MOBILIFT MECHANICAL HANDLER OPERATING AND MAINTENANCE MANUAL — MOBILIFT Sa LIMITED MOBILIFT “KAISER KRIS “Grane __ExcavaTors | VACUUM crores fag woes 49 Rolle Strast, Spartan Ext 9, Kempton Pask 1619 Telephone or 703 Po gon 706, Elocle 1610, PSA e011) 974-98MOBILIFT INDEX CONTENTS GENERAL DESCRIPTION SAFETY PRECAUTIONS 11.1 CARRY QUT VISUAL INSPECTION OF MACHINE: 1.2 ROUTINE MAINTENANCE AND SERVICING. 2 STARTUP DRIVING THE MACHINE 4° OPERATING THE MACHINE WITH LOAD o GENERAL TECHNICAL 5 HYDRAULICS 6 STEERING PUMP, ORBITROL CONTROL 7 MAIN HYDRAULIC PUMP AND DRIVE 8 HYDRAULIC TANK AND CONTROL VALVE 9 MAIN LIFT CYLINDER AND LIFT CIRCUIT 10 EXTENSION CYLINDER 11 WINCH 12 BRAKES, TYRES AND WHEELS HYDRAULICS FAULT FINDING LIST CAUSES OF PUMP FAILURE TECHNICAL DATA DEALER DISTRIBUTOR MAINTENANCE MANUAL RECOMMENDED SPARES LIST PAGE 10 13 16 16 16 v7 v7 18 18 18 2 27MOBILIFT MECHANICAL HANDLER GENERAL DESCRIPTION The Mobilit mechanical handler is a rough terrain pick-up-drop-and-cary crane and as such operates without the use of outriggers. It therefore has no block duty as in the case of conventional cranes and combines the advantage of lifting and canying its load. The machine also therefore has a large capacity at a. good radius. Conventional cranes are fully slewing and have outriggers and they fall into the following categories: a) Lattice boom truck mount b) Telescopic boom truck mount ¢) — Allterrain highway d) Industrial fully slewing yard cranes The Mobilift can be split into three units: a) — Power Unit b) Crane frame. ©) Telescopic boom. The Ford power unit is mounted in a subframe and allowed to pivot through front and rear bearings which gives the drive axle oscillation of 22° thus when the machine is travelling over uneven terrain the power unit pivots from side to side and maintains contact with the ground to ensure traction is maintained. This subframe is connected to the machines main crane frame through a slew ring which allows the power unit to articulate thus the design incorporates the centre pivot principle, steering being achieved by operation of two double acting rams mounted horizontally on the frame giving a total steering movement of 80°. Mounted at the rear of the power unit is a hydraulic fank and counter weight. The counter weight is to balance the engine mass in front of the slew ring thus ensuring that the load on the slew ring Is evenly distributed at all times. The operator sits in the power unit driving seat as in a conventional tractor. The machines mainframe consists of two sideframes of heavy duty fabricated stool sections which are coupled together by cioss members including the 1.6 inch thick cross plate on which is mounted the power unit subframe. The mainframe is mounted on.a rigid front beam axle which acts as a fulcrum: The fully telescopic boom fits between the yoke ie, the two side frames and pivots on a main boom pin. Two heavy dulyliftrams are able toluffthe boom up fo 60° and each ram has a protection guard for swinging loads.The boom is manufactured from pressed steel box sections reinforced and plated. Internally a fabricated steel section incorporates the hardenedsteel cam carry rollers on which the intermediate section is supported, The intermediate sectionis a fabricated box section which sis on the carry rollers and is supported at the end by vesconite wear blocks. The boom Is open throated. This allows the telescopic extensions with lifting lugs hung off the first extension allowing hook movement through the boom. Thus the load can be powered in or out and carried in the horizontal plane. Incorporated in the main boom section is a telescopic ram which is used to power out the telescopic sections. An independent hydraulic winch which allows the crane to operate in the conventional manneris mounted onthe rear or heel of the crane boom.MOBILIFT SAFETY PRECAUTIONS 1.1 CARRY OUT VISUAL INSPECTION OF THE MACHINE AS FOLLOWS: 1.1.1 Wheel nuts: front 1.1.2 Air cleaner B 1.1.3 Fan belts 1.1.2 AirCleaner A 1.1.4 Engine oll dipstickSAFETY PRECAUTIONS Cont VISUAL INSPECTION OF MACHINE 1.1.6 Radiator coolant level 1.1.9 Check hooter working 1.1.10 Check anyleaks under machine whilst parked 1.1.7 Fuel level .MOBILIFT SAFETY PRECAUTIONS Cont. VISUAL INSPECTION OF MACHINE 1.1.11 Compressor oil level 1.1.13 Check hoses and hose clampsSAFETY PRECAUTIONS Cont. 1,2 ROUTINE MAINTENANCE AND SERVICING DAILY CHECKS ‘Check engine oll evel Check water coolant level Check hydraulic oll level Check wheel nuts fortorque (Ist 50 hours) Check transmission oil level Steering Rams > 2points WEEKLY SERVICE GREASE MACHINE Rear pivot pin > T point Turntable + SpointsMOBILIFT SAFETY PRECAUTIONS Cont. ROUTINE MAINTENANCE AND SERVICING cont Front pivot pin ~ points i ~ 2point Universal coupling = 2points Boom Pivot pin 