Documente Academic
Documente Profesional
Documente Cultură
NOTE
The contents of this Crane Inspectors
Training Manual include all publications or
excerpts from publications referenced in
the Preventive Maintenance Schedules.
However, it is recommended that the
inspector read, understand and follow all
instructions contained within the cranes
OPERATING AND SERVICE and REPAIR
AND OVERHAUL MANUALS prior to
performing any inspections or service
procedures to these cranes.
PCM 120 SS
PCM 350 SS
COPYRIGHT 2002
LeTourneau, Inc.
Okay
n
1.
2.
Check overall condition of crane and support structure. Look for damage.
3.
Check safety and instructional signs. Replace any that are illegible, deteriorated
or missing.
4.
Visually check column, boom and swing components for cracked welds and
broken or missing bolts.
5.
SLOWLY operate all powered components to their travel limits to check for prop
er limit switch operation.
6.
Check wire rope for attachment, damage, deterioration and proper lubrication.
7.
8.
9.
10.
Check all lighting for proper operation. (Include helicopter warning light if appli
cable).
11.
12.
Check hydraulic lines to brakes for damage and leaks (where applicable).
13.
Check hydraulic brake unit high pressure filters service indicator (located in Ma
chinery House). Service when required.
14.
Check hydraulic brake power unit (located in Machinery House) breather filter
service indicator. Service when required.
15.
16.
17.
Check hook and block for proper attachment and condition of safety latch.
18.
19.
20.
Check fire extinguisher for proper charge, seal, and certification interval.
21.
22.
Check for proper CW and CCW rotation and REPORT any unusual noises and
vibrations.
23.
Check load rating chart at operator's controls. It must be correct and visible.
24.
25.
Visibly check loose gear to be used, such as slings, sling hooks and shackles.
26.
9OSM4.2.1b(M1), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
Needs
Attention
n
MONTHLY
TO BE PERFORMED BY QUALIFIED OPERATOR OR QUALIFIED INSPECTOR
Okay
n
1.
2.
Check overall condition of crane and support structure. Look for damage.
3.
Check safety and instructional signs. Replace any that are illegible, deteriorated
or missing.
4.
Visually check column, boom and swing components for cracked welds and
broken or missing bolts.
5.
SLOWLY operate all powered components to their travel limits to check for prop
er limit switch operation.
6.
Check wire rope for attachment, damage, deterioration and proper lubrication.
7.
8.
9.
10.
Check all lighting for proper operation. (Include helicopter warning light if appli
cable).
11.
12.
Check hydraulic lines to brakes for damage and leaks (where applicable).
13.
Check hydraulic brake unit high pressure filters service indicator (located in Ma
chinery House). Service when required.
14.
Check hydraulic brake power unit (located in Machinery House) breather filter
service indicator. Service when required.
15.
16.
17.
Check hook and block for proper attachment and condition of safety latch.
18.
19.
20.
Check fire extinguisher for proper charge, seal, and certification interval.
21.
22.
Check for proper CW and CCW rotation and REPORT any unusual noises and
vibrations.
23.
Check load rating chart at operator's controls. It must be correct and visible.
24.
25.
Visibly check loose gear to be used, such as slings, sling hooks and shackles.
26.
Further check all control mechanisms for proper adjustment, excessive wear of
components, and contamination by foreign matter.
9OSM4.2.1b(M2), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
Needs
Attention
n
PUBLICATION OSM4
Okay
n
27.
Check boom hoist limit and anti-two block devices for proper operation. Care
should be exercised to prevent damage to crane components.
28.
29.
Needs
Attention
n
1.
Thoroughly inspect wire rope per the instructions in Publication OSM 5, located
in the Operating and Service Manual.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
COPYRIGHT 2002
LeTourneau, Inc.
9OSM4.2.1b(M2), Gorilla
06/24/02
PUBLICATION OSM4
6
4
7
8
1
2
10
PCM 350SS
10
4
3
6
4
7
1
2
PCM 120SS
1CGNGO1600, P1031
9OSM4.2.1b(M2), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
9OSM4.2.1b(M2), Gorilla
06/24/02
QUARTERLY
TO BE PERFORMED BY QUALIFIED INSPECTOR
Okay
n
Needs
Attention
n
2.
Check overall condition of crane and support structure. Look for damage.
3.
Check safety and instructional signs. Replace any that are illegible, deteriorated
or missing.
4.
Visually check column, boom and swing components for cracked welds and
broken or missing bolts.
5.
SLOWLY operate all powered components to their travel limits to check for prop
er limit switch operation.
6.
Check wire rope for attachment, damage, deterioration and proper lubrication.
7.
8.
9.
10.
Check all lighting for proper operation. (Include helicopter warning light if appli
cable).
11.
12.
Check hydraulic lines to brakes for damage and leaks (where applicable).
13.
Check hydraulic brake unit high pressure filters service indicator (located in Ma
chinery House). Service when required.
14.
Check hydraulic brake power unit (located in Machinery House) breather filter
service indicator. Service when required.
15.
16.
17.
Check hook and block for proper attachment and condition of safety latch.
18.
19.
20.
Check fire extinguisher for proper charge, seal, and certification interval.
21.
22.
Check for proper CW and CCW rotation and REPORT any unusual noises and
vibrations.
23.
Check load rating chart at operator's controls. It must be correct and visible.
24.
9OSM4.2.1b(M3), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
25.
Visibly check loose gear to be used, such as slings, sling hooks and shackles.
26.
Further check all control mechanisms for proper adjustment, excessive wear of
components, and contamination by foreign matter.
27.
Check boom hoist limit and anti-two block devices for proper operation. Care
should be exercised to prevent damage to crane components.
28.
29.
Needs
Attention
n
1.
Thoroughly inspect and lubricate wire rope per the instructions in Publication
OSM 5, located in the Operating and Service Manual.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
COPYRIGHT 2002
LeTourneau, Inc.
9OSM4.2.1b(M3), Gorilla
06/24/02
PUBLICATION OSM4
6
4
7
8
1
2
10
PCM 350SS
10
4
3
6
4
7
1
2
PCM 120SS
1CGNGO1600, P1031
9OSM4.2.1b(M3), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
Needs
Attention
n
DRIVERS
MAIN HOOK, BOOM, AUXILIARY HOOK (OPTIONAL):
1.
Take samples for lubricating oil analysis and refill. Service if iron content is 100
ppm or greater. Refer to LUBRICATING OIL ANALYSIS, Publication OSM4, for
additional information.
CRANE SWING COMPONENTS
SWING GEARBOX:
1.
Take sample for lubricating oil analysis and refill. Service if iron content is
100 ppm or greater. Refer to LUBRICATING OIL ANALYSIS, Publication OSM4,
for additional information.
HYDRAULIC BRAKE SYSTEM
1.
Take oil sample for analysis. Flush system and refill if water or solid particle con
tamination is 60 ppm or greater.
WIRE ROPE
Thoroughly inspect and lubricate wire rope per the instructions in Publication
OSM 5, located in the Operating and Service Manual.
2.
Inspect sheaves for wear, cracks, rope path alignment and bearing condition.
Check torque on wire rope dead end setscrews (140150 lbs. lubricated with
30W motor oil).
OPERATIONAL INDICATORS
1.
1.
Check the condition of all motor brakes. Refer to Publication OSM6 in the OP
ERATING AND SERVICE MANUAL.
2.
Check all motor brakes for proper operation. Refer to Publication OSM6 in the
OPERATING AND SERVICE MANUAL.
3.
Check swing motor brake for proper adjustment. Refer to Publication OSM6 in
the OPERATING AND SERVICE MANUAL.
4.
5.
LeTourneau, Inc.
9OSM4.2.1b(M3), Gorilla
06/24/02
PUBLICATION OSM4
Okay
n
Needs
Attention
n
Okay
n
Needs
Attention
n
Inspect and test the power loss lowering system. Refer to POWER LOSS LOW
ERING SYSTEM, located in Publication OSM4 in the OPERATING AND SER
VICE MANUAL.
CAUTION
Be sure all electrical power is turned off and locked out before touching any
electrical connection or terminal. Due to the potential for injury, only
qualified experienced persons should enter the Machinery House.
ELECTRICAL CONTROLS GROUP:
1.
Check hook Controller condition. Insure card cover is secure and harness con
nections are tight.
2.
Check Boom Controller condition. Insure card cover is secure and harness con
nections are tight.
3.
Check Swing Controller condition. Insure card cover is secure and harness
connections are tight.
4.
Check all converter panels for tight connections and condition of components.
Remove any accumulated dust.
5.
6.
7.
Check backup batteries for clean, tight terminal connections (located on top of
machinery house).
9OSM4.2.1b(M3), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
BRUSH
TA8010CG
MOTOR
BRUSH #
DIM.
REPLACED?
ANY SPECIAL
CONDITIONS
1.
1.
SWING
S1A MOTOR
2.
3.
4.
1.
2.
MAIN HOOK
N 9 MOTOR
N9
2.
3.
4.
1.
2.
BOOM
N9 MOTOR
2.
3.
4.
1.
4.
AUXILIARY HOOK
N9 MOTOR
2.
3.
4.
NOTES! 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE.
2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS.
3. SEE CHAPTER 4.0 OF TAKING CARE OF YOUR DC MOTOR" LOCATED IN SECTION 2, DC MOTORS, OF THE REPAIR
AND OVERHAUL MANUAL FOR CONDITIONS TO LOOK FOR.
COPYRIGHT 2002
LeTourneau, Inc.
9OSM4.2.1b(M3), Gorilla
06/24/02
PUBLICATION OSM4
1CG1083, P01112
MOTOR
TRACK #
TIR
MAX. BARTOBAR
1.
1.
SWING
S1A MOTOR
2.
3.
4.
1.
2
2.
MAIN HOOK
N9 MOTOR
2.
3.
4.
1.
3
3.
BOOM
N9 MOTOR
2.
3.
4.
1.
4.
AUXILIARY
HOOK
N9 MOTOR
2.
3.
4.
NOTES! 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE.
2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS.
3. IN THE SURFACE CONDITIONS" COLUMN INDICATE OBSERVED CONDITION OF COMMUTATOR SURFACE CON
CERNING THE FOLLOWING: (a) CONDITION OF FILM, (b) SIGNS OF ARCING, (c) GROOVING, (d) OTHER CHARACTER
ISTICS. REFER TO TAKING CARE OF YOUR DC MOTOR" FOR AN INTERPRETATION OF THE OBSERVATIONS.
9OSM4.2.1b(M3), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Needs
Attention
n
CAUTION
Dye penetrant and magnetic particle tests shall be conducted on any welds
suspected of being cracked. Structural repairs MUST be made in
accordance with the guidelines in STRUCTURAL REPAIRS, Publication
ROM1, in the REPAIR AND OVERHAUL MANUAL and LeTourneau, Inc.,
Publication LeT1, FIELD WELDING PROCEDURES, located in the back of
Section 1 of the REPAIR AND OVERHAUL MANUAL. Before ANY structural
repairs are made to the crane, the certifying authority shall be notified and
his surveyor present when the repairs are performed. Any inspections and
tests required by the certifying authority after structural repairs are made
shall be completed and a new certificate issued BEFORE the crane is
returned to service.
AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS):
1.
2.
3.
4.
5.
2.
3.
4.
5.
6.
Closely inspect all bearings, wear bands and king pin condition.
BOOM:
1.
Closely inspect main boom hinge pins and attachment point welds.
2.
3.
4.
LeTourneau, Inc.
9OSM4.2.1b(M3), Gorilla
06/24/02
PUBLICATION OSM4
Okay
n
5.
6.
7.
8.
Closely inspect boom sections attachment points for loose, broken or missing
bolts.
9.
Closely inspect boom light assemblies for proper attachment, broken lenses,
lose wiring and proper operation.
10.
11.
Closely inspect catwalks and handrails for cracked welds and loose, broken or
missing bolts.
Needs
Attention
n
2.
3.
4.
5.
2.
3.
4.
5.
6.
7.
Closely inspect swing bearing and gear for loose, broken or missing bolts.
2.
3.
9OSM4.2.1b(M3), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
2.
3.
Closely inspect gearbox pinion adjustment. Should be .020" gap. Refer to the
REPAIR AND OVERHAUL MANUAL, Section 1, SWING GEAR UNIT, for informa
tion on Swing Gearbox adjustment.
4.
Needs
Attention
n
2.
3.
Closely inspect cable drum structures for cracks, wear and proper attachment.
GANTRY ASSEMBLY:
1.
2.
3.
4.
5.
2.
3.
4.
2.
3.
4.
5.
10
1.
2.
3.
LeTourneau, Inc.
9OSM4.2.1b(M3), Gorilla
06/24/02
PUBLICATION OSM4
Okay
n
4.
5.
Closely inspect hook assembly for bends, cracks and overall condition.
Needs
Attention
n
2.
3.
4.
5.
Closely inspect hook assembly for bends, cracks and overall condition.
9OSM4.2.1b(M3), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
11
ANNUAL
TO BE PERFORMED BY QUALIFIED INSPECTOR
Okay
n
Needs
Attention
n
2.
Check overall condition of crane and support structure. Look for damage.
3.
Check safety and instructional signs. Replace any that are illegible, deteriorated
or missing.
4.
Visually check column, boom and swing components for cracked welds and
broken or missing bolts.
5.
SLOWLY operate all powered components to their travel limits to check for prop
er limit switch operation.
6.
Check wire rope for attachment, damage, deterioration and proper lubrication.
7.
8.
9.
10.
Check all lighting for proper operation. (Include helicopter warning light if appli
cable).
11.
12.
Check hydraulic lines to brakes for damage and leaks (where applicable).
