minimum two parts 1 inch (2.54cm) diameter E1PS load line. 7. Lift counterweight and off-load. Counterweight Installation (One Piece) 1. Pull ramps (4) and (5) onto carrier deck and put into brackets (J), secure with pin (K). Leave doors (F) open. 2. Pick up and swing counterweight over carrier ramps (4) and (5). 3. Lower counterweight onto ramps, being sure that front edge enters over marker strips on carrier. 4. Remove pins (H) from counterweight, move pins (G) to outboard position, and extend coun- terweight supports (3) full travel 5. Putpins (H) into lower holes in counterweight. 6. Retract counterweight supports (3), pulling counterweight off ramp, and keeping both sides even. 7. Remove pins (H) from lower hole and place in upper hole in counterweight. Put pins (G) in inboard position, slide ramps (4) and (5) into wells. in carrier. 8 Swing crane to side and close doors (F). 8 Ny 8 | el ‘APPLY OILOR ‘CAUTION: DO NOT | GREASE TO SHIM UUaricaTE RAMPS : (0) To case 9) j | ‘ OPERATION: Printed in U.S.A, Counterweight Removal (One Place) 1M 2000147 3/80 TM oosore7 8-7405OPERATION American Crane Corporation 800 Series Truck Crane Wilmington, North Carolina Bumper Counterweight Use The bumper counterweight is used for boom erec- tion only. It must be removed when moving about the job or over the road. Tighten chains by raising crane on outrigger jacks. BUMPER CARRIER COUNTERWEIGHT SUPPORTS COUNTEAWEIGHT EST. WT, 18,000 LS, (@.168 KG) Bumper Counterwoight TM 0000148 9 Printed in U.S.A, 3780 Tm 0000148 8-7501American Crane Corporation Wilmington, North Carolina OPERATION et AMERICAN 800 Series Truck Cranes BUMPER COUNTERWEIGHT TRAVEL RESTRICTIONS COUNTERWEIGHT MOUNTING LUGS, 18,000 Las: (2.185 «9) Figure t USE: The 18,000 ibs (8,165 kg) front bumper counter- weight may be required for some heavy lifts, or for erecting longer boom combinations. Consult the Ratings charts atthe back of this book for a complete list of boom combinations which must be erected with the front counterweight in place on the carrier, and for those lifting weight/boom length @ radius combinations which will require this counter- weight. TRAVEL RESTRICTION: 1. NO TRAVEL permitted when the full counter- weight (front bumper counterweight plus all upper deck counterweight sections) has been instatled on the machine. In this configuration carrier outriggers must be extended to prevent cover-loading of tires and carrier suspension. Printed in USA, CAUTION tlt rear dee counterweight on the ‘machine, outriggers must be extended before installation of tront counterweight ‘To0s00%9-1 2. FIRST GEAR travel (only) is permitted when ‘the full upper deck counterweight (base section plus overlays) is on the machine, but the front bumper counterweight has been removed from the carrier. (3 WARNING © When traveling the crane with an allowed, partis! counterweight (never travel th ‘machine with the full rear deck counte welght and the front bumper counter welght installed at the same time) make sure the boom Is pointing rearward, in line with the center of the carrier. Page 8-7503 10789) ‘Taso0so018American Crane Corporation Wilmington, North Carolina eta OPERATION AMERICAN 800 Series Truck Cranes 3, FIRST GEAR travel (only) is permitted when the front bumper counterweight is on the machine with the rear deck counterweight base section (29,900 Ibs) only, The rear deck overlays (total- ling 68.500 Ibs) must all be removed. CAUTION ‘Always check tire inflation pressures be- fore traveling the craneinany gear at any speed. 4, FIRST GEAR travel (only) is allowed when the frontbumper counterweightis on the machine by itself, and all rear deck counterweight sections have been removed. Print in USA 1083 5, HIGHWAY TRAVEL is permitted only when all counterweight sections--rear deck counter- weights as well as the front bumper counter- weight--have been removed trom the machine. Boom must be pointed rearward CAUTION See Traveling Welght Charts for safe travel recommendations before under- taking over the road travel. Page 8-7504 ‘TMo0s0018American Crane Corporation Wilmington, North Carolina OPERATION eee 800 Series Truck Crane AMERICAN Gantry Erection and Retraction (Up Through GS-17112) When lowering the gantry, use caution to avoid bending the hydraulic cylinders, Perform the follow- ing procedure carefully. 1. Remove pins from positions ."F" and “L” Refer to following figure. 