2 points Main lift rams - 2points per ram Front brake cams 1 point per cam Extension rollers + 1 point per rollerSAFETY PRECAUTIONS / ROUTINE MAINTENANCE AND SERVICING cont WEEKLY SERVICE Cont Extensionslide block - 2 points per block Snatch block > Tpoint TORQUE CONVERTOR (/F APPLICABLE) Lubricate clutch release bearing (cop filed with grease). Half tum clockwise, when emply, refill with grease, DO NOT overgrease. Check for hydraulic oil leaks. Tighten up. nuts. Check tyres for pressure, See schedule, Check wheel nuts for torque. Check all oil and water levels, including battery. Clear dust from pre-cleaner. Clean machine.MOBILIFT SAFETY PRECAUTIONS Cont. ROUTINE MAINTENANCE AND SERVICING cont 1ST SERVICE - 100 HOURS Repeat as for weekly service. Change engine oll and filers. Change fuel fiter and transmission fiter, Check alr filter Change hydraulic oil filters Check clutch and brakes for adjustment ‘Check winch brake for adjustment ‘Check machine overall, Tighten up nuts. 300 HOUR SERVICE & SUBSEQUENTLY EVERY 300 HOURS Same as first service, except it may not be necessary to change retuin tine fiter. Refer lubrication and maintenance section - Ford Operator's Manual, for furiher points ‘on tractor. ‘Change oil in compressor. If torque convertor fitted, reter Maintenance Manual for Torque Convertor. 1000 HOUR INTERVALS Drain oilfromhydraulic tank, remove sludge, refill and fit new fitter. Drain winch gearbox and replenish with + 1 litre of SAESO. Check clutch for adjustment and replace if necessary. ‘Check torque on tumtable retaining bolts, Check steering bushed for wear Check boom extension rollers for wear Check nylon pads on extension slide block for wear Check winch rope and hooks for wear Check tyres for wear and cuts Repack front wheels hubs with grease Refer Lubrication and Maintenance Section = Ford 5610 Tractor Operator's Manual, for Instructions regarding prime mover. NOTES: Maintenance personnel should study the Ford Operator's Manual as well as this write- up in order to acquaint themselves with maintenance requirements. (Also Brockhouse manual).SAFETY PRECAUTIONS Cont. 2 START UP: 2.2 Donotstart engine or operate controls whilst standing beside the machine. Always sit atthe drivers seat to operate the machine 2.1 Apply park brake and ensure ‘transmission is in neutral before starting engine, 2.3 Donot bypass the neutral start switchit the safety controls malfunction-cailthe machine decler. 2.4 Avoid accidental contact with the gearshift whilst engine is running 25 Test all hydraulic functions before going to work, 2.6 Check brakes are operational,MOBILIFT SAFETY PRECAUTIONS Cont. 3 DRIVING THE MACHINE 3.1 Change gear and start off smoothly in the conect ratio Hi/Low. 3.2. Avoid sudden braking. 3.3 Avoid rapid slewing, 3.4 Check that noone is behind the crane when reversing. 3.5 Use Indicators well in advance. 3.6 Put on the flashing beacon when fravelling with or without load. 3.7 Always use driving mirror to check following vehicles. 3.8 Check brake lights are operational before driving crane. 3.9 Alwaysuse park brake when stationary nd take out of gear. 3.10 Do not get off the machine whilst in motion,SAFETY PRECAUTIONS / DRIVING THE MACHINE Cont 3.12 3.13 3.14 3.15 3.16 317 3.18 3.20 3.21 Shut off engine ond apply park brake before getting out of machine Do not park on incline or steep slope. Do not operate in enclosed building without adequate ventilation Watch where you ate going especially with the boom projection in confined ‘reos on roads around bullcings and ensure boom is lowered to clear low hanging obstacles or low heacroom. To avoid accidents drive the machine with due care and at speeds compatible with safety especially over rough terrain and tuming comers. When transporting by lowbed/trailer ensure machine's handbrake has been applied before moving off. Keep machine in same gear when going downhill as used when going Uphil, Do not coast or free-wheel downhil. Any towed trailer whose total weight exceeds that of the machine must be equipped with brakes. 319 Always check overhead clearance especially when transporting. Dip headlights when meeting oncoming traffic. Use flosher for tum signals at all times ‘and ensure that amber beacon is operating when machine is in use to wam others. 