13.
Check hydraulic brake unit high pressure filters service indicator (located in Ma
chinery House). Service when required.
14.
Check hydraulic brake power unit (located in Machinery House) breather filter
service indicator. Service when required.
15.
16.
17.
Check hook and block for proper attachment and condition of safety latch.
18.
19.
20.
Check fire extinguisher for proper charge, seal, and certification interval.
21.
22.
Check for proper CW and CCW rotation and REPORT any unusual noises and
vibrations.
23.
Check load rating chart at operator's controls. It must be correct and visible.
24.
9OSM4.2.1b(M4), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
25.
Visibly check loose gear to be used, such as slings, sling hooks and shackles.
26.
Further check all control mechanisms for proper adjustment, excessive wear of
components, and contamination by foreign matter.
27.
Check boom hoist limit and anti-two block devices for proper operation. Care
should be exercised to prevent damage to crane components.
28.
29.
Needs
Attention
n
1.
Thoroughly inspect and lubricate wire rope per the instructions in Publication
OSM 5, located in the Operating and Service Manual.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
COPYRIGHT 2002
LeTourneau, Inc.
9OSM4.2.1b(M4), Gorilla
06/24/02
PUBLICATION OSM4
6
4
7
8
1
2
10
PCM 350SS
10
4
3
6
4
7
1
2
PCM 120SS
1CGNGO1600, P1031
9OSM4.2.1b(M4), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
Needs
Attention
n
S Boom
S Auxiliary Hook
CRANE SWING COMPONENTS - SERVICE REQUIREMENTS
SWING GEARBOX:
1.
1.
1.
Thoroughly inspect and lubricate wire rope per the instructions in Publication
OSM 5, located in the Operating and Service Manual.
2.
Inspect sheaves for wear, cracks, rope path alignment and bearing condition.
CABLE DRUM DEAD END INSPECTION
1.
Check torque on wire rope dead end setscrews (140150 lbs. lubricated with
30W motor oil).
OPERATIONAL INDICATORS
1.
1.
Check the condition of all motor brakes. Refer to Publication OSM6 in the OP
ERATING AND SERVICE MANUAL.
2.
Check all motor brakes for proper operation. Refer to Publication OSM6 in the
OPERATING AND SERVICE MANUAL.
3.
Check swing motor brake for proper adjustment. Refer to Publication OSM6 in
the OPERATING AND SERVICE MANUAL.
4.
5.
COPYRIGHT 2002
LeTourneau, Inc.
9OSM4.2.1b(M4), Gorilla
06/24/02
PUBLICATION OSM4
Needs
Attention
n
CAUTION
Be sure all electrical power is turned off and locked out before touching any
electrical connection or terminal. Due to the potential for injury, only
qualified experienced persons should enter the Machinery House.
ELECTRICAL CONTROLS GROUP:
1.
Check hook Controller condition. Insure card cover is secure and harness con
nections are tight.
2.
Check Boom Controller condition. Insure card cover is secure and harness con
nections are tight.
3.
Check Swing Controller condition. Insure card cover is secure and harness
connections are tight.
4.
Check all converter panels for tight connections and condition of components.
Remove any accumulated dust.
5.
6.
7.
Check backup batteries for clean, tight terminal connections (located on top of
machinery house).
CORROSION INHIBITORS:
1.
9OSM4.2.1b(M4), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
BRUSH
TA8010CG
MOTOR
BRUSH #
DIM.
REPLACED?
ANY SPECIAL
CONDITIONS
1.
1.
SWING
S1A MOTOR
2.
3.
4.
1.
2.
MAIN HOOK
N 9 MOTOR
N9
2.
3.
4.
1.
2.
BOOM
N9 MOTOR
2.
3.
4.
1.
4.
AUXILIARY HOOK
N9 MOTOR
2.
3.
4.
NOTES! 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE.
2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS.
3. SEE CHAPTER 4.0 OF TAKING CARE OF YOUR DC MOTOR" LOCATED IN SECTION 2, DC MOTORS, OF THE REPAIR
AND OVERHAUL MANUAL FOR CONDITIONS TO LOOK FOR.
COPYRIGHT 2002
LeTourneau, Inc.
9OSM4.2.1b(M4), Gorilla
06/24/02
PUBLICATION OSM4
1CG1083, P01112
MOTOR
TRACK #
TIR
MAX. BARTOBAR
1.
1.
SWING
S1A MOTOR
2.
3.
4.
1.
2
2.
MAIN HOOK
N9 MOTOR
2.
3.
4.
1.
3
3.
BOOM
N9 MOTOR
2.
3.
4.
1.
4.
AUXILIARY
HOOK
N9 MOTOR
2.
3.
4.
NOTES! 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE.
2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS.
3. IN THE SURFACE CONDITIONS" COLUMN INDICATE OBSERVED CONDITION OF COMMUTATOR SURFACE CON
CERNING THE FOLLOWING: (a) CONDITION OF FILM, (b) SIGNS OF ARCING, (c) GROOVING, (d) OTHER CHARACTER
ISTICS. REFER TO TAKING CARE OF YOUR DC MOTOR" FOR AN INTERPRETATION OF THE OBSERVATIONS.
9OSM4.2.1b(M4), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Needs
Attention
n
CAUTION
Dye penetrant and magnetic particle tests shall be conducted on any welds
suspected of being cracked. Structural repairs MUST be made in
accordance with the guidelines in STRUCTURAL REPAIRS, Publication
ROM1, in the REPAIR AND OVERHAUL MANUAL and LeTourneau, Inc.,
Publication LeT1, FIELD WELDING PROCEDURES, located in the back of
Section 1 of the REPAIR AND OVERHAUL MANUAL. Before ANY structural
repairs are made to the crane, the certifying authority shall be notified and
his surveyor present when the repairs are performed. Any inspections and
tests required by the certifying authority after structural repairs are made
shall be completed and a new certificate issued BEFORE the crane is
returned to service.
COLUMN GROUP - BASE:
1.
2.
3.
4.
5.
2.
3.
4.
5.
6.
Closely inspect all bearings, wear bands and king pin condition.
BOOM:
1.
Closely inspect main boom hinge pins and attachment point welds.
2.
3.
4.
5.
6.
7.
LeTourneau, Inc.
9OSM4.2.1b(M4), Gorilla
06/24/02
PUBLICATION OSM4
Okay
n
8.
Closely inspect boom sections attachment points for loose, broken or missing
bolts.
9.
Closely inspect boom light assemblies for proper attachment, broken lenses,
lose wiring and proper operation.
10.
11.
Closely inspect catwalks and handrails for cracked welds and loose, broken or
missing bolts.
Needs
Attention
n
2.
3.
4.
5.
2.
3.
4.
5.
6.
7.
Closely inspect swing bearing and gear for loose, broken or missing bolts.
2.
3.
2.
3.
Closely inspect gearbox pinion adjustment. Should be .020" gap. Refer to the
REPAIR AND OVERHAUL MANUAL, Section 1, SWING GEAR UNIT, for informa
tion on Swing Gearbox adjustment.
9OSM4.2.1b(M4), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
4.
Needs
Attention
n
2.
3.
Closely inspect cable drum structures for cracks, wear and proper attachment.
GANTRY ASSEMBLY:
1.
2.
3.
4.
5.
2.
3.
4.
2.
3.
4.
5.
10
1.
2.
3.
4.
5.
Closely inspect hook assembly for bends, cracks and overall condition.
COPYRIGHT 2002
LeTourneau, Inc.
9OSM4.2.1b(M4), Gorilla
06/24/02
PUBLICATION OSM4
Okay
n
Needs
Attention
n
2.
3.
4.
5.
Closely inspect hook assembly for bends, cracks and overall condition.
9OSM4.2.1b(M4), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
11
PUBLICATION OSM4
Needs
Attention
n
Inspect and test the backup AC pump motor. Refer to Publication OSM6 in the
OPERATING AND SERVICE MANUAL.
Inspect and test the power loss lowering system. Refer to POWER LOSS LOW
ERING SYSTEM located in Publication OSM4 in the OPERATING AND SER
VICE MANUAL.
Test the AOPS, Refer to AOPS TEST AND CALIBRATION PROCEDURE, located
in Publication ROM6 in the REPAIR AND OVERHAUL MANUAL.
PCM 350SS
RADIUS
SWL
RADIUS
SWL
22 ft.
98,400
30 ft.
146,800
30 ft.
20,000
35 ft.
20,000
Okay
n
Needs
Attention
n
The following inspection or tests must be performed before doing any load testing.
12
1.
2.
3.
4.
Verify that all limit switches are adjusted and functioning properly.
5.
Inspect cable to verify proper reeving and that no rubbing or looseness of cable
is occurring.
6.
7.
LeTourneau, Inc.
9OSM4.2.1b(M4), Gorilla
06/24/02
PUBLICATION OSM4
Start
1.
Record time required to raise boom from horizontal to maximum boom up posi
tion.
2.
3
3.
4.
5.
End
LEFT
RIGHT
CAUTION
Always use a minimum load of 2000 lbs. on the hook when running the hook at full speed to prevent
slack in cable spooling off of the drum.
Distance
1
1.
2
2.
3
3.
4
4.
Time
Speed
FPM
Motor
Volts
UP
DOWN
UP
DOWN
UP
DOWN
UP
DOWN
Okay
n
5
5.
Motor
Current
Needs
Attention
n
MAIN
AUX
With boom full up, lift rated load. During this test it is recom
mended that the load not be raised over two feet from the deck
surface.
2
2.
9OSM4.2.1b(M4), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
MAIN
AUX
MAIN
AUX
13
PUBLICATION OSM5
TABLE OF CONTENTS
Page
FIGURE
Page
8.
15
9.
15
10.
16
11.
16
12.
16
13.
17
14.
20
15.
22
16.
22
17.
24
NOTE
LIST OF ILLUSTRATIONS
FIGURE
Page
1.
2.
ROPE MEASUREMENT . . . . . . . . . . . . . . . . .
3.
4.
ROPE LAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.
10
6.
13
7.
13
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM5
NOTE
Mandatory rules of this publication per
ANSI/ASME are characterized by the word
SHALL." If a provision is of an advisory
nature, it is indicated by the word SHOULD"
and is recommended to be considered, the
advisability of which depends on the facts in
each situation.
Never overload.
NOTE
In order to ensure that there is no slack in the
rope at the start of loading, start the load
carefully and apply the power smoothly and
steadily.
WIRE (2)
WIRE ROPE
NOTE
CAUTION
CORE (1)
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
NOTE
STORAGE PROCEDURES:
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
NOTE
Wire rope removed from service should be
identified and marked as unfit for use on
cranes, slings or other load carrying devices.
NOTE
UNDER NO CIRCUMSTANCES shall any
machine be rerated in excess of the original
load ratings unless rating changes are
approved by LeTourneau, Inc. and a new load
chart is available.
LeTourneau, Inc.
PUBLICATION OSM5
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
NOTE
Wire rope removed from service should be
identified and marked as unfit for use on
cranes, slings or other load carrying devices.
b.
D Awl
2. General corrosion
D Marlin spike
D Steel tape
D Sheave groove gauges
D Calipers
D Chalk
D Wiping cloth
D Gloves
a.
INSPECTION PROCEDURES:
ACTUAL DIAMETER
B. CORRECT
A.
C. INCORRECT
1OSM5.1, 350SS
5/8/00
TA8023CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM5
NOTE
PERIODIC INSPECTION
Wire ropes which have been idle for one month or more
should be inspected by a qualified person before being
placed into service. A written, signed and dated
inspection report should be kept and readily available
for two years or until the wire rope is retired.
NOTE
A long range inspection program should be
established to include records on examination
or ropes removed from service to establish a
relationship between visual observation and
actual condition of the internal structure.
k.
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
VALLEY BREAKS
CHECK FOR INTERNAL DAMAGE AFTER DISCOVERING
BROKEN WIRES BETWEEN STRANDS.
1CG1231, P0815
1OSM5.1, 350SS
5/8/00
LeTourneau, Inc.
TA8002CG
PUBLICATION OSM5
NOTE
Localized abrasion and fatigue can be dealt
with, without the necessity of discarding the
whole rope, by installing a longer rope than
necessary, initially, and cutting one end or the
other to expose a new section of rope to the
place where the deterioration occurs.
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
NOTE
f.
Kinking, crushing, birdcaging, or any other dam
age resulting in distortion of the rope structure.
g.
NOTE
The term ROPE LAY or LAY LENGTH will be
used in later paragraphs of this publication. A
ROPE LAY or LAY LENGTH is the distance
measured parallel to the axis of the rope in
which a strand makes one complete helical
revolution about the core. Refer to Figure 4 for
an illustration of a ROPE LAY.
Rope Diameter
Up to 5/16" (8 mm)
NOTE
ONE ROPE LAY
1OSM5.1, 350SS
5/8/00
TA8001CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM5
NOTE
NOTE
Wire rope on the machine MUST be replaced
with same diameter, length, construction and
grade rope as the machine was originally
equipped. The replacement rope MUST not be
different unless approved by LeTourneau, Inc.
and all furnished load rating charts MUST be
reviewed and changed as required. Replace
ment wire rope shall be certified to original
specifications and the certificate kept on file in
the Control Book.
WRONG
WRONG
REEL
REEL
DRUM
DRUM
BRAKE
BRAKE
RIGHT
RIGHT
REEL
REEL
DRUM
DRUM
BRAKE
BRAKE
10
LeTourneau, Inc.
TA8000CG
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
NOTE
The wire rope is retained to the cable drum
dead end with 3/4 UNC setscrews. These
setscrews tighten to 140150 lbs. torque with
the threads lubricated with 30W motor oil.