2. Lower gantry using levers located at the left rear walkway on the machinery deck. 3. With the gantry in the fully retracted position, insert the pin through hole “J", making sure the CYLINDER INSIDE pin goes through all the slides, then secure the pin 4, Store the extra pins in the tool box. 5. Reverse the procedure to raise the gantry. NOTE For intermediate positions, raise the gan- try so that hole “L" in the top member aligns with “E" and “H" or “D" and “G" of the lower member. (Intermediate posi- tions carry no ratings.) Gantry (Up Through @S-17112) Tm cooooes Printed in U.S.A. 3780 TM 0000148 B-7601American Crane Corporation i Wilmington, North Carolina — AMERICAN OPERATION 800 Series Truck Crane Gantry Erection and Retraction (GS-17250 Through GS-18028) (On machines that have the hydraulic cylinder extending from the telescoping back legs, use the following procedure. 1. Lowerthe boom to the ground or onto blocks, Leave the boom hoist lines taut. 2. Remove pins from positions Reter to the following figure. | Cae rm 0000160 1 Gantry (GS-17250 Through GS-18028) Printed in USA, 3/80 TM 0000150 3. Lower the gantry by paying out the boom hoist line until plates “M" come in contact with plates "K" 4. Slack off the boom hoist line, and continue lowering the gantry using the gantry levers located at the left rear walkway on the machinery deck. Machines that have the gantry unloader, have six control levers. NOTE On single stage cylinders, gravity or vent- ing of the cylinders is used to fower the gantry. 5. Insert the pin through hole "J", making sure ‘the pin goes throughall the slides, then secure the pins. 6. Store the extra pins in the tool box, 7. Reverse the procedure to raise the gantry. NOTE For intermediate positions, raise the gan- try so that hole “L” in the top member aligns with “E" and “H” or “D” and “G" of the lower member. (Intermediate posi- tions carry no ratings.) 8-701American Crane Corporation Wilmington, North Carolina ot AMERICAN OPERATION 800 Series Truck Crane Gantry Erection and Retraction (GS-18488 and Up) (On machines where the hydraulic cylinder is not attached to the gantry front leg, the following proce- dure must be used. | 1. Lower the boom tothe ground or onto blocks. Leave boom holt lines taut | 2. Remove pins from position “ to the following figure. 3. Raise the hydraulic cylinder to maximum extension with the GANTRY levers located at the left rear walkway on the machinery deck, 4. Lower the gantry by paying out the boom hoist line until plates "M” come in contact with plates“k”: y 5. Continue lowering gantry gently, until cylin- ders rest in the pad mounting on the gantry front legs. 6. Slack off the boom hoist line and lower the gantry using the cylinders. 7. Insert pin through hole “J", making sure it goes all the way through, then secure the pin 8. To raise the gantry, reverse the procedure Alter the gantry is raised, return the cylinders to their lowered position. NOTE For intermediate positions, raise the gan= try so that hole “L” in top member aligns with “E" and “H" or “D” and "6" of lower member. (Intermediate positions carry no ratings.) Gantry (GS-18488 and Up) Tm 0000161 Printed in U.S.A, 3/80 TM 0000181 8-7801THE AMERICAN CRANE CORPORATION WILMINGTON, NORTH CAROLINA 28402 OPERATION TRUCK CRANES RECOMMENDED STORAGE PRECAUTIONS Before placing a crane in storage for an extended Period, observe the following recommended storage precautions: Store Crane in a level, dry location where there is sutticient working area to travel, swing, and move boom a few feet in each direction. 2. Lubricate crane completely. Be sure to follow operator's manual lubrication chart including all assemblies which require monthiy, quartery, and semi-annual lubrication. Apply a light film of lubricant spray on all moving parts, that may be subject to damage from corrosion (tor ‘example, cab door hinges and latches, etc.) 3. Coat cables and fleeting sheaves with grease. 4. _Drain oil from all compartments and replenish them with fresh oil. ) 5. Make sure hydraulic system is full to prevent condensation in reservoirs. After storage, check for ‘condensation and, if necessary, drain water from the system. 6.. Change ail fters. 7. Drain and flush the engine cooling system. Fill cooling system with permanent type Glycol anti-freeze for expected site weather conditions. After filling system, engine should be brought up to running temperature and run for at least a half hour at operating temperature. 8. Drain cartier air reservoirs. 9. All switches should be in “off” position. All doors, windows or shutters should be closed. 