3.22 3.23 When manoeuvreing around buildings or tight comes itis better to articulate first rather than move then articulate. Do not articulate with the handbrake on, 3.24 3.25 3.26 3.27 3.28 3.29 3.30 NB: Do not articulate with the diff lock engaged If the power steering fails the orbitrol steering valve will give sufficient power ‘to manoeuvre the machine to a safe parking place. Avoid travelling over sharp objects which may damage sidewalls of tyres. Always select the correct gear ratio when preparing to move off with or without the load. Donotteave snatch block andrope on ground as this may cause a rope to Jumpthe pulley block andjam causing damage to the hoist rope. Do not cary passengers, Do not leave chains toiling loose behind the machine. THE MAXIMUM UNLOADED IS 25kph ‘THE MAXIMUM TRAVEL SPEED LOADED MUST NOT EXCEED Skph. TRAVEL SPEEDMOBILIFT SAFETY PRECAUTIONS Cont. 4 OPERATING THE MACHINE WITH LOAD 4) Rated load capocities are marked on the boom as well as on the load chart insicie the cab. 42 43 44 If the weight of load is unknown the operator may test by lifting the load. if foundto be too heavy the load should be slung near the front axle with the boom horizontal, The boom elevation will increase the load that may be carried because the load radius is shortened. The operator should retract the ‘extension before lowering a load on the boom because lowering the boom increases the load radius, 19 loads ensure that the load is low down in the event of load swing. This enables the operator to drop G load in an emergency. 46 ay 48 49 4.10 45 ® Loads cartled over uneven terrain should be carried with utmost care asa swinging lateral load at excessive fravel speeds could tip the machine sideways, When carrying loads down a steep gradient the operator should use the independent air brakes as well as the inboard rear brakes. Ifthe loadistoo heavy forthe winchthe load has to be dropped vertically. tris possible to do this by lowering the load Using the boom as follows: ©) Retract load on extension b) Lower the boom ¢) Retract load on extension ) Lower boom thus the load remains constant. When, lifting the reverse procedure applies. Do not travel with snatch block swinging. Thisshould be 15cms(")from the sheave head. The front and rear axles oscillate 22° relative to each other to travel over uneven terrain, When the maximum oscillation is attained ie. the oxle is on the stop then extra care must be taken especially when travelling over very uneven ground. This is due to the fact that the load will swing in the direction of oscillation and tend to lift the opposite rear wheel.4.11 The telescoping ram has @ double eye to enable first one extension and then the other extension tobe powered out, To facilitate removal and insertion of pins move the ram lever rapidly. Strict procedure must be followed. 4.12 EXTENDING BOOM 4.12.1 Remove locking black pin from holder and insert to lock main boom to first extension. SAFETY PRECAUTIONS Coni. 4.122 Remove blue pin ie, the intermediate extension pin to ‘iow ram to push out first extension. Power out the first extensionto full each and play ou winch rope so block does not foul sheave head,MOBILIFT SAFETY PRECAUTIONS Cont. 4.12.5 Place in pin holder. A126 4.12.7 Now power out intermediate extension after removing black taper locking pin. 4.13 RETRACTING BOOM 4.13.1 413.2 413.3 4.13.4 413.5 Retract boom ie. intermediate extension and lock to the main boom with black taper pin. Remove blue pin, Extend ram to first extension and insert green pin, Retract extension into intermediate extension and insert the blue pin. Remove locking black pin ‘and place in holder.GENERAL TECHNICAL 5 HYDRAULICS 5.1 52 53 The Mobilit is equipped with a single hydraulic reservoir which gravity feeds the main hydraule pump, The main hydraulic pump supplies oil through a triple bank control valve which feeds the ollsupply tothe telescopic ram, the main boom rams and the hydraulic winch, An independent, engine driven, steering pump is also supplied from the same reservoir and articulation through the two double acting rams is achieved by an orbitro! control valve ‘onthe steering column. In the event of pump fallure the machine may still be steered by the orbitrol steering valve which acts as a pump. The twin lift boom cylinders incorporate safety check valves which inthe event of hose failure prevents the boom from dropping under load. 6 STEERING PUMP, ORBITROL CONTROL The standard Ford steering column operates an orbitrot metering valve. The steering column shaft couples the spines in the orbitrol valve to the steering wheel. When the steering wheel is turned the direction of travel ‘the steering shaft opens or closes and the displacement ports in the valve, directing the flow of oil either left or Tight to the steering rams or back to reservoirwhen fulllock exceeds contol valve pressure. 