Torque should be checked every six months.
NOTES
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
11
PUBLICATION OSM5
NOTES
12
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
CAUTION
MS(1)
HT(2)
S(3)
1/2
2.2
2.0
2.3
5/8
3.4
3.0
3.6
3/4
4.9
4.2
5.1
7/8
6.6
5.5
6.9
8.5
7.2
9.0
11/8
10.0
9.0
11.0
11/4
13.0
11.0
14.0
13/8
15.0
13.0
17.0
11/2
18.0
16.0
20.0
13/4
25.0
21.0
27.0
32.0
28.0
34.0
MS(1)
HT(2)
MS(1)
CAUTION
ANGLE A
15
30
45
60
COSINE OF ANGLE A
0.966
0.866
0.707
0.500
b.
CHOKER SLINGS
Cosine of Angle A
BRIDLE SLINGS
For bridle slings and basket hitches where both legs are
not vertical use the following computation of the sling
arrangement rated capacity. Rated Capacity equals
Single leg capacity (refer to Figure 7) times the number
of legs times the cosine of angle A.
1OSM5.1, 350SS
5/8/00
Number of Legs
Capacity from Fig
ure 6
Rated Capacity = 12.73 tons
d.
SLING INSPECTION:
COPYRIGHT 2002
LeTourneau, Inc.
13
PUBLICATION OSM5
NOTE
d.
e.
f.
Hooks that have been opened more than 15
percent of their normal throat opening or twist more than
10 degrees from the plane of the unbent hook.
g.
NOTES
14
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
TAIL
LENGTH*
RIGHT
CORRECT INSTALLATION OF WEDGE SOCKET ASSEMBLY
*TAIL LENGTH
Standard 6 to 8 strand wire rope
COTTER KEY
1CG1959, P1073
WEDGE
NOTE
TA9257CG
TA9259CG
CABLE CLAMP
1CG1958, P1073
COPYRIGHT 2002
LeTourneau, Inc.
15
PUBLICATION OSM5
WRONG
ROPE
BACKWARD
WRONG
WEDGE
BACKWARD
TA9258CG
1CG1961, P1073
3/8
7/16
1/2
9/16
5/8
3/4
Clip Size
3/8
7/16
1/2
9/16
5/8
3/4
*Torque Ft./Lbs.
45
65
65
95
95
130
7/8
11/8 11/4
7/8
11/8 11/4
225
225
225
TA9256CG
360
*The tightening torque values shown are based upon the threads
being clean, dry and free of lubrication.
16
WRONG TAIL
CLIPPED TO
LIVE LINE
COPYRIGHT 2002
NOTE
Efficiency rating of the wedge socket termina
tion is based upon the catalog breaking
strength of wire rope. The efficiency of a
properly assembled wedge socket is 80%.
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
f.
Drum flange should be checked for cracks, chips
or other deterioration.
j.
Smooth drums checked for surface conditions to
ensure that there are no cracks or corrugation from the
rope.
MAINTENANCE OF SHEAVES, ROLLERS AND
DRUMS
Proper maintenance of the equipment over which the
ropes operate has an important bearing on rope life.
Worn grooves, poor alignment of sheaves and worn
parts resulting in shock loads and excessive vibration
will have a deteriorating effect.
Sheaves and grooved rollers should be checked
periodically for wear in the grooves, which may
cause pinching and abrasion of the ropes. If the
CHECK SHEAVE
GROOVES FOR
WEAR.
CHECK GROOVES
FOR PROPER SIZE
OBSERVE THE GROOVE SO THAT IT
MAY BE CLEARLY SEEN WHETHER
THE CONTOUR OF THE RADIUS GAUGE
MATCHES THE CONTOUR OF THE
BOTTOM OF THE RADIUS GAUGE.
1OSM5.1, 350SS
5/8/00
TA7635CG
COPYRIGHT 2002
LeTourneau, Inc.
17
PUBLICATION OSM5
NOTES
18
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
NOTES
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
19
PUBLICATION OSM5
3
6
1
METHOD A"
METHOD B"
Seizing Lengths
inches
mm
inches
mm
inches
mm
1/85/16
3.58.0
.032
0.813
1/4
6.0
3/89/16
9.514.5
.048
1.21
1/2
13.0
5/815/16
16.024.0
.063
1.60
3/4
19.0
11-15/16
26.033.0
.080
2.03
1-1/4
32.0
1-3/81-11/16
35.043.0
.104
2.64
1-3/4
44.0
1-3/42-1/2
45.064.0
.124
3.15
2-1/2
64.0
2-9/163-1/2
65.089.0
.124
3.15
3-1/2
89.0
*The wire rope manufacturer should be consulted for seizing wire diameters of rope not included in this chart.
tag: wir rop seiz
1CG1240, P0815
20
LeTourneau, Inc.
TA6029
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
NOTE
Lubricants recommended by LeTourneau, Inc.
are listed in Publication OSM4, PCM CRANE
LUBRICATION SPECIFICATIONS, this manu
al. Lubricate the wire rope at regular intervals
in accordance with the PREVENTIVE MAINTE
NANCE SCHEDULES in the back of publica
tion OSM4. For off shore cranes, a rust
preventive lubricant such as Mobil Mobilar
ma 798" or Texaco Crater X" or equivalent is
recommended.
Corrosion resistance.
Water repellent.
Penetrating ability.
Chemically neutral.
Temperature stability.
1OSM5.1, 350SS
5/8/00
CAUTION
CAUTION
CAUTION
b.
LeTourneau, Inc.
21
PUBLICATION OSM5
COMPRESSED AIR
WIRE BRUSHES
TEMPORARY
WINDING DRUM
PREFERRED
METHOD SINCE
ROPE OPENS UP
OVER SHEAVE
ALLOWING OIL
TO PENETRATE.
AIR BLAST
APPLICATION
AIR OIL
OIL BATH
APPLICATION
BRUSH
APPLICATION
1CG705, P0151
22
LeTourneau, Inc.
TA7654CG
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
NOTE
If a wire rope is taken out of service for an
appreciable length of time, it should be
cleaned, lubricated and stored in a dry place
where it will be protected from the elements.
NOTES
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
23
PUBLICATION OSM5
(2)
(3)
(4)
(5)
Operating Condi
tions
Ropes working in in
dustrial or marine en
vironments.
Ropes subject to
heavy wear.
Predominant cause
of rope deterioration
Corrosion.
Abrasion.
Fatigue.
Fatigue-corrosion.
Corrosion.
Typical applications
Dressing require
ments
Good penetration to
rope interior. Ability to
displace moisture. In
ternal and external
corrosion protection.
Resistance to wash
off". Resistance to
emulsification.
Good penetration to
rope interior. Good lu
brication properties.
Resistance to fling
off".
Nonslip property.
Good penetration to
rope interior. Ability to
displace moisture. In
ternal and external
corrosion protection.
Good corrosion
protection. Resistance
to wash off". Resist
ance to surface crack
ing.
Type of lubricant
Usually a formulation
containing solvent
leaving a thick
(0.1 mm) soft grease
film.
Usually a solventdis
persed temporary cor
rosion preventative
leaving a thin, semi
hard film.
Usually a relatively
thick, bituminous
compound with sol
vent added to assist
application.
Application tech
nique. Refer to Fig
ure 16.
Manual or mechani
cal.
Manual or mechani
cal.
Mechanical.
Normally by hand.
Normally by hand.
Frequency of ap
plications*
Monthly.
Weekly.
Monthly.
*The periods indicated are for the general case. The frequency of operation, the environmental conditions and the economics of service dressing will more
correctly dictate the period required.
24
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
c.
NOTE
NOTE
Must have written certification of 70.03 tons
breaking strength.
b.
2. Rotation resistant.
2. Constructex
3. DYFORM 18 HSLR
NOTE
NOTE
NOTES
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
25
PUBLICATION OSM5
26
TA8664CG
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
10 TON HOOK
1CG1583, P1029
1OSM5.1, 350SS
5/8/00
TA8678CG
COPYRIGHT 2002
LeTourneau, Inc.
27
PUBLICATION OSM5
6
8
10
12
3
5
7
GANTRY SHEAVE WHEELS
D.E.
11
1 WIRE ROPE (9 X 40 CONSTRUCTEX)
1075 LONG, 62.5 TONS B.S.
CABLE DRUM
PCM-350SS CRANE
BOOM UP CABLE REEVING SCHEMATIC
1CG1582, P1029
28
TA8925CG
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
c.
BRIDLE PENDANTS
1. 13/4 inch x 50 ft. (P/N 4229572)
NOTE
4. Rotation resistant
NOTE
Must have written certification of 70.03 tons
breaking strength.
b.
d.
LUFFING
3. DYFORM 18 HSLR
4. Rotation resistant.
3. CONSTRUCTEX
NOTE
NOTE
NOTES
1OSM5.2, 120SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
25
PUBLICATION OSM5
1CG1586, P1030
26
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.2, 120SS
5/8/00
PUBLICATION OSM5
DEAD END
3
1 WIRE ROPE
460 LONG
62.5 TONS B.S.
TA8928CG
1OSM5.2, 120SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
27
28
PUBLICATION OSM5
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.2, 120SS
5/8/00
PUBLICATION OSM6
TABLE OF CONTENTS
TABLE OF CONTENTS
Page
Page
10
13
14
15
10
19
11
21
12
22
LIST OF ILLUSTRATIONS
FIGURE
Page
BRAKE WIRING . . . . . . . . . . . . . . . . . . . . . . .
LeTourneau, Inc.
BRAKES
PUBLICATION OSM6
the maximum air gap. Maximum air gap for the brake is
0.125 inch (refer to Figure 1).
When the working air gap reaches the Reset gap (refer
to Figure 1), perform the following procedure:
CAUTION
CAUTION
COPYRIGHT 2002
NOTE
If brake air gap is allowed to open to 0.150
inch, the brake will start to slip.
LeTourneau, Inc.
PUBLICATION OSM6
AIR GAP
SETTINGS
BRAKES
Working Air Gap
.080"
0.125"
STATIONARY
DISC
ENDBELL
COILS
MAGNET RINGS
BRAKE HEAD
ASSEMBLY
BRAKE
ADJUSTING
SCREW
P/N 0955056
SPRINGS
BRAKE DISCS*
ROTATING
DISC
LOCKING
CAPSCREW
MAXIMUM
AIR GAP
ADJUSTING NUT
MAXIMUM
AIR GAP
P/N 4036240
WORKING
AIR GAP
BRAKE
SPRING
INNER
MAGNET
RING
NOTE
1CG700, P0602
TA7661CG
NOTE
NOTE
OUTER
MAGNET
PLATE
COPYRIGHT 2002
LeTourneau, Inc.
BRAKES
PUBLICATION OSM6
L1
L1
1
5
1
L2
10
11
11
3
6
12
5 8
5
12
4
7
L3
6
10
3
4
L3
L2
SWING BRAKE
FIGURE 3. BRAKE WIRING
1CG1577, P1037
f.
With three (3) 1/2" UNF nuts, pull the outer magnet
ring and coil assembly down until the proper air gap is
met (refer to WORKING AIR GAP ADJUSTMENT
PROCEDURES, page 2, to adjust the maximum air
gap). Use the other three (3) 1/2" UNF nuts to lock this
adjustment.
NOTE
There must not be interference or dragging of
the inner magnet ring with the coil boxes. If
necessary, loosen the anchors of the offend
ing coil and readjust.
CAUTION
TA8985CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM6
BRAKES
ROTATING DISCS
STATIONARY DISCS
FIGURE 4. SWING MOTOR DISC BRAKE STACKING
TA8980S
1CG1564, P1032
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
BRAKES
PUBLICATION OSM6
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM6
BRAKES
CAUTION
CAUTION
CAUTION
SYSTEM DESCRIPTION
NOTE
The hydraulic power unit owner's manual is
provided at the end of this publication. Refer to
Figure 6 for an illustration of the hydraulic
power unit.
a. Hydraulic System: The primary hydraulic power
source is a low pressure gear pump. A secondary
480 VAC pump (see Figure 5) is available as a backup to
the primary pump (see BACKUP AC PUMP MOTOR
section in Publication OSM4 of this manual). In the
event of crane power loss, a Power Loss Lowering
System (PLLS) exists to allow for the constant speed
lowering of a load from the operator's console (see PCM
Crane Power Loss Lowering System, located in Section
5, SOLID STATE CONVERSION SYSTEM, in the REPAIR
AND OVERHAUL manual). This system uses a 24 VDC
motordriven pump mounted on the hydraulic power
unit and powered by four 12 VDC batteries. A manual
release method also exists (see page 15 OF THIS
PUBLICATION) as a backup to the PLLS.
b. Primary Hydraulic Power Source: The primary
hydraulic power source is mounted on a 20gallon
reservoir with the pump inside the reservoir and the
COPYRIGHT 2002
LeTourneau, Inc.
BRAKES
PUBLICATION OSM6
SYSTEM OPERATION
a. The hydraulic pump becomes operational when
the MASTER switch is turned to the ON position. System
pressure is regulated to 130 psi when the BRAKE switch
is turned to the ENABLE position.
b. The brakes do not release until the appropriate
joystick (hoist or boom) is moved off of the neutral
position. The appropriate electronic controller ener
gizes relay CR2 (hoist) or CR3 (boom) which applies
system pressure through solenoids to the appropriate
springapplied brake canisters and releases the brakes.
Various external conditions, however, can prevent the
controller from releasing the brakes or automatically set
the brakes once they have been released (low hydraulic
fluid pressure, low hydraulic fluid level, high hydraulic
fluid temperature, various limit switches, etc.).