10.Paint all bare spots or scratches on exposed assemblies (i.e. cab). Be sure to touch up paint on base of boom. } Z Printed in U.S.A. (1/87) 3/89 11.The crane engine should be started and brought up to running temperature every 30 days. Operate the boom, travel, swing, and hoist controls for short cycles. Be sure to run crane long enough to bring batteries up to full charge before shutting down. Drain cartier air reservoirs during this 30-day interval, also. 41 itis not possible to start up the crane and work through all functions at regular monthly intervals, remove the storage batteries from the crane so that they can be recharged according to their manufacturer's recommendations. Return the batteries to the crane and operate the machine for short cycles as close to monthly intervals as possible. Drain the carrier air reservoirs every 30 days without fail. 8-79002 OPERATION American Crane Corporation enon 800 Series Truck Crane Wilmington, North Carolina Useful Operating Information Weights of Common Materials Material los/cutt | tbs/cuyd | kg/m ‘snes - Ped Dry 35 se 6 Brick Bais = 1488 ste Cement Portang 3a 2508 ars ‘Grareoa 3 are 2 Ginders 5 1488 12 Ginter -Porland Cement a 2296 ist Gay Ory m comps 33 1701 $08 Gly - Compact Neural Bed 108 2348 1015 Goal = Arhraci 56 i512 S21 Goal Bhurinous FoF W Ped = 14a a Goal Bituminous Slack, Pilea 50 1350 285 Coke» Blast Funace Size 2 723 281 Sake = Foundry Sze 25 3 er Coneete = Ready to Pour 143 2088 1378 Dolomite - Crusted Fine 3 256s 20 Dolonis Braker Lump 38 2565 ee Earth = Loamy, ry Loose 75 2028 08 Earth - Ory Packed 38 2568 ae Earth Wet (ud) 770 3570 To8e Flue Oust = Bast Furnace ns S108 toro Flue Oust - Blast Furnace, Wet 150 4089 1596 Gypsum = Crushed te 35 2585 eee Gypsum -Calcned 60 1820 558 Gravel: Oy, Loose 110 2870 see Gravel Dry Packed 113 3051 To82 Gravel - Wet Packed 120 3240 ini? tron Ore 60% on 300 100 ae iron Ore 50% on 250 8750 wer iron Ore 405 ron 200 5400 ‘62 tron Punchings « Serap 270 7280 2513 Ton Tanne Serap 17 3728 Te23 Limestone» Run of Crushed 3 2868 e64 Limestone - Fines Out 100, 2700 sat Limestone “1-172 of Graded 35 2238 731 Limestone» Above 2 Graded 80 2160 ms Pnosphat Acid -(Fenlizen) 85 2295 71 Phosshate- Rock 20 2166 Tis Pres 135 2645 1387 sat 38 108 540 Sand Diy. Loose 35 2565 ae Sand - Wet. Packed 120 2240 unr Scale = Roling Mi, Wet 12 2564 223 Shale = Broken 3 2285 7st Sag Blast Furnace, Sroken 138 sre 1238 Sag - Open Hearth, Crushed 108 2808 or Printed in U.S.A. 3/80 Weights of Common Materials (Over) 7m 0000182 B-7901OPERATION A ated 800 Series Truck Crane American Crane Corporation eeriend Wilmington, North Carolina Weights of Common Materials (Continued) Material lbs/eutt | Ibs/cuyd | kg/m? Slag - Granulated, Ory 38 1028 354 Slag - Granulated, Wet 58 1586 540, Snow 33 aot 307 Sulphur= Broken 80 7620 558 Timber - Green Cedar 37 990. 34a, Douglas Fr 38 1026 354 Herniack 4 1107 382 Southern Pine, 55 1485 512 36 972 335) . 50 1960 465 Zine Ore - Broken 150 4050 1396 Weights of Common Materials (Continued) Printed in U.S.A. 8-7902 rw 2000182 3/80American Crane Corporation Wilmington, North Carolina HOIST. With forearm vernea!. fore finger porting up. move hand in| small onzontal exce, z “ USE WHIPLINE (Auxiliary Hoist Tap elbow with one Nand: then uae regular signa, Printed in U.S.A. 7/75(R1-3/92) LOWER. With arm extended down- ‘ward, foretingar pointing down, RAISE BOOM. Arm extended, fingers closed. thume pownting upward, RAISE THE BOOM AND LOWER THE LOAD Watn arm extended. thumb ointing up, flax Hngers im aed out 28 ong as load movement desired. HAND SIGNALS (OVER) OPERATION AMERICAN CRANES USE MAIN HOIST. Tap fet on nes: ‘han us rogue sana LOWER BOOM. Arm extended, clot, thumb pointing LOWER THE BOOM AND RAISE THE LOAD. With arm extended. num Boinong down. Hex fingers in and ‘ut ag 1ong as losd movement's, Seured. 8-7903,amaibind American Crane Corporation AMERICAN Wilmington, North Carolina SWING, Arm extended, point with finger in ivecton of swing of oom. TRAVEL. Arm extended forward, hand open and slighty raised, ‘make pushing motion in rection of travel TRAVEL. (One Track) Lock the track on side indicated by raised fist. ‘Travel opposite track in direction indicated by circular motion of other fist. rotated vertically in front of ody. (For land eranas only) STOP Arm extended, palm down, ‘move arm back and forth Foeitontaiy DOG EVERYTHING. Clasp hands in front af body EXTEND BOOM (Telescoping Booms), Bath fists 1m front of body wth thumbs peinting outward HAND SIGNALS (CONTING EMERGENCY STOP Both ams. extended, palms down, move arms back and forth Roraontaly ‘TRAVEL (Both Tracks). Use bath r Fig in front of body, making 8 reular mation about wach other indicating direction of rave forward or backward. (For and eranes only. RETRACT BOOM (Telescoping Booms). Both fists in front of booy with thumbs pointing toward each other Extracted from American National Standsard. Safety Code for Crawler, Locomotive and Truck Cranes. B30.5-1968 with the permission of the publisher. The American Society of Mechanical Engineers. United Engineering Center, 345 East 47th Street, G New York, N.Y, 10017 Printed in U.S.A. 7/75(r1-3/92) B-7904