62 63 The machine is equipped with independent geartype steering pump replacing the standard Ford power steering pump. Thisis coupled toa reliet valve set at 10.35MPA (1600 PSI) to the orbitrol metering valve at the base of the steering column which supplies hydraulic olf to the steering rams on either side of the slew ring. he flow of oil via the steering pump is increased by engine RPM and therefore slower steering will be experienced at idle speeds Compared ‘to normal running RPM. Thus when the operator Is articulating in a stationary position improved steering is obtained by setting the hand throttle at ahigher RPM. 7 MAIN HYDRAULIC PUMP AND DRIVE a 72 73 The crane isequippedwith a geartype main hydraulic pump operating a maximum pressure of 17.5MPA. (2500 PSD. This pump is driven by a direct dtive shaft ond thus the pump is driven continuously whilst the engine is running, Should the pump seize the key will shear in the keyway and there will bbe loss of hydraulic power. The pressure should not be increased forany reason, andifone of the control levers cannot be depressed the ‘CO ring on the spool may be displaced.MOBILIFT GENERAL TECHNICAL Cont 8 HYDRAULIC TANK AND CONTROL VALVE 81 82 SAIOW hydraulic oll Is used in the hydraulic system and supplies oll to both the steering and main pump hydraulic circuits. A tank indicator is situated behind the operatorsseat and should be read with the boom retracted. Conect levels are necessary for efficient cooling and prevent oll starvation to the hydraulic pumps. The 10 micron retum line fiers situated directly behind the operators seat and coupled to the tank. 8.3 Athree bank controlvaive for it, boom extension, and winch operations, incorporates a pressure relief valve situated next to the outer spool with a screw on cap covering the pressure regulator. Pressure Is increased by turning the screw clockwise. 9 MAIN LIFT CYLINDER AND LIFT CIRCUIT ol 92 The crane isequippedwithtwin double acting main lift cylinders which incorporate safety restrictor valves which in the event of hose failure prevent the boom from falling. Ram guards are fitted to protect the barrel assembly and the telescopic ram guards are intended as defiectors to protect the exposed cylinders from damage caused by swinging loads. They are not designed to absors Constant impacts from swingingheavy loads otherwise these deflectors willbe damaged and unserviceable.10 EXTENSION CYLINDER 10.1 The double acting extension cylinder isfittedinto the main boom body and a safety holding vaive Is fitted to the extension return line. 10.2. Inthe event of hose failure the valve will lock and hold the extension in Position. WINCH 11.1 The Mobilift hydraulic winch incorporates a winch drum brake which is activated by hydraulic pressure, Awinchthuscanbe driven. both ways only by hydraulic pressure which must release the brake first. If loads heavier than the rated capacity are attempted the relief valve allows oil to bypass the winch motorandthe unitwillnot ft. Histhus recommended that heavier loads should be therefore lifted with the sings hung off the appropriate boom hook postions. n2 GENERAL TECHNICAL Cont 12 BRAKES, TYRES AND WHEELS 12.1 122 123 124 125 Expander type drum brakes are fitted to the front wheels and these brakes are activated by a cam which has an adjustment nut. Airis fed from the tanks situated between the ballast box and the hydraulic tank fo the diaphragm ‘andthe plungeractivatesthe brake cam which applies the brakes, The airreceivertankisfitted with asatety pressure release valve. The cit Compressor is belt driven from a pulley attached to the engine ‘crankshatt and the alr brake control lever is situated next to the ‘operatorsseat onthe left hand side. Inboard wet disc brakes are fittedto the drive axle. In all cases the machines are supplied with water ballasted tyres. The procedure to fill the tyre following a puncture Is stand the fyre with the valve uppermost and tothe point where water comes out of the vaive. Insert valve and blow up with air to recommended pressure For the first SO hours of operation its important that the wheel nuts are checked before start up and at shutdown. The torque settings are indicotedin the enclosed Technical Schedule.MOBILIFT HYDRAULICS FAULT FINDING LIST LOSS OF STEERING, CHECK THE FOLLOWING: © Check hydraulic hose failure. b) Test of steering on idle. ©) Uncouple hose leading from relief valve onthe pumpdelivery andattach pressure gauge. Ariculate to take a reading, ) If the system is bypassing at low pressure it means the relief valve has failed or the spring stuck in the open position. EXTENSION CYLINDER AND CIRCUIT, IN THE EVENT OF FAILURE CHECK THE FOLLOWING: Oil leaking out of the back of the extension with the boom elevated indicates either: @) the seals are leaking or b) a pipe inside the extension to the hydraulic ram is leaking, WINCH AND BRAKE CIRCUIT: 1 Check oll leaks appearing on the motor covers and @) First check the torque on the nuts b) _ Ifoitisleaking it requires areplocement seal ©) Motor failure requiring replacement @) Always ensure that the oll level in the winch gearbox is corect. CAUSES OF PUMP FAILURE NB Dit inthe oil Cillevelin the reservoirtoo low causing cavitation and overheating. Defective pump. Asuction line filteris fitted prior to PDI to clean the circutt Should the suction line filter be blocked this causes olf starvation and pump tollure Theretum line filter must be changed at regular service intervals, ‘When a pump has foiled itis ikely an excess of metal contaminates the oi. 