CAUTION
NOTE
Refer to SERVICE UPON RECEIPT, located in
Publication OSM1, in the OPERATING AND
SERVICE MANUAL for service and inspec
tions required during startup and the initial 50
and 100 hours of operation. It is essential that
these services be performed to achieve
proper operation and efficient service from the
hydraulic brake system.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM6
BRAKES
1
7
12
10
11
13
13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
FITTING
FITTING
HOSE
FITTING
CHECK VALVE
BUSHING
PUMP MOTOR
FITTING
HOSE
FITTING
PIPE FITTING
POWER UNIT
NIPPLE
DRAIN VALVE
14
1CG2077, P1041
COPYRIGHT 2002
LeTourneau, Inc.
BRAKES
1CG1601, P1041
10
A
10
18
11
9
8
19
1
SOL 1
4
C
COPYRIGHT 2002
13
LeTourneau, Inc.
20
17
16
12
15
7
21
14
7
24
3
25
18
11
10
22
23
11
AB
a
SOL 2
19
AB
b
SOL 3
1
SOL 4
AB
b
SOL 6
SOL 5
AB
a
b
PT
SECTION A-A
23
MOTOR
CHECK VALVE
BREATHER
PRESSURE FILTER
MANIFOLD
OIL FILTER
RESERVOIR
SANDWICH BODY
DIRECT. CONT. VALVE
RELIEF VALVE
3 HP MOTOR
OIL LEVEL GAUGE
GEAR PUMP
14
15
16
17
18
19
20
21
22
23
24
25
SHUTTLE VALVE
SUCTION STRAINER
COUPLING
RELIEF VALVE
PRESSURE GAUGE
GEAR PUMP
ADAPTER
SUCTION STRAINER
PRESSURE SWITCH
DIRECT. CONT. VALVE
OIL LEVEL SWITCH
TEMP. SWITCH
19
SECTION B-B
PUBLICATION OSM6
10
AB
a
TA8982CG
SOL 7
1
2
3
4
5
6
7
8
9
10
11
12
13
PUBLICATION OSM6
BRAKES
CAUTION
NORMAL OPERATION
c.
SPRING BRAKE
APPLICATION
INSPECTION
COPYRIGHT 2002
NOTE
If adjustment is required, the brakes must be
released.
LeTourneau, Inc.
11
BRAKES
d.
PUBLICATION OSM6
ADJUSTMENT
CAUTION
CAUTION
CAUTION
NOTE
Replace the brake pads if lining is less than
1/4" thick.
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM6
BRAKES
NOTE
If excessive wear is observed on the brake
head carrier linings, the brake rotor run out
should be checked. This should be done at the
time new carrier linings are installed.
12
15
14
13
16
9
17
66
2
11
55
10
10
14
12
LOCKNUT
STOP BOLT
FLOATING PAD
ROTOR
SETSCREW
ADJUSTING NUT
PISTON ACTUATED PAD
ACTUATOR
SPRING
LINING BOLT
LINING BOLT
MOUNT BOLTS
CALIPER
CALIPER MOUNT
BRAKE MOUNT BRACKET
BACKING PLATE
BACKING PLATE
1NGO1602, P1041
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
COPYRIGHT 2002
LeTourneau, Inc.
13
BRAKES
PUBLICATION OSM6
3
4
5
6
7
16
10
8
13
15
14
12
20
19
18
17
11
21
30
22
34
29
33
32
24
25
23
26
31
28
27
1
2
3
4
5
6
7
BRAKE HUB
DISC
LOCKWASHER
BOLT
BRAKE ACTUATOR
SETSCREW
INSERT
8
9
10
11
12
13
14
SLEEVE NUT
RING
BOSS
CAPSCREW
LOCKWASHER
CLAMP PLATE STR.
PLATE
15
16
17
18
19
20
21
PAD
MOUNT STR.
JAMNUT
BOLT
CAPSCREW
LOCKWASHER
NUT
22
23
24
25
26
27
28
LOCKWASHER
BAR
LOCKWASHER
BOLT
FLATWASHER
SPACER
PLATE
29
30
31
32
33
34
CLAMP STR.
SPRING
BOLT
WASHER
BOLT
LOCKWASHER
1CG2078, P1041
14
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM6
BRAKES
1 1
1 SPECIAL TOOL
P/N 4232980 & 4232981
2 ACTUATOR TOP PLATE
3 CYLINDER ROD
4 JAMNUT
5 PISTON
1CG1593, P1037
COPYRIGHT 2002
LeTourneau, Inc.
TA8932CG
15
BRAKES
PUBLICATION OSM6
NOTES
16
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM6
BRAKES
DISASSEMBLY
Numbers in parentheses refer to Figure 10.
a. Do not remove pipe plug (24). Plug will act as guide
for press stud.
b. Position the brake actuator into brake actuator
press (P/N 4235028) with the 5/818 UNF studs
protruding through the bottom of the press' base plate.
Secure with mounting nuts. Refer to Figure 10.
REMOVAL
Numbers in parenthesis refer to Figure 8.
f.
Remove the springs (4 & 5) and piston (7) from the
actuator.
CAUTION
c. Loosen the jamnut (19) and back the stop bolt (20)
into the brake mount bracket (18) to release the tension
on the springs (32).
d. Unhook the springs (32) from the clamp structure
(31).
COPYRIGHT 2002
LeTourneau, Inc.
17
BRAKES
PUBLICATION OSM6
NOTE
f.
Install the actuator onto the caliper. Tighten mount
nuts to 200 ft. lbs.
g.
h.
ASSEMBLY
Numbers in parentheses refer to Figure 10.
CAUTION
c.
e. Install the four 3/8" acorn nuts (1) and washers (2)
onto the bolts (23) which the secure the cover structure.
Torque to 25 ft. lbs.
NOTES
18
COPYRIGHT 2002
LeTourneau, Inc.
WARNING
NEVER attempt to disassemble the brake actuators while mounted on the motor:
The brake actuators are under spring pressure and can cause serious injury if not
disassembled and assembled in the proper manner. Disassemble and assemble
the brake actuators only with the proper tools and per the instructions in
SERVICING THE HYDRAULIC BRAKE ACTUATORS, page 17.
2
12
24
A
3
13
B
4
14
25
15
SECURE WITH
MOUNTING NUTS
1OSM6.2b, Gorilla
6/6/00
CYLINDER SHOWN IN
RELEASED POSITION
COPYRIGHT 2002
LeTourneau, Inc.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
6
17
18
7
19
20
8
21
26
10
22
11
23
TA8931CG
19
H
T
P
6A
6B
P T
SOL. 8
7A
1A 1B
7B
P T
SOL. 3
B
H
A
P T
H
SOL. 5
SOL. 9
A
3A 3B
SOL. 2
P T
PUBLICATION OSM6
HOIST BRAKE
5A 5B
SOL. 4
P T
SOL. 7
COPYRIGHT 2002
LeTourneau, Inc.
130 PSI
SOL. 1
100 PSI
AC
5 GPM
DC
RESERVOIR
3 GPM
FUNCTIONAL DESCRIPTION:
SOLENOID 1
- ENERGIZE REQUIRED FOR ALL FUNCTIONS.
SOLENOID 2
- ENERGIZE FOR RELEASE OF HOIST BRAKE.
SOLENOID 2, 3 & 8 - ENERGIZE FOR POWER LOSS LOWER AND EMERGENCY RELEASE TENSION ON HOIST BRAKE.
SOLENOID 4
- ENERGIZE FOR RELEASE OF AUXILLIARY HOIST BRAKE.
SOLENOID 4, 5 & 9 - ENERGIZE FOR POWER LOSS LOWER AND EMERGENCY RELEASE TENSION ON AUXILIARY HOIST BRAKE.
SOLENOID 4, 5 & 9 - ENERGIZE FOR CONSTANT TENSION ON AUXILIARY HOIST BRAKE.
SOLENOID 7
- ENERGIZE FOR RELEASE OF BOOM HOIST BRAKE.
NOTE:
1. THERE ARE 2 BRAKE CALIPERS ON EACH MOTOR.
2. HOLD IS SHOWN AS H, TENSION IS SHOWN AS T.
21
BRAKES
TA8943CG
22
1NGO2757, P0327
LeTourneau, Inc.
COPYRIGHT 2002
E5
T3
E5
T3
UPPER
CYLINDER
20
M1
20
LOWER
CYLINDER
E1
HOIST BRAKE
UPPER
CYLINDER
E1
LOWER
CYLINDER
E1
M1
E1
10
10
10
14
A3
14
A2
SOL 3
A3
10
A2
SOL 5
E4
T1
24
25
22
28
25
22
E4
23
T1
24
23
29
28
29
A2
E4
18
A2
E4
3
SOL 9
E3
SEE NOTE
P1
P1
19
SEE NOTE
E3
SOL 8
12
12
AB
AB
21
21
SOL 1
VALVE DETAIL
SOL 7
SOL 4
SOL 2
AB
SEE NOTE
15
A4
26
E6
A4
11
UPPER
CYLINDER
A1
T2
16
A4
17
M1
LOWER
CYLINDER
T4
E5
T3
13
M2
E7
P2
5A
5B
E2
21
P2
4A
4B
P2
P2
3A
3B
E2
P2
2A
2B
P2
21
P2
1A
1B
E2
BRAKES
PUBLICATION OSM6
TA102434
PUBLICATION OSM6
BRAKES
COPYRIGHT 2002
ADAPTERS:
A1 HYDRAULIC
A2 HYDRAULIC
A3 HYDRAULIC
A4 HYDRAULIC
FITTING
FITTING
FITTING
FITTING
ELBOWS:
E1 HYDRAULIC
E2 HYDRAULIC
E3 HYDRAULIC
E4 HYDRAULIC
E5 HYDRAULIC
E6 HYDRAULIC
E7 HYDRAULIC
FITTING
FITTING
FITTING
FITTING
FITTING
FITTING
FITTING
PLUGS:
P1 JIG PLUG
P2 PLUG W/#12 ORING
TEES:
T1 HYDRAULIC
T2 HYDRAULIC
T3 HYDRAULIC
T4 HYDRAULIC
FITTING
FITTING
FITTING
FITTING
MISCELLANEOUS FITTINGS:
M1 PIPE REDUCER
M2 CAP NUT
LeTourneau, Inc.
23
BRAKES
PUBLICATION OSM6
NOTES
24
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
NOTE
Lubricating oil analysis is designed to detect
only that type of failure which characteristical
ly begins with an increase in metal wear; that
is, worn bearings, worn gears and slowly
progressing fatigue failures. Component
failures which are catastrophic and instanta
neous in nature are not caught by lubricating
oil analysis.
SAMPLE COLLECTION
NOTE
A suction pump should be used to draw the oil
sample, as this will result in the most accurate
analysis reports. BE SURE to thoroughly clean
the suction pump between taking samples in
several components.
PROGRAM OPERATION
With lubricating oil analysis, the wear of internal
components can be determined without taking the
machine apart. At the recommended oil change
interval or as otherwise recommended; a sample of the
oil should be collected and sent to a testing facility who
analyzes its microscopic metal content with special
emission or atomic absorption spectrophotometry
equipment. When this is done regularly, a record or
wear trend is established for that component or group
on components from several machines. If the amount of
certain metal or other foreign matter rises suddenly
above the normal wear trend, it can indicate failure is
imminent. The type of metal or material detected in the
4OSM 4.3a, Gorilla
8/30/01
NOTE
Samples must be sent promptly to the testing
facility. Analysis and reporting must be
likewise equally prompt. Any delay could
negate the application of the analysis report.
All samples must be analyzed under identical
conditions or the results will not be usable.
Newly changed oil or oil recently added to a system will
not give a true picture when it is analyzed. Also,
deviation from accepted procedures in taking the
sample can invalidate the analysis results. Any of these
conditions could have dangerous or misleading conse
quences because the sample analysis would be
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
b.
PROPER DOCUMENTATION
NOTE
Flushing the driver or gearbox is strongly
recommended if iron content reaches 100
ppm. If these high levels of iron content
continue after flushing, disassembly and
inspection should be considered. In order to
maximize component life, the amount of iron
contained in the oil must be kept as low as
possible.
1. Date of sample
2. Serial or identification numbers of the compo
nent
3. Total hours of component life
4. Hours of operation since last oil change
5. Complete results of all tests conducted
NOTE
RECOMMENDED TESTS
1. Spectrographic analysis: This test checks
for the metal content in the oil. The amounts in
parts per million should be compared to the
previous sample. If a significant increase in
any of the elements appears, perform a
gearcase inspection. A sudden increase in
iron content will indicate excessive wear of
one or more of the drive train components. A
sudden increase in chromium should indicate
unusual wear of a bearing. If silicon content
only shows a large step change, the oil should
be changed.
a.
NOTE
It is important to emphasize that a large
increase in iron or chromium content between
two consecutive tests indicates component
failure.
10
COPYRIGHT 2002
CAUTION
LeTourneau, Inc.
PUBLICATION OSM4
NOTE
The ultimate success of a lubricating oil
analysis program rests with the owner or
equipment manager. If good samples are
taken, forwarded promptly, and the feedback
used wisely, a lubricating oil analysis program
will be very effective.
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
11
PUBLICATION OSM4
NOTES
12
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
NOTE
f.
With the MASTER switch in the ON position and
the HOIST SELECT switch in the AUX position, lift any
convenient load to approximately 25% of full up travel.
g. Position the HOIST joystick to NEUTRAL and the
BRAKE switch to the SET position.
COPYRIGHT 2002
CAUTION
LeTourneau, Inc.
17
PUBLICATION OSM4
NOTE
The SPEED/TEMP WARNING light should be
out and stay out throughout this procedure
(unless brake rotor temperature exceeds
approximately 700F).
f.