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WweB ee uit op1 Buvenep cundoes | auiyt g2t Buuonlop dune ses | wdd arzi un steoulsnieD Season sonnwaaaH cava wnozKe owe wnazxe uve wnozxe our wnaexe NOISSINSNVAL 0192 auiog 0192 atiog 0198 auos OL Ly/0L6z Guos AON Skid SHIN zt oun sh t LITOMOBILIFT DEALER DISTRIBUTOR MAINTENANCE MANUAL 1 MAIN FRAME AND SLEW RING. 1,1. The slew ting is attached with high tensile bolts. The outer section bolts tothe mainframe andthe innerpart Is attached to the main frame cross plate, which in tum is pinned to the rear sub-frame, allowing 22° oscillation. 1.2 There are two grease points on the ‘outer ring which require regular greasing fo prevent wear. 1.3. The nuts securing the attaching bolts must be checked for conect torque at least every six months. 1.4 Should the slew ting have to be removed for any reason, first remove the ballast box, then articulate the crane toone side and block the prime mover with @ jack placed under the front cross member next to the radiator support. 1.5 Then block the rear end of the main frame and support the boom to prevent tipping. 1.6 After removing the attaching bolts Ye slew ting can be removed by sliding it towards the rear of the machine. BOOM AND EXTENSION 2.1 The main boom is of box section design with three pairs of fixing lugs welded tothe underside af positions to enable the machine to lift the rated tonnage. 2.2 Contained within the main boom is the hydraulically operated boom extension, which is fully supported by replaceable vesconite nylon slides and wear pads, 2.3 Anylon support rolleris provided for the hydraulic cylinder to preclude tt from ‘fouling’ the inner walls of the main boom, when the extension is fully extended, 2.4 Inthe case of the larger cranes the extension booms are supported by cany rollers. a 25 26 27 28 29 The extension has sets of fixed lifting lugs welded to the underside giving additional lifting postions. Separate hooks may be attached to these lugs using the pins supplied, The sheave head for winching ‘operation is also caried by the ‘extension boom, Ititisnecessary toremove the boom from the rain frame tocamry out the following procedure: 2.7.1 Place boom in the horizontal plane and support with appropriate lifting equipment. 27.2 Disconnect and __ plug hydraulic hoses to extension, and winch. 2.7.3 Remove the guards from the derticking/or lift cylinders. 2.7.4 Take out bolts securing the lift cylinder pivot pins at the top ‘and bottom, drive out pivot pins using a suitable punch, ‘and remove lif cylinders. 2.7.5 Remove bolts securing the main boom pivot pins ond drive the pivot pins out from the inside using a suitable punch and a large hammer. When replacing the boom assembly reverse the procedure. ‘There are two grease points on the upper surface and one on the lower of the main boom extension, Regular lubrication of these points is required to prevent undue wear of jhe vesconite nylon support and wear pads. Failure to lubticate these willresuttin premature wear of the pads and the extension boorn will un our of alignment. To replace pads, remove nuts, take ‘out worn pads and fit new and secure with the countersunk headed bolts and lubricate before commencing work.COUNTERWEIGHT AND SUB-FRAME 3.1. The counterweight is of a box type made especially tofit the sub-frame ‘and secured by two orfourbolts. itis baliastedwith metalpunchings and sealed, 32 The sub-frame is secured to the prime mover by front and rear pivot pins. This allows the prime mover to oscillate laterally 22° with the sub- frame relative to the main frame, thus maintaining full ground contact on all four wheels giving stability over rough terrain, SPLITTING THE TRACTOR PRIME MOVER WITHIN THE FRAME Ifit necesscry to reploce a clutch the tractor Is split and the following procedure must be adhered to: 4.1 Articulate the crane fully to one side. 42 Remove ballast box from sub-frame using suitable lifting equipment. 43 Loosen the eight rear mounting plate bolts. four of which are tapped. four with nuts and place o jock underthe sub-frame at the rear mic-point of the rear bumper and raise sufficiently to support the weight. 44 Place a support bar actoss the sub- frame underneath the transmission housing ontop of the sub-frame side members. Thisservesas asuppor for the tear end of the tractor behind the section to be spilt. 