Position the HOIST joystick to NEUTRAL and the
BRAKE switch to the SET position.
NOTE
CAUTION
18
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
f.
Position the HOIST joystick to NEUTRAL and the
BRAKE switch to the SET position.
NOTE
Once disabled by any of the three means
above, constant tension mode will stay
disabled until the CONSTANT TENSION
switch is cycled from ON to OFF and back to
ON again.
COPYRIGHT 2002
LeTourneau, Inc.
19
PUBLICATION OSM4
NOTES
20
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM6
CAUTION
NOTE
NOTE
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
73
PUBLICATION ROM6
74
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM6
COPYRIGHT 2002
LeTourneau, Inc.
75
PUBLICATION ROM6
NOTE
Power Loss Hoist Lower mode will be
overridden by constant tension mode (wire
CT3 hot) and emergency hoist release mode
(wires ER1 or ER2 hot).
76
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM6
will also drop if it weighs more than 3300 lbs. There will
be no motor power, of course, to take up the slack when
the deck rises again.
Top motor speed allowed by the PLLC in constant
tension mode is 2665 rpm. Should motor speed exceed
this maximum, the park brake will be fully set and the
constant tension switch will have to be cycled from OFF
back to BAT in order to resume constant tension
operation.
Temperature sensing circuitry and logic are discussed
in the Temperature Sensing section following.
NOTE
NOTE
Emergency hoist release mode overrides
constant tension (wire CT4 hot) and power
loss hoist lower (wire EL4 hot) modes.
d. TEMPERATURE SENSING: A descending load
opposed by friction drag torque on the motor brake
rotor will generate heat. Brake rotor temperature is
sensed by a thermocouple mounted .050 inches from
the radial edge of the rotor (cold). As the rotor heats up it
expands and its heat is transmitted through the air gap
to the thermocouple. The thermocouple's millivolt
signal is routed to a 420mA temperature transmitter
which sends a proportional current signal to the PLLC
on wire TX1 (main hoist) or TX2 (auxiliary hoist). If the
rotor temperature is sensed to be greater than approxi
mately 700F, the PLLC will set the park brake until rotor
temperature drops to less than approximately 450F, at
which point lowering will be reenabled.
COPYRIGHT 2002
NOTE
Rotor temperature has no effect on emer
gency release mode.
CAUTION
LeTourneau, Inc.
77
PUBLICATION ROM6
NOTE
Refer to Figure 25 for an illustration of the
thermocouple and installation procedures.
Refer to Figure 26 for an illustration of the
temperature transmitters.
e. SPEED/TEMPERATURE Warning Light: The
SPEED/TEMPERATURE warning light (located on the
operator's console) comes on in the following modes
and for the following reasons (for further information on
troubleshooting what is specifically causing a flashing
or a steady light, refer to PLLC LED'S, below):
1. Steady Mode: The light will come on and
glow steadily and the park brake will be set
(exception: in emergency release mode, the
park brake will remain released regardless of
the status of this light) in the event of:
(a) The motor brake rotor reaching its maxi
mum allowed temperature of approxi
mately 700F. The light will go out and
lowering will be allowed once the rotor
temperature has cooled to less than
approximately 450F.
(b) A failure of the brake rotor temperature
sensing thermocouple.
(c) A failure of the brake rotor 420mA
temperature transmitter.
NOTE
A failure of one hoist motor's thermocouple
and/or temperature transmitter will cause the
SPEED/TEMPERATURE warning light to come
on steady but will not disable the lowering
capability of the other hoist motor. For further
information on troubleshooting what is
specifically causing a flashing or a steady
light, refer to PLLC LED's, below.
2. Flashing Mode: This light will flash in the
event of:
78
f.
PLLC LED'S: Mounted on the PLLC are eight
LED's (light emitting diodes) (refer to Figure 24). These
LED's have the following labels and meanings:
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM6
COPYRIGHT 2002
NOTE
Circuitry on the PLLC essentially compares
the signals received from the auxiliary hoist
speed sensor 1 and auxiliary hoist speed
sensor 2 and turns on LED5 if a signal is
sensed from speed sensor 2 but not from
speed sensor 1. Consequently if both speed
sensors or both speed sensor signal process
ing circuits are malfunctioning, no difference
between the two will be detected and LED5 will
not come on.
6. LED6 (AH SS2 Fail). If auxiliary hoist motor
speed is greater than 250 rpm and this LED
comes on, the SPEED/TEMPERATURE warn
ing light on the operator's console will come
on and flash. This LED comes on if:
(a) Auxiliary hoist speed sensor 2 is not
sending a signal to the PLLC (see NOTE
below).
(b) The auxiliary hoist speed sensor 2 signal
processing circuitry on the PLLC is
malfunctioning (see NOTE below).
NOTE
Circuitry on the PLLC essentially compares
the signals received from auxiliary hoist
speed sensor 1 and auxiliary hoist speed
sensor 2 and turns on LED6 if a signal is
sensed from speed sensor 1 but not from
speed sensor 2. Consequently if both speed
LeTourneau, Inc.
79
PUBLICATION ROM6
NOTE
Circuitry on the PLLC essentially compares
the signals received from main hoist speed
sensor 1 and main hoist speed sensor 2 and
turns on LED8 if a signal is sensed from speed
sensor 1 but not from speed sensor 2.
Consequently, if both speed sensors or both
speed sensor signal processing circuits are
malfunctioning, no difference between the two
will be detected and LED8 will not come on.
NOTE
Circuitry on the PLLC essentially compares
the signals received from main hoist speed
sensor 1 and main hoist speed sensor 2 and
turns on LED7 if a signal is sensed from speed
sensor 2 but not from speed sensor 1.
Consequently, if both speed sensors or both
speed sensor signal processing circuits are
NOTES
80
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM6
3
3
2
1
4
1
BRACKET INSTALLATION
BRAKE CALIPER
ASSEMBLY
THERMOCOUPLE
BRACKET ASSEMBLY
THERMOCOUPLE
ASSEMBLY
OUTSIDE EDGE
OF BRAKE DISC
OUTSIDE EDGE
OF BRAKE DISC
.002"
.050" CLEAR
(REF)
1.
2.
3.
4.
MOUNTING BRACKET
COMPRESSION FITTING
THERMOCOUPLE ASSEMBLY
THREAD LOADING COMPOUND - LOCTITE RC271
1. Insert compression fitting (Item 2) into bracket (Item 1) using Loctite (Item 4).
2. Install bracket onto brake caliper using caliper mount bolt as shown. Adjust bracket as necessary so
that compression fitting is perpendicular to radial edge of brake disk. Tighten caliper mount bolt.
3. Loosen compression fitting nut and insert thermocouple (Item 3) through fitting bushing and teflon
ferrule (internal to fitting) until thermocouple tip measures .050" above brake disk edge. Tighten fitting
nut using Loctite (Item 4) and recheck for .050 .002" clearance. Loosen nut and readjust if
necessary.
4. Route thermocouple wire as shown on machine wire layout; terminate thermocouple wire as shown
on machine schematic.
1CG1875, P1064
LeTourneau, Inc.
TA8987CG
81
TX2
CASE
GRND
ACT2
(YEL)
ACT1
(RED)
AUX HOIST
5 6
7 8
SET 2
SET 1
3B
PUBLICATION ROM6
T/C , MV
8 9
OUT+
3B
TX1
CASE
GRND
MTC 1 MTC 2
(RED) (YEL)
9
SET 2
MAIN HOIST
5 6
7 8
SET 1
T/C , MV
8 9
OUT+
TEMP XMIT
AUX HOOK
4180161
TEMP XMIT
MAIN HOOK
4180161
TA8988CG
NOTES
82
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
Page
Page
TABLE OF CONTENTS
TABLE OF CONTENTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 33
CRITICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 5
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
WELDING REQUIREMENTS . . . . . . . . . . . . . . . . . . 37
STRUCTURAL MATERIALS . . . . . . . . . . . . . . . . . . . 37
STRUCTURAL REPAIR PROCEDURES . . . . . . . . . 37
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . 39
PAINT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 40
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13
REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13
FIGURE
Page
10
14
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
16
20
REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 19
27
29
30
10
32
11
34
12
36
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
NOTE
In several places in this publication, the terms
qualified" or competent" person are used
with regards to inspection, repair and
certification of the crane and its components.
A qualified" or competent" person is defined
as follows: A person who, by possession of a
professional degree, certificate of profession
al standing or who by extensive knowledge,
training, and experience, has successfully
demonstrated the ability to solve or resolve
problems relating to the subject matter and
work.
NOTE
CAUTION
CAUTION
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
NOTE
ANNUAL EXAMINATIONS
Cranes shall undergo a thorough examination at least
every twelve (12) months by a competent person, or
more frequently if required by the certifying authority.
a.
STRUCTURAL INSPECTION
COPYRIGHT 2002
LeTourneau, Inc.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
CRITICAL COMPONENTS
The following is a list of components of the crane which
should be considered as critical components." These
components are ones which affect the safety of the
crane from a structural and load hoisting standpoint.
These components should be of prime concern to the
deck supervisor, operator and maintenance personnel
with regards to certification, inspection, maintenance
and prompt repair per the appropriate guidelines.
b.
c.
d.
c.
e.
d.
f.
e.
COPYRIGHT 2002
LeTourneau, Inc.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
Refer to
Section 4
location
electrical,
nents.
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1
2
4
5
3
4
5
1.
2.
3.
4.
5.
6.
7.
8.
1CG1857, P1058
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
DISASSEMBLY PROCEDURES
NOTE
Small burrs and nicks can be dressed out, but
damaged or worn bearings and bushings
must be replaced.
NOTE
A suitable hoisting device such as an auxiliary
crane will be required for disassembly and
reassembly procedures.
CAUTION
REASSEMBLY
NOTE
Use care to prevent damage to grease seals
during reassembly and installation.
c.
Remove the three jacking screws from the bearing
hub.
NOTE
e.
f.
Recheck torque on bearing hub and seal cap
bolts.
NOTE
f.
Remove the two grease seals from the bearing
hub.
g. With a suitable tool, drive the thrust bearing,
bearing spacer and roller bearing out of bearing hub.
1ROM 1.2a, 120SS (Gorilla)
4/20/99
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
3
4
12
5
6
11
8
13
9
10
18
17
16
17
16
14
19
15
20
21
22
27
23
28
29
24
30
21
31
25
26
32
1NGO2265, P1234
10
LeTourneau, Inc.
TA8992CG
PUBLICATION ROM1
COPYRIGHT 2002
LeTourneau, Inc.
11
PUBLICATION ROM1
5
6
7
4
2
1.
2.
3.
4.
5. ELBOW STR.
6. WIRE TUBE STR.
7. UPPER BEARING ASSY.
12
TA9488S8
COPYRIGHT 2002
LeTourneau, Inc.
DISASSEMBLY PROCEDURES
REASSEMBLY PROCEDURES
NOTE
NOTE
NOTE
NOTE
d. Adjust all rollers out until they touch the swing gear.
Position of the rollers can be seen through the viewing
access hole next to the roller flange.
NOTE
Large adjustment is made by rotating the
roller flange independently of the retainer
pad. Smaller adjustment can be made using
the slotted holes of the retainer pad.
f.
Remove oil seal holder, oil seal and oil seal ring
from bearing pin.
NOTE
Use care to prevent damage to oil seal, rings,
holder, bearing and rollers.
f.
Secure the bolt retainer pads to roller flanges and
roller table.
COPYRIGHT 2002
LeTourneau, Inc.
13
PUBLICATION ROM1
PRYBAR
ROLLER
ACCESS
HOLE
SWING GEAR
FEELER GAUGE
.020
14
TA8981P
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
SWING GEARBOX
Refer to Section 6, Gearboxes, for information concern
ing the disassembly, repair and replacement and
reassembly procedures for the # 5 gearbox assembly.
COPYRIGHT 2002
LeTourneau, Inc.
15
PUBLICATION ROM1
18
3
4
5
19
17
16
7
15
8
14
10
13
12
11
1CG1858, P1058
16
LeTourneau, Inc.
TA8994CG
PUBLICATION ROM1
LID STRUCTURE
TOGGLE LATCH
ORING
BOLT
LOCKWASHER
ORING
S1A DC MOTOR
BOLT
BOLT
WASHER BAR
LOCKNUT
#5 SWING GEARBOX
LOCKWASHER
BOLT
TERMINAL TUBE
TERMINAL TUBE
COVER STRUCTURE
MACHINERY HOUSE
& WINCH GROUP
19. SWING TABLE GROUP
COPYRIGHT 2002
LeTourneau, Inc.
17
18
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
NOTE
NOTE
DISASSEMBLY
NOTE
REASSEMBLY PROCEDURES
COPYRIGHT 2002
LeTourneau, Inc.
19
PUBLICATION ROM1
25
6
7
2
24
1
4
5
23
22
2
1
21
20
7
17
16
18
17
15
6
15
7
1
19
9
14
10
13
12
11
20
TA8998CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
BOLT
LOCKING BAR
PIN
R.H. VERTICAL GANTRY STR.
L.H. VERTICAL GANTRY STR.
PIN
PIN
CENTER PIPE STR.
FRONT GANTRY STR.
BOLT
GREASE FITTING
BOLT
BEARING RETAINING
SHEAVE PIN
SPACER
SHEAVE
SEAL
BEARING
SPACER
SUPPORT STR. - SHOCK
PIN
PUSHER STR.
SPRING
BOLT
BOOM STOP SUPPORT STR.
COPYRIGHT 2002
LeTourneau, Inc.
21
22
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
NOTE
Sheaves and sheave wheel pins are to be
magnetic particle tested.