45 Following the removal of engine panels, radiator, steering pump hoses and connecting lines. using suitable iting equipment, remove the front oscillating pivot pin and spit the engine unit from the bell housing. Refer to further information suppliedin the Ford Tractor manual. 1 The crane must be articulated first otherwise the engine or transmission willnot come out asthe frames cause obstruction, 2 2 The ballast box must be removed otherwise the load on the rear wil be excessive and may cause the crane to overbalance. FRONT AXLE AND HUB ASSEMBLY 5.1 The front ax’e is a heavy duty box section canying large diameter stub axles fitted with heavy duty taper roller bearings, mounted in ‘cast steel hubs. 52 The bearings are lubricated by grease packed into the hubs and the outer cops, which should be checked and replaced every 600 hours. The front axle is an Integral part of the main frame ond acts as the fulcrum of the crane. STEERING AND ORBITROL CONTROL VALVE 6.1 The steering column bolts on top of the orbitrol control valve where the shaffs are splined to each other. 6.2 When the steering wheel is tuned, the direction of travel is transmitted tothe orbitrolvalve which opens tho necessary ports fo supply pressure to the steering cylinders on the one side and simultaneously opens ‘other ports allowing oil out of the otherside ofthe cylinderto return to the tank. 63 When full lock is reach pressure builds up and overcomes ihe relief vaive andoilis again returnedtothe tank, The steering system hasitsown Independent pump. 64 The orbittol contro! vaives are trouble free units and will usually only fait if dit is introduced into the system, or if persistently over pressurised which causes extemal oil leaks. 65. In the event of replacement, the orbitrol control valve Is easily removed by disconnecting the hoses and unbolting trom its mounting brackets,MOBILIFT CRANE OPERATING CONTROL VALVE 7.1. The crane is equipped with a three bank control valve, governing lift, extension and winch functions. 7.2 The pressure relief valve is situated next to the inner spool and a screw on cap covers the pressure regulating screw. Pressure may be increased by turning the screw clockwise and decreased by screwing anti-clockwise. 7.3 The control vaive is made up of jhree separate sections, each with thelr own sealed spring, centered spool. When the operating levers are depressed or elevated, ports in the spook direct oll to the selected circuit. The sp0o's automatically return to neutral whenthe levers are released by the operator. Due to {he simple and robust design, these valves give iitfle trouble and ‘occasionally it is necessary to replace ‘O’ ring seats. NB: 1 The pressure relief valve is set at 10:35 mPa (1500 psi) as required by the manufacturers to prevent overloading of the crane and to protect the hydraulic system. Pressure should not be altered for any teason unless specifically authorised by the suppliers. 2. fit is reported that the operator is unable to operate any of the control valve levers, this usually indicates that the 'O' ring is leaking ll into the iower housing, this can eventually cause a hydraulic tock which stops the:spool’s downward stroke. MAIN HYDRAULIC PUMP AND DRIVE 8.1 The crane is fitted with a gear type main hydraulic pump rated at a maximum pressure of 17.5 mPa (2500 psi). The performance is as indicated in the technical schedule, 23 82 83 a4 85 The pump is driven directly off either the engine crankshaft pulley or at ine back of the rear axle casing, In each case it is live with a Key ond Keyway in the flange ond thus running at engine speed when the engine is running. In the event of pump seizure this failsafe Keyway wilisplit aliowing the driveshaft to run free. To remove the pump disconnect hoses and plug them, remove mounting boits Gnd pull the pump. straight out. To remove the Inner universal coupling, when applicable, carry out the above ond then unbott the coupling from front crankshaft pulley, done from underneath with crane articulated to one side. TESTING PUMP FOR PRESSURE 91 92 OUTPUT A pressure test tapping point is provided in the hydraulic pressure: pipe from the pump to the control vaive. To test. fit testing gouge into circuit ‘at this point, start engine and run at 1200 RPM. Lower the main boom to its stops, when the pressure relief valve startsto by-pass ollbackto the tank take a pressure reading. A pressure lower than specified can mean either, the relief valve needs readiusting or the pump is worn, To determine the fault, fist adjust the pressure relief vaive setting screw to bring the pressure up tothe required figure and operate the machine to warm the oll ifthe pressure remains correc’, the faull was on the reliot valve. If the pressure drops again after the oll has warmed up the pump is worn and inefficient.10 CAUSES OF HYDRAULIC PUMP FAILURE iW 10.1. Dirt in the oil, 10.2. Oillevel in tank top too low causing cavitation and overheating 10.3 Defective pump. Incorrectly assembled or mounted 104 Air leaks on suction lines causing ‘eration and overheating. NB: When the craneisbuilt afiterisused to clean the oil initially. This fiter is subsequently removed and return line fitter is put in the system which must be changed at regular service intervals. STEERING PUMP SYSTEM V1 The crane is fitted with an independent gear type steering pump delivering the required ‘amount of ollforthe steering system, see schedule, 11.2 From the pump, the oil passes through the body of the relief valve which is set at 10.35 mPa (1500 psi). From there via the orbitrol control valve to the steering rams on either side of the slew ring. 11.3. Asthe flow of oil is dependent upon engine speed, steering will be lighter and quicker with a higher engine RPM, When the job calls for articulation with the crane in a stationary condition, the operator can improve the steering operation bysetting the hand throttle to give a higher idiing speed. 11.4. The handbrake must be released in order forthe crane to articulate and neither must the differential lock be engaged. 11.5. An indication of a foiling steering pump will be heavy steering. To test for causes, uncouple the hose from the relet valve body to the orbitrol control valve supply. Attach a hydraulic pressure gauge into circuit and arliculate crane fully in 24 one direction, take a reading from the gauge. A low reading indicates that either the relief vaive is set 100 low or the pump is failing. Ascertain the fault Using the same method described for testing the main hydraulic pump. NB: 1 Excessive pump wear and stuck relief valves are generally caused by dirt in the system, Over pressurising due to articulation with the differential lock engaged, or continuously blowing the relief valve by staying on full lock will cause oil leaks and contribute to excessive wear of parts 2. If cn airbrake system is fitted, it ‘May be necessary toremove the compressor before attempting to remove the steering pump. 12 HYDRAULIC TANK AND FILTER 12.1 A single hydraulic tonk, os per schedule copacity. supplies both main and steering pumps. 12.2 SAEIOW hydraulic oil is used in the system. 12.3 A marked sight glass on top of the tank mounted behind the driver's seat indicates the comect oil level which with the boom retracted and inthe lowered position should be at the recommended level. corect oil levels are important for cooling Purposes and to prevent oil starvation of pumps, 12.4 A retum line oil fitter s mounted directly on the tank and coupled to tt NB: 1 Where the crane is working in extremely dusty conditions, the hydraulic tankshouldbe drained every 6 months, or 1000 hours. Remove any dit or sludge and cleanout. Replace fterand refill using the correct grade of oiMOBILIFT 13° MAIN 4 13.1 13.2 13.3 13.4 2. Whenever the oil is changed or components replaced, check the oil for contamination. If metalic particles are present this is indicative of pump failure. Should a pump fail or wear out, the complete system must be thoroughly flushed and cleoned, the filter must be reploced before filing with new oll, prior to trying out the system. LIFT CYLINDERS AND CIRCUITRY The crane is equipped with twin double acting main iit cylinders. The size isindicated as perschedule, Seal kits are available to repair any oilleaks that mayoccurandthe seal retainer unscrews in order to remove the shaff. Guards are fitted to protect the tift cylinder casings and they are intended to be used only os deflectors to protect the exposed cylinders against damage by a swinging load. They are not designed to absorb constant impacts from heavy loads. The check vaives fitted into the ciroult are of the type which willhold the boom and prevent ‘creep’ in the event of a hose failure. STEERING CYLINDERS AND CIRCUIT 141 142 M43 The unit is equipped with twin double acting steering cylinders as per enclosed schedule, Seal kits are available to repair any oilleaks. When replacing steering rams, ensure the hydraulic hoses are connected correctly or the rams may work against each other or the crane may articulate incorrectly. 15 14.4 The steering cylinders pivot at both ‘ends on spherical bearings which when lubricated with grease are trouble free. EXTENSION CYLINDER AND CIRCUIT 15.1. To remove the extension cylinder, fist disconnect the winch rope at the sheave head and rollit ontothe winch drum, Fully retract the extension, uncouple ‘the hoses and plug them. Disconnect the two retainer plates securing the rearendofthe cylinder to the main boom, Place the boom on trestles and with suitable lifting equipment, draw the boom extension and its cylinder out of the front end of the main boom box section. 