REASSEMBLY
a. Reassemble and lubricate wheel bearing assem
blies.
NOTE
DISASSEMBLY
a. With a suitable hoisting device attached, remove
the pin retainers and pin from the Gantry Sheave
Housing Assembly. This will allow the whole Gantry
Sheave Housing Assembly to drop down.
b.
NOTE
NOTE
CAUTION
f.
With a suitable hoisting device, raise Gantry
Sheave Housing Assembly up and connect back to top
of gantry with the gantry hinge pin. Replace keeper
plates with two (2) 5/8inch bolts in the end of each pin.
Tighten bolts. Refer to the CAPSCREW TORQUE
CHART, in the appendix of this manual for the proper
torque.
COPYRIGHT 2002
LeTourneau, Inc.
23
24
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
g.
NOTE
A suitable hoisting device such as an auxiliary
crane will be required for disassembly and
reassembly procedures.
CAUTION
NOTE
BOOM REASSEMBLY
f.
Remove boom wire rope dead end for gantry
sheave assembly.
COPYRIGHT 2002
LeTourneau, Inc.
25
26
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
12
19
13
20
20
14
11
22
21
18
10
16 15
21
18
17
VIEW - D
VIEW A
VIEW B
VIEW C
SECTION A-A
C
B
5
6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
PLATE
BOLT
CAP PLATE
GREASE FITTING
LUFFING CABLE
12.
13.
14.
15.
16.
BOLT
NUT
IDLER
WASHER
NUT
17.
18.
19.
20.
21.
22.
TA8999CG
COPYRIGHT 2002
LeTourneau, Inc.
27
28
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
11
12
14
1
3
7
16
13
12
11
12
5
14
13
12
11
17
4
8
16
9
6
5
4
10
5
6
15
11
6
12
13
14
12
5
11
12
13
14
11
12
14
13
12
11
12
11
1.
2.
3.
4.
5.
BOLT
LOCKWASHER
TOP PLATE
PIN RETAINER
BOLT
1CG1861, P1059
6.
7.
8.
9.
GREASE FITTING
BOLT
PLATE
PLATE
10.
11.
12.
13.
GREASE FITTING
BOLT
PLATE
PLATE
14.
15.
16.
17.
SHEAVE
SHEAVE PIN
SHEAVE PIN
BOOM TIP EXT. STR.
COPYRIGHT 2002
LeTourneau, Inc.
TA9001CG
29
PUBLICATION ROM1
2
1
10
7
4
5
5
6
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
30
TA9002CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
NOTE
NOTE
REASSEMBLY
DISASSEMBLY
a. Lower the Floating Sheave Housing Assembly into
the cradle provided on the top of the boom. Remove the
two (2) 1/2inch bolts and retainer plate that holds the
bridal connector pin in place. With proper hoisting
device remove pin.
b. Lower Floating Sheave Housing Assembly to a
prepared working surface.
c. Remove the square nuts, bolts and pipe spacers
that hold the 4 side and inner plates together.
NOTE
NOTE
NOTE
COPYRIGHT 2002
LeTourneau, Inc.
31
PUBLICATION ROM1
3
4
5
22
8
8
23
11
10
15
12
21
7
8
13
20
11
14
15
19
15
19
14
17
18
16
17
1.
2.
3.
4.
5.
6.
7.
8.
1CG1862, P1059
32
9.
10.
11.
12.
13.
14.
15.
16.
NUT
RETAINER
GREASE FITTING
BOLT
SHEAVE
BEARING SPACER
SPACER
SEAL
17.
18.
19.
20.
21.
22.
23.
BEARING SPACER
BEARING
BOLT
CENTER PIN
PIN
SIDE PLATE
INNER PLATE
LeTourneau, Inc.
TA8977CG
PUBLICATION ROM1
DISASSEMBLY
a. Lower the Hook and Block Assembly to a prepared
working surface.
b. The Hook Assembly itself is disassembled by first
removing the keeper plates that retain the swivel block.
REASSEMBLY
a. In reassembling the Sheave Housing Assembly,
first reassemble an lubricate all bearing assemblies.
b. Insert bearing assemblies and spacers into the
first wheel. Put wheel into position between spacers,
bearing seals, wheel bearings and sheave wheel.
NOTE
NOTE
NOTE
NOTE
Hook wheels and pins are to be Magnetic
Particle Tested every four (4) years or if
disassembled, to A.P.I. 2C 1983.
NOTE
Check crane hooks for deformation or cracks.
Hooks will be discarded where cracks exist or
throat opening is 15 percent more than the
original throat opening. Hooks will also be
discarded where they are bent or twisted more
than 10 from the plane of the original hook
configuration. The shank of the hook shall
NOTE
The Auxiliary Hook Assembly is a vendor
supplied item. Refer to the Parts Catalog for
ordering information.
COPYRIGHT 2002
LeTourneau, Inc.
33
PUBLICATION ROM1
1
2
3
28
29
5
6
8
27
9
10
11
14
1
26
15
25
3
16
11
24
10
17
13
23
18
12
22
19
20
21
1.
2.
3.
4.
5.
6.
7.
SPACER
KEEPER PLATE
BOLT
BEARING RETAINER
GREASE FITTING
BOLT
NUT
8.
9.
10.
11.
12.
13.
14.
RETAINER ROD
SHEAVE
BEARING SPACER
BEARING SPACER
SEAL
BEARING
BOLT
15.
16.
17.
18.
19.
20.
21.
LOCKWASHER
COVER STR.
COTTER PIN
THRUST BEARING
BEARING BLOCK
HOOK
LATCH KIT
22.
23.
24.
25.
26.
27.
28.
29.
FELT SEAL
NUT
ORING
TIE PIN
MOUNT PLATE
SHEAVE PIN
SIDE PLATE
DIVIDER PLATE
34
TA8971CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
35
PUBLICATION ROM1
B
2
B
A
5
4
6
7
5
7
8
8
VIEW A-A
1.
2.
3.
4.
5.
6.
7.
8.
MACHINERY HOUSE
KING PIN & SWING TABLE STR.
CABLE DRUM STR.
LOCK PIN STR.
BOLT
LOCK PIN MOUNT STR.
BOLT
PLATE
VIEW B-B
36
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
WELDING REQUIREMENTS
Certain materials are manufactured exclusively by
LeTourneau, Inc. Substitution of these materials is not to
be attempted without prior approval by LeTourneau,
Inc. due to the possible incompatibility of alternate
materials. Should the owner desire, LeTourneau, Inc.
will provide personnel and materials for repairs and/or
replacements if requested.
CAUTION
NOTE
NOTE
STRUCTURAL MATERIALS
COLUMN PLATES: 1" thick and made from N20 BHT
MAIN BOOM PIPES: 65/8" O.D. LET. X .375 wall
thickness and are made from high strength steel
(70,000 minimum yield, 100,000 minimum tensile
charpy of 20 lb. at -40).
CAUTION
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
37
PUBLICATION ROM1
NOTES
38
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
NOTE
NOTE
Materials and equipment listed above are
used successfully by LeTourneau, Inc. in the
manufacturing process. Substitute items that
meet specifications listed are acceptable.
CAUTION
NOTE
Do not reuse blasting sand. Oil and grease
should be removed by hosing or by wiping
with a suitable solvent.
NOTE
MATERIALS RECOMMENDED
CAUTION
a.
EQUIPMENT RECOMMENDED
SURFACE PREPARATION
b.
COPYRIGHT 2002
LeTourneau, Inc.
39
PUBLICATION ROM1
f.
All rough welds, burrs, weld splatter and other
sharp surface projections should be ground smooth.
Any grinding done after sandblasting should be re
blasted to obtain a surface like the remainder of the area
to be painted.
g. Sandblasting and painting operations should be
scheduled so that they will not be in progress at the
same time or so that blasting is not in progress while
there is wet paint within the range of sandblasting
contamination. The blast cleaned surface should be
coated with one coat of primer as specified during the
same day as blasted and also before any visible rust
occurs. Sandblasted steel wet by rain or moisture prior
to priming should be reblasted.
NOTE
Surfaces which do not require painting should
be masked or otherwise protected during the
painting of adjacent work. Also, be aware of
possible damage to surrounding rig compo
nents from overspray and take appropriate
measures to protect them.
NOTE
A color contrast has been purposely estab
lished between the primer and the finish coat.
The color contrast is designed to act as an
indicator to insure complete coverage with
both primer and finish coat. The contrast is not
to be so great as to markedly influence the
appearance of the top coat.
PAINT APPLICATION
a. Primer and paint used should be the original used
in the manufacturing process or equivalent, conform to
the paint manufacturers specifications and be applied
listed in Figure 13.
b. Painting should be done in a neat and workman
like manner and all joints and crevices should be filled
where necessary and thoroughly painted. Paint should
be applied only on surfaces that are completely dry.
c. Painting should only be permitted within a range of
temperature and humidity recommended by the paint
manufacturer as published in specifications for the
particular product.
40
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
Component
Metal Prep
Near white
shot or
sand blast
SSPC10
Primer
Tie Coat
Boom Tip
Machine House
Interior
Wire brush to
remove rust
and loose
scale. Wash
to remove oil,
grease and
foreign matter.
Welded Hand
Railjoints
YELLOW
None
None
None
ORANGE
Top Coat
COPYRIGHT 2002
LeTourneau, Inc.
TA8941CG
41
PUBLICATION ROM1
TABLE OF CONTENTS
Page
Page
ANNUAL EXAMINATIONS . . . . . . . . . . . . . . . . . . . . 3
CONTROL BOOK AND CERTIFICATE . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CRITICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 5
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
STRUCTURAL MATERIALS . . . . . . . . . . . . . . . . . . . 35
WELDING REQUIREMENTS . . . . . . . . . . . . . . . . . . 35
STRUCTURAL REPAIR PROCEDURES . . . . . . . . . 35
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 9
SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . 37
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13
PAINT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 38
REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13
LIST OF ILLUSTRATIONS
FIGURE
Page
WINCH INSTALLATION . . . . . . . . . . . . . . . . 8
GANTRY ASSEMBLY
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
NOTE
In several places in this publication, the terms
qualified" or competent" person are used
with regards to inspection, repair and
certification of the crane and its components.
A qualified" or competent" person is defined
as follows: A person who, by possession of a
professional degree, certificate of profession
al standing or who by extensive knowledge,
training, and experience, has successfully
demonstrated the ability to solve or resolve
problems relating to the subject matter and
work.
NOTE
Mandatory rules of this publication per
ANSI/ASME are characterized by the word
SHALL." If a provision is of an advisory
nature, it is indicated by the word
SHOULD" and is recommended to be consid
ered, the advisability of which depends on the
facts in each situation.
CAUTION
CAUTION
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
NOTE
ANNUAL EXAMINATIONS
Cranes shall undergo a thorough examination at least
every twelve (12) months by a competent person, or
more frequently if required by the certifying authority.
a.
STRUCTURAL INSPECTION
COPYRIGHT 2002
LeTourneau, Inc.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
CRITICAL COMPONENTS
The following is a list of components of the crane which
should be considered as critical components." These
components are ones which affect the safety of the
crane from a structural and load hoisting standpoint.
These components should be of prime concern to the
deck supervisor, operator and maintenance personnel
with regards to certification, inspection, maintenance
and prompt repair per the appropriate guidelines.
b.
c.
d.
c.
e.
d.
f.
e.
COPYRIGHT 2002
LeTourneau, Inc.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
COPYRIGHT 2002
CAUTION
LeTourneau, Inc.
PUBLICATION ROM1
2
4
5
1
3
4
5
3
4
6
7
1.
2.
3.
4.
5.
6.
7.
8.
TA8919CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
DISASSEMBLY PROCEDURES
REASSEMBLY PROCEDURES
NOTE
NOTE
NOTE
NOTE
e. Adjust all rollers out until they touch the swing gear.
Position of the rollers can be seen through the viewing
access hole next to the roller flange.
NOTE
f.
Remove oil seal holder, oil seal and oil seal ring
from bearing pin.
NOTE
f.
Using a feeler gauge between the rollers and the
swing gear, adjust the three nonloaded rollers (oppo
site the boom) in, leaving a .020 inch gap between the
roller and the gear (refer to Figure 3).
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
23
22
21
4
20
7
19
8
10
11
12
18
13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
14
GREASE FITTING
BOLT
PAD
ROLLER PIN
OIL SEAL
ROLLER
BEARING
OIL SEAL RING
OIL SEAL HOLDER
RETAINER RING
OIL SEAL
BUSHING
BEARING
SOCKET STR.
OIL SEAL
HEX NUT
BOLT
COLUMN & GEAR STR.
SWING TABLE &
KING PIN STR.
BOLT
ORING
MANHOLE COVER
BOLT
15
17
16
1CG1844, P1052
10
LeTourneau, Inc.
TA8904CG
PUBLICATION ROM1
PRYBAR
ROLLER
ACCESS
HOLE
SWING GEAR
FEELER GAUGE
.020
TA8981P
COPYRIGHT 2002
LeTourneau, Inc.
11
12
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
DISASSEMBLY PROCEDURES
NOTE
Magnetic particle tests should be conducted
on all gears and shafts every four (4) years or
when disassembled for repairs.
NOTE
A jack and a hoisting device such as an
auxiliary crane of sufficient size and capacity
will be required for disassembly and reas
sembly procedures.
a.
REASSEMBLY PROCEDURES
a.
NOTE
NOTE
f.
Replace the nut on the bottom of the swing turn
table.
d.
b.
NOTE
COPYRIGHT 2002
LeTourneau, Inc.
13
14
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
COPYRIGHT 2002
LeTourneau, Inc.
15
PUBLICATION ROM1
3
4
5
17
6
16
7
15
14
13
9
10
12
11
1.
2.
3.
4.
5.
6.
7.
8.
9.
LID STR.
TOGGLE LATCH
ORING
BOLT
LOCKWASHER
ORING
S1A DC MOTOR
BOLT
BOLT
1CG1846, P1053
16
10.
11.
12.
13.
14.
15.
16.
17.
WASHER BAR
LOCKNUT
#5 SWING GEARBOX
LOCKWASHER
BOLT
TERMINAL TUBE
TERMINAL TUBE
COVER STR.
LeTourneau, Inc.
TA8962CG
PUBLICATION ROM1
NOTE
NOTE
DISASSEMBLY
NOTE
REASSEMBLY PROCEDURES
COPYRIGHT 2002
LeTourneau, Inc.
17
PUBLICATION ROM1
1
2
3
22
21
20
3
19
23
18
4
2
17
1
15
16
15
14
8
4
1
5
6
14
2
13
4
3
11
12
10
1
3
9
2
8
18
TA8970CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
GANTRY ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
BOLT
KEEPER PLATE
PIN
PIN
LOWER GANTRY STR.
REAR GANTRY STR.
LOWER GANTRY STR.
FRONT GANTRY STR.
GREASE FITTING
BOLT
RETAINER PLATE
SHEAVE PIN
BEARING SPACER
BEARING SPACER
SEAL
BEARING
SHEAVE
SLEEVE
PUSHER STRUCTURE
BOOM STOP SPRING
BOLT
BOOM STOP STR.
BOOM STOP SUPPORT STR.
COPYRIGHT 2002
LeTourneau, Inc.
19
20
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
NOTE
Sheaves and sheave wheel pins are to be
magnetic particle tested.
REASSEMBLY
a. Reassemble and lubricate wheel bearing assem
blies.
NOTE
DISASSEMBLY
a. With a suitable hoisting device attached, remove
the three (3) capscrews from the end of the gantry hinge
pins. Remove the two gantry hinge pins. This will allow
the whole Gantry Sheave Housing Assembly to drop
down.
b. Remove the two 1/2inch bolts that hold the sheave
housing pin keeper plates. Remove sheave housing pin
and six (6) spacers.
NOTE
Only one sheave housing pin needs to be
removed and if the back pin is removed a
complete inspection of all wire ropes can be
made.
CAUTION
NOTE
COPYRIGHT 2002
LeTourneau, Inc.
21
22
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
i.
In succession, remove the capscrews and nuts
that hold the upper, middle and lower boom sections
together and remove each with a suitable hoisting
device.
j.
Remove pin retainers, idler sheave pin, bearing
and 30 inch sheave wheel from auxiliary hoist boom tip
weldment.
k. Remove cotter pin and sheave pin form guide
sheave housing assembly.
l.
Remove bolts, lockwashers and lock plate from
guide sheave housing assembly and drive out sheave
housing pin. Remove the 22 inch sheave wheel.
Remove bearing seal and bearing assembly.
NOTE
CAUTION
NOTE
BOOM REASSEMBLY
To reassemble the Boom Assembly, reverse the proce
dures in BOOM DISASSEMBLY AND REMOVAL, above.
COPYRIGHT 2002
LeTourneau, Inc.
23
24
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
14
15
8
12
13
16
10
19
17
VIEW A
VIEW B
11
VIEW C
20 21
14
SECTION EE
18
A
C
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
BOLT
CAP PLATE
GREASE FITTING
LUFFING ATTACHMENT STR.
BOLT
NUT
BOLT
15.
16.
17.
18.
19.
20.
21.
PIN RETAINER
BUSHING, SELFALIGNING
BUSHING, PIN
GREASE FITTING
HINGE PIN
IDLER
NUT
NOTE: REFER TO FIGURE 6, PARTS 2 AND 3, FOR ILLUSTRATIONS OF THE BOOM TIP ASSEMBLY.
FIGURE 6. BOOM AND AUXILIARY HOIST (1 of 3)
1CG1848, Ldgr221
TA8991CG
COPYRIGHT 2002
LeTourneau, Inc.
25
26
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1CG1849, P1054
LeTourneau, Inc.
COPYRIGHT 2002
11
12
14
13
16
12
11
15
12
12
14
13
17
12
14
13
11
12
18
11
19
11
12
10
13
13
14
12
14
12
11
12
11
12
13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
14
12
11
BOLT
TOP PLATE
PIN RETAINER
BOLT
GREASE FITTING
BOLT
CUFFING ATTACHMENT
CAP PLATE
BOLT
GREASE FITTING
BEARING SPACER
BEARING SEAL
BEARING ASSY.
SHEAVE
BOOM TIP EXTENSION STR.
IDLER SHEAVE PIN
SHEAVE PIN
BOOM TIP STR.
SHEAVE PIN
PUBLICATION ROM1
PCM 350SS ELECTRIC DECK CRANE STRUCTURAL COMPONENTS
TA8993CG
27
PUBLICATION ROM1
2
1
3
10
7
6
4
5
5
6
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1CG1850, P1055
28
TA8989CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
NOTE
NOTE
REASSEMBLY
a. Reassemble and lubricate wheel bearing assem
blies.
DISASSEMBLY
a. Lower the Floating Sheave Housing Assembly into
the cradle provided on the top of the boom. Remove the
three (3) 1/2inch bolts on the end of the pin that holds
the bridal connector structure in place. With proper
hoisting device remove pin.
b. Remove the two (2) 1/2inch bolts and keeper
plates on the end of sheave housing pins that holds the
five (5) sheave divider plates together. remove pin and
six (6) spacer pipes.
NOTE
NOTE
NOTE
COPYRIGHT 2002
LeTourneau, Inc.
29
PUBLICATION ROM1
3
18
2
17
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
16
15
4
5
6
7
8
9
14
13
12
5
11
10
1CG1851, P1055
30
TA8934CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
DISASSEMBLY
a. Lower the Hook and Block Assembly to a prepared
working surface.
b. The hook Assembly itself is disassembled by first
removing the keeper plates that retain the swivel block.
REASSEMBLY
a. In reassembling the Sheave Housing Assembly,
first reassemble an lubricate all bearing assemblies.
b. Insert bearing assemblies and spacers into the
first wheel. Put wheel into position between spacers,
bearing seals, wheel bearings and sheave wheel.
NOTE
NOTE
NOTE
NOTE
Hook wheels and pins are to be Magnetic
Particle Tested every four (4) years or if
disassembled.
NOTE
Check crane hooks for deformation or cracks.
Hooks will be discarded where cracks exist or
throat opening is 15 percent more than the
original throat opening. Hooks will also be
discarded where they are bent or twisted more
than 10 from the plane of the original hook
configuration. The shank of the hook shall
1ROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
NOTE
The Auxiliary Hook Assembly is a vendor
supplied item. Refer to the Parts Catalog for
ordering information.
COPYRIGHT 2002
LeTourneau, Inc.
31
PUBLICATION ROM1
1
2
3
24
23
23
7
8
5
4
22
6
9
10
7
11
8
1
21
20
3
14
2
19
11
18
10
13
12
17
16
1.
2.
3.
4.
5.
6.
7.
8.
SPACER PIPE
KEEPER PLATE
CAPSCREW
RETAINER ROD
NUT
RETAINER PLATE
GREASE FITTING
BOLT
15
9.
10.
11.
12.
13.
14.
15.
16.
SHEAVE WHEEL
BEARING SPACER
BEARING SPACER
SEAL
BEARING
COTTER PIN
SAFETY LATCH
HOOK
17.
18.
19.
20.
21.
22.
23.
24.
SWIVEL BLOCK
THRUST BEARING
NUT
TIE PIN
MOUNT PLATE
SHEAVE PIN
SIDE PLATE
DIVIDER PLATE
32
TA8964CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
COPYRIGHT 2002
LeTourneau, Inc.
33
PUBLICATION ROM1
A
2
3
4
5
8
6
7
8
VIEW A-A
1.
2.
3.
4.
5.
6.
7.
8.
MACHINERY HOUSE
KING PIN AND SWING TABLE STR.
CABLE DRUM STR.
LOCK PIN STR.
BOLT
LOCK PIN MOUNT STR
BOLT
PLATE
VIEW B-B
34
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
WELDING REQUIREMENTS
NOTE
CAUTION
NOTE
STRUCTURAL MATERIALS
COLUMN PLATES: 1" thick and made from N20 BHT
MAIN BOOM PIPES: 65/8" O.D. LET. X .375 wall
thickness and are made from high strength steel
(70,000 minimum yield, 100,000 minimum tensile
charpy of 20 lb. at -40).
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
35
36
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
PUBLICATION ROM1
NOTE
NOTE
Materials and equipment listed above are
used successfully by LeTourneau, Inc. in the
manufacturing process. Substitute items that
meet specifications listed are acceptable.
SURFACE PREPARATION
a. Securely seal the ventilator fan, access door and
any other place blasting sand or paint overspray might
enter the Machinery House or Operator's Cab (option
al). Cover the glass and weatherstripping on the
Operator's Cab (optional). Use masking tape or other
suitable material to seal these areas.
CAUTION
NOTE
Do not reuse blasting sand. Oil and grease
should be removed by hosing or by wiping
with a suitable solvent.
NOTE
MATERIALS RECOMMENDED
EQUIPMENT RECOMMENDED
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
37
PUBLICATION ROM1
f.
All rough welds, burrs, weld splatter and other
sharp surface projections should be ground smooth.
Any grinding done after sandblasting should be re
blasted to obtain a surface like the remainder of the area
to be painted.
g. Sandblasting and painting operations should be
scheduled so that they will not be in progress at the
same time or so that blasting is not in progress while
there is wet paint within the range of sandblasting
contamination. The blast cleaned surface should be
coated with one coat of primer as specified during the
same day as blasted and also before any visible rust
occurs. Sandblasted steel wet by rain or moisture prior
to priming should be reblasted.
NOTE
A color contrast has been purposely estab
lished between the primer and the finish coat.
The color contrast is designed to act as an
indicator to insure complete coverage with
both primer and finish coat. The contrast is not
to be so great as to markedly influence the
appearance of the top coat.
NOTE
Surfaces which do not require painting should
be masked or otherwise protected during the
painting of adjacent work. Also, be aware of
possible damage to surrounding rig compo
nents from overspray and take appropriate
measures to protect them.
PAINT APPLICATION
a. Primer and paint used should be the original used
in the manufacturing process or equivalent, conform to
the paint manufacturers specifications and be applied
listed in Figure 10.
b. Painting should be done in a neat and workman
like manner and all joints and crevices should be filled
where necessary and thoroughly painted. Paint should
be applied only on surfaces that are completely dry.
c. Painting should only be permitted within a range of
temperature and humidity recommended by the paint
manufacturer as published in specifications for the
particular product.
38
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
Component
Metal Prep
Near white
shot or
sand blast
SSPC10
Primer
Tie Coat
Boom Tip
Machine House
Interior
Wire brush to
remove rust
and loose
scale. Wash
to remove oil,
grease and
foreign matter.
Welded Hand
Railjoints
YELLOW
None
None
None
ORANGE
Top Coat
COPYRIGHT 2002
LeTourneau, Inc.
TA8941CG
39
PUBLICATION LeT-1
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
To ensure that no damage occurs to solidstate components, the welding ground clamp
should be as close as possible to the area to
be welded.
CAUTION
CAUTION
NOTE
Machines with Detroit Diesel engines
equipped with the DDEC system (instead of
the governor system) are also equipped with
an electronic battery equalizer. To avoid
reverse polarity damage when disconnecting
battery terminals, always remove the
equalizer ground terminal first and replace
the equalizer ground terminal last.
1. For machines with an articulating joint,
make certain that the ground strap in the
pivot area is left firmly connected
because this cable electrically ties the
two frame sections together.
2. If the welding unit is connected to
commercial power such as in a shop
area, the machine must be isolated from
all other contacts to ground other than
the welding ground clamp if possible.
Machine attachments must not contact
any steel wear rails in the floor. If an
overhead crane is used to support any
part of the machine, a nonconductive
sling should be used.
CAUTION
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
WELDING TECHNIQUES
For multiple pass welds, starts and stops should
stagger for each weld pass. All starts and stops should
occur before or after the corner of a structure. No slug
welding will be permitted. Where possible, use run-off
tabs. All stops and starts should be on the tabs.
Remove all tabs by oxy-fuel cutting or arc gouging and
grind flush. No weave welding is allowed.
CLEANING REQUIREMENT
Prior to welding, all lose scale, cutting dross, grease,
oil, water, paint, rust, dirt and other contaminants are
to be removed at least 2 from the edge of the joint.
During welding, all individual passes are to be cleaned.
No slag welding is allowed. After welding, remove slag
and spatter from the weld and welding area by
appropriate means. Excessive grinding should be
avoided, but blend grind all repairs.
WELDING DEFECTS
The following discontinuities will cause the weld to be
deemed defective and will require for the discontinuity
and/or the defective weld to be removed.
Porosity (Pinholes) - any cavity type
discontinuity.
Overlap (Cold lap) - protrusion of weld metal
beyond the weld toe or weld root.
Crack - a fracture of the weld metal and/or the
base metal characterized by a sharp tip and high
length to width ratio.
Undercut - Removal of parent material at the toes
of the weld.