15.2 153 154 155 To replace the seals. unscrew the seal retainer from the head of the cylinder and remove the ram shaft and piston assemblies, Reverse the procedure to refit the extension boom and its cylinder into the main boom section and at the same time check the condition of vesconite nylon wear pads and support rollers whilst the extension Is removed from the crane. A check vaive is fitted to the boom exfension return tine, which in the ‘event of hose failure will hold the load and prevent the extension from retracting under the weight of the load. 186 187 NB: Oil leaking from the rear end of the extension when the boom is elevated indicates a leak from one ‘oF two sources: 1 The extension boom cylinder seals are leaking. 2 A hose or connection to the cylinder Is leaking.16 THE WINCH 161 16.2 163. The crane is fitted with a winch, driven by hydraulic motor. It is a double reduction planetary gear type unit with two sets of three planetary gears, which revolve within a dual annulus gear. The primary set of planet gears are driven by a sun gear directly mounted on the hydraulic motor output shaft, and supported by the primary part of the dual annulus gear, The primary planet gear Carrier In tum drives the three fina stage planetary gears which diive the final stage annulus gear, which Isanintegral part of the winch drum. The winch drum brake is automatic, itisheldin the ON posttion by springs. Its only released when hyciraulic oil under pressure is supplied for hoist end lowering functions. Should a hose fail or for any other reason the oil pressure drop, the broke would ‘automatically be applied by the springs The maximum bare drum single ine pull of the winch is enclosed in the technical schedule. The system & treble sheaved with 6 falls thus providing a maximum lifting capacity of the machines rated ‘capacity. With loads heavier than the rated capacity the relief valve will ft and allow oil to pass back to ‘the tank. Aitempts to support loads of this weight will cause the brake to ‘creep’, Therefore loads in excess of the rated capacity should not be attempted. % 17 FRONT WHEEL AIR BRAKES. (Available as a factory fitted option) 17.1. A heavy duty broke system of the expanding shoe type, cir operated by foot control, works on the front whee's only. 17.2. Special stub axles and hubs are used to support the backing plates ‘and shoes which are supplied with ‘compressed cir via spring boosters ‘and the foot lever situated on the Giivers right hand side and fed from reservoirfitted with asatety pressure release valve. This in tums charged bya compressor. driven bya'V" belt from a pulley attached to the tractor engine's fan pulley. The system is uly protected by pressure relief valve buitt into the charging line between the compressor and the reservoir 17.3 The compressor has its own supply of SAE30 oll contained in the crankcase which is fitted with an oll evel plug. 174 The rear brakes are oil immersed nd for any major repair reference should be made to the Ford Tractor Parts manual section.f MOBILIFT RECOMMENDED SPARES LIST (Note 2 machines) ANNUAL PARTNO | DESCRIPTION QUANTITY | COMMENTS A ROUTINE SERVICING (Field or Base) OL FLIER 10 FUEL FILTER 10 seis AIR CLEANER OUTER DONALDSON 2 HYDRAULIC FILTER 6 TORQUE FILTER ELEMENT 6 B_ RUNNING REPAIRS/ MINOR (Field or Base) COMMON HYDRAULIC HOSE 4 Standard hose common to most fitings HOOK SAFETY CATCH 6 Insurance spare STEERING PUMP DELIVERY HOSE ' Insurance spare MAIN LIFT HOSE 1 Inswance spare MAIN PUMP DELIVERY HOSE 1 Insurance spare (CONTROL VALVE DELIVERY HOSE 1 Insurance spare WHEEL STUD REAR PLUS NUT 4 Insurance spare WHEEL STUD FRONT PLUS NUT 4 insurance spare (ett hone plus | ight hana C MAJOR REPAIRS (Field or base) - INSURANCE SPARES ‘CLUTCH PLATE 1 It wil not be necessary to change fy wheel unless problem allowed to continue too long PRESSURE PLATE 1 UNIVERSAL DRIVE SHAFT 1 Not Bkely fo fal insurance only SEAL KIT MAIN UFT RAM Not ikely to fall Insurance only SEAL KIT STEERING RAM 1 Not kely to fall Insurance ony ‘SEAL KIT EXTENSION RAM ) Not likely to tall Insurance only ’ REAR PIVOT ROLLER Not kely to fal insurence only STEERING PUMP 1 Not tkely to fall fest yor MAIN PUMP: 1 Not Ikety to fall fest yeor SUDE BLOCK 2 Not Bkaly to fal fist yeor ‘ORBIT MOTOR, WINCH 1 Not Bkely to ‘all fist yeor WINCH ROPE 1 Not Ikely total fist yeor SPARE HOOK (10 TON) 1 Not ikely to fol fist yeor 7 SPARE HOOK ( 5 ON) 1 Not Ikely to fol fist yeor NYLON WEAR STRP 2 NOTE: THE FOLLOWING ROUTINE MAINTENANCE TOOLS HAVE GEN DELIVERED WITH EACH MAGHINE “HEAVY DUTY WHEEL SPANNER * GREASE GUN WITH FLEXIBLE COUPLING. LUBRICANTS HYDRAULIC lL SAE 10 21008 ENGINE OIL SAE SD 85 ro TORQUE CONVERTOR OL, MOBI. ATF 210 (or attemotives pg 9 of manual) 18-20 ites. DO NOT USE DEXRON BASED OILS, DIFFERENTIAL OWL BPTRACTRAN9 or equivalent WINCH GEARBOX SAE 90 COMPRESSOR SAE 90 2NOTES4 fi i 2