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
Electrode
E7018-1
E7018-1
E8018C3
E9018-M
E9018-M
FIELD WELDING
Defined as any welding done outside of the original
fabrication environment in which an item is being
welded to the structure for the first time.
a. Check with the engineering print to ensure
dimensional accuracy.
b. Determine the base metals being joined to
determine the proper preheat and interpass
temperatures (refer to Figure 1, Figure 2,
Figure 3).
c. Preheat the weld joint.
d. Weld using
described above.
requirements
and
techniques
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
Class 1
Class 2
Class 3
Class 4
Class 5
A-36
EH36
A-106-B
A500
1026
C1010
CMS10
Mild .33 Max Carbon
C23M (1506)
NC23M (1517)
C1035
A572 Gr-50
4820H
N20 Cl-1 (1518)
N20 Cl-2 (1518)
N20 Cl-3 (1518)
N20 Cl-5 (1518)
M&M Class 2 (1512)
M&M A/R (1512)
A516-70
8720-H
4130
8630M
NN30 (1508)
N20 HS (1503)
NN-20HS (1503)
N20 Hi Moly (1504)
N20 HMRB (1505)
NN25 (1507)
M&M Class 3 (1512)
M&M Tubing (1511)
N-20 Cl-6 (1518)
A710 Class 1
A710 Class 3
Material Thickness
Class 1
Class 2
Class 3
Class 4
Class 5
< or = 3/4
100F
100F
125F
175F
200F
>3/4 to 1-1/2
125F
150F
225F
225F
250F
>1-1/2 to 2-1/2
150F
225F
250F
275F
300F
>2-1/2
225F
300F
300F
325F
350F
Material Thickness
Class 1
Class 2
Class 3
Class 4
Class 5
< OR = 3/4
500F
500F
500F
450F
450
>3/4 to 1-1/2
500F
500F
500F
450F
450F
>1-1/2 to 2-1/2
500F
500F
500F
450F
450F
>2-1/2
500F
500F
500F
450F
450F
A5.1
Electrode
Maximum
Exposure
Time (hours)
Electrode
Maximum
Exposure
Time (hours)
E70XX
E70XX-X
E70XXR
E80XX-X
E70XXHXR
E90XX-X
E7018M
E100XX-X
1/2
E110XX-X
1/2
A5.2
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
NOTE
This procedure applies only to crack repairs.
Replacement of a ball or socket should be
done in accordance with the Lower Ball,
Pivot Ball and Pivot Ball Socket Field
Replacement Procedures.
Figure 5. GRINDERS
PREPARATION
a. Steam clean the area to remove all contamination
on weld joints.
b. Clean the area to be welded of all rust, paint, oil,
grease, dirt and/or mill scale.
ELECTRODE
GREATER THAN 3X
DIAMETER WEAVE
NOTE
1-NGO-2859, P03-53
WELDING
a. Use AWS Class E7018-1 low hydrogen electrodes
for the repair. These electrodes must be clean and dry.
b. Control the moisture in low hydrogen electrodes by
purchasing electrodes in 10 pound (4.5 kg) sealed
packages.
c. Remove only one hours supply of electrodes at a
time. Keep the remainder in a ventilated holding oven
at 225F (107C).
TA-10310
NOTE
If the crack is in a casting or a weld attached
to a casting, the preheat is 350F (177C).
The preheat area should extend 3 from the
crack. Check periodically and maintain the
preheat temperature during the repair
procedure. The temperature should be
checked using heat crayons or heat sticks.
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
ELECTRODE
WELD BEADS
ELECTRODE
MAX
3X
ELECTRODE
GREATER THAN 3X
DIAMETER WEAVE
WELD BEADS
STRINGER BEAD
WIDTH OF BEAD = MAXIMUM 3X ELECTRODE DIAMETER
1-NGO-2860, P03-53
TA-10309
i.
TA-10311
NOTE
If there are problems with cracks in the root
pass using the 7018 electrode, then it is
permissible to use either 6013 or 6011
electrodes to make the root pass.
n. Continue the bead for a full pass the length of the
weld prior to beginning a second pass. Refer to Figure
9.
o. Interpass temperature (temperature in the base
material 1 away from the weld) should not exceed
10
1-NGO-2862, P03-
TA-10312
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
HEAT CRAYON
OR
HEAT STICK
GRINDER
GRINDING TO BE ACROSS
THE WELD DIRECTION
SMOOTH FINISH
NO GRINDING
MARKS
1-NGO-2863, P03-53
TA-10313
1-NGO-2866, P03-53
TA-10316
TA-10314
TA-10317
1-NGO-2865, P03-53
TA-10315
COPYRIGHT 2001
LeTourneau, Inc.
11
PUBLICATION LeT-1
NOTES
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12
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
UPPER BALL
FIELD REPLACEMENT PROCEDURE
accomplished by laying a straight edge on the ball
base and measuring out from the side plate ring to the
straight edge (refer to Detail 1, Figure 15).
SCRIBE LINE
STEP "b"
DO NOT CUT
PAST THIS LINE
WHILE CUTTING
BASE OFF
STEP "e"
TUBE
BALL BASE
SHIMMING
DIMENSION
ORIGINAL
WELD AREA
1-3/4"
STEP "h"
DETAIL 2
B
1/4"
SCRIBE LINE
GRIND THE
END OF THE
TUBE CLEAN
STEP "c"
ADDITIONAL WELD
WILL BE REQUIRED
TO FILL THE ID OF
TUBE WHERE AIR ARC
UNDER CUT THE TUBE
CUT
VIEW C
STEP "d"
CUTS FOR
LOCATING
DIMENSION
AREA
REMOVED
STEP "a"
LOCATION
DIMENSION
STEP "e"
VIEW A
VIEW D
AREA CUT
1-3/4"
SCRIBE LINE
STEP "d"
BALL BASE
16,965
VIEW B
TOOL DRAWING
6 TO 8 FT.
LOCATING
DIMENSION
STEP "a"
SIDE PLAE
RING
DETAIL 1
1" DIA. ROD
1-NGO-1281, P08-24
1/4"
1"
DRILL 7/16" DIA. HOLE
MUST BE IN THE SAME
PLANE AS THE LIFTING
LUG. INSERT 3/8" x 2"
BOLT FROM THIS SIDE
LOCATION FOR
1" FLAT WASHER
TA6075CG
COPYRIGHT 2001
LeTourneau, Inc.
13
PUBLICATION LeT-1
14
m. TUBE EXPANSION:
1. Heat is required to enlarge the tube bore. The
five-inch slab around the tube is to be heated
first to about 300F (149C), and then the tube
can be heated to 300F (149C).
2. Use the gage rod to check expansion of the
tube. If gage rod will not go into tube, then
increase slab and tube temperature by 25F (4C) and recheck with gage rod.
n. BALL INSTALLATION PROCEDURE:
1. Be sure the shim install in Step j, 3 is still in
place. Hoist the frozen ball into position and
insert into the heated tube. You will have three
to four minutes to locate the ball. The ball
should bottom against the shim. Check the
locating dimension obtained in Step a. This
should be checked in three or four places
around the ball. Reposition, as necessary, to
hold this dimension until the ball temperature
increases to the point that the ball is held
snugly in place within the tube. This dimension
must be held for proper ball location (refer to
View D of Figure 15).
2. Allow the ball and tube to return to room
temperature.
3. Rotate the ball installation tool until the 3/8 X
2 bolt falls out. Remove the installation tool.
o. BALL WELDING PROCEDURE:
1. Preheat the weld area to 300F (149C) and
maintain this temperature while welding out
the joint. Arc weld with 1/8 diameter
E-8018C1 electrodes or MIG weld with TriMark TM-911N2 flux cored wire. The
electrodes must have been stored in a sealed
container and heated in a 250F (121C) oven
for 30 minutes before welding. Do not weave
weld.
2. The cap passes must be blended smooth. If
not, they must be ground smooth.
3. Paint the repair area.
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
LOWER BALL
FIELD REPLACEMENT PROCEDURE
The following procedure is set forth for the field
replacement of the lower ball structure.
a. Before removing the damaged ball, a locating
dimension must first be established so that the new
ball can be located. This dimension is taken from the
edge of the side plate ring to the shoulder of the base
ball.
b. Scribe a mark around the weld joint one inch out
from the side plate ring. Do not cut past this line when
cutting the ball off. See View A, Figure 16.
c. Scribe a mark around the base of the ball
1-13/16 in from the outer diameter of the ball base.
d. Use air-arc to cut the ball weld joint out. Do not cut
past the one-inch reference line at the surface. The 113/16 reference line and the 2-9/16 depth dimension
can be used to locate the root of the weld joint.
e. The end of the tube is to be repaired by grinding
clean and welding up the air-arc undercut with
E-8018C1 electrodes. Preheat to 300F (149C) before
welding. Do not over weld I.D. or it will have be ground
by hand.
COPYRIGHT 2001
LeTourneau, Inc.
15
PUBLICATION LeT-1
NOTES
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16
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
l. Follow
the
PIVOT
BALL
SOCKET
REPLACEMENT PROCEDURE. One socket must be
removed and reinstalled to insure correct alignment
and preload with the new ball.
PILOT STUD
1-NGO-1284, P08-25
TA8246CG
COPYRIGHT 2001
LeTourneau, Inc.
17
PUBLICATION LeT-1
NOTES
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18
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
COPYRIGHT 2001
LeTourneau, Inc.
19
PUBLICATION LeT-1
NOTES
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20
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
NOTE
Before beginning these repairs, review
WARNINGS AND CAUTIONS. All weld and
heat treat procedures used in these repairs
should be per the welding instructions,
located in STRUCTURAL WELDING OF HIGH
STRESS JOINTS. Use 7018 electrodes.
NOTE
CAUTION
NOTE
Although not expected to be required, the
same procedure applies to the boom side A
frame pin configurations.
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
21
PUBLICATION LeT-1
A-Frame
Boom
A-Frame Pin
Locations
Counterweight Boom
1-NGO-2070, P10-94
TA-9347-CG
22
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
P/N 413-9717
Tie Plate, Inside A-Frame
P/N 413-4779
Tie Plate, Outside A-Frame
1-CG-2071, P10-94
TA-9348-CG
COPYRIGHT 2001
LeTourneau, Inc.
23
PUBLICATION LeT-1
LETOURNEAU, INC.
FIELD WELDING PROCEDURE
MATERIAL HANDLING EQUIPMENT
LIST OF ILLUSTRATIONS
TABLE OF CONTENTS
PAGE
PAGE
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
GRINDERS .............................................................9
Figure 6.
Figure 7.
Figure 8.
Figure 9.
FIELD WELDING...................................................................... 6
Figure 10.
INTERPASS TEMPERATURE............................... 11
Figure 11.
Figure 12.
Figure 13.
PREPARATION ........................................................................ 9
Figure 14.
WELD POLISHING................................................ 11
WELDING................................................................................. 9
Figure 15.
Figure 16.
Figure 17.
Figure 18.
Figure 19.
Figure 20.
Figure 21.
WELDING INSTALLATION.................................... 24
Figure 22.
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
A-Frame
Structure
Tie Plate
P/N 413-9717
Tie Plate
P/N 413-4779
Weld Areas
(both sides of eye)
Typ
I Beam
1-NGO-2072, P10-94
TA-9349-CG
A-FRAME
TYP
413-4779
TIE PLATE
413-9717
TIE PLATE
TYP
NO WELD
TYP
1-NGO-2073, P10-94
TA-9350-CG
24
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION ROM6
COPYRIGHT 2002
LeTourneau, Inc.
83
PUBLICATION ROM6
COPYRIGHT 2002
LeTourneau, Inc.
85
14
ON
SS8
BLK
WARNING
BLK
PB3
HORN
BLK
PB9
ACKNOWLEDGE
LEFT
SWING
LT9
POWER ON
BAT
SS1
BLK
OFF
1CG2458, P0222
LeTourneau, Inc.
COPYRIGHT 2002
MASTER
RIGHT
LT3
GREEN
ON
DRIVE SYSTEM
FAIL
RUN
RED
LT4
SWING BRAKE
ENGAGE
LT8
WARNING
BOOM LOWER
LIMIT OVERRIDE
POWER LOSS
HOIST LOWER
SPEED/TEMP
RED
PB8
RED
LT3
AMB
RED
LIGHTS
OFF
LT1
SET
SS3
BRAKE
LT34
RED
LT23
SS2
LT7
AUX
BOOM
SLACK WIRE
ROPE
LT5
LIMIT
SWITCHES
HOIST SELECT
MAIN
RAISE
LOWER
LT24
AMB
LT6
AMB
HOIST BRAKE
HYD. PRESS.
GREEN
AUX
EMERGENCY
HOOK RELEASE
ENABLE
RED
RUN
HOIST
GREEN
MAIN
SS7
ON
RED ONCONSTANT
TENSION
OFF
SS6
OFF
BAT
RUN
EMERGENCY
STOP
PB2
RED
LT2
GREEN
TA95806
11
10
WALL M
WALL G
12
13
14
PUBLICATION OSM2
TA97346
COPYRIGHT 2002
LeTourneau, Inc.
15
14
15
14
16
18
WALL B
19
17
18
19
PUBLICATION OSM2
18
16
TA95816
COPYRIGHT 2002
LeTourneau, Inc.
14
10
20
21
10
18
22
22
23
9CG2454-1, Ldgr2391
COPYRIGHT 2002
LeTourneau, Inc.
TA97396
17
23
23
23
23
TA97386
COPYRIGHT 2002
LeTourneau, Inc.
19
PUBLICATION OSM2
WARNING
For use during crane power loss situations to lower load at a constant speed.
Emergency Hoist Release Switch: OFF
Before activating :
Constant Tension Switch:
OFF
(1) Inspect Power Loss Lowering Card, thermocouples
Master Switch:
BAT
and temperature transmitters as per OSM-4.
FLASHING
Power On Light:
(2)Place a man in the machinery house to monitor
Brake Switch:
ENABLE
Power Loss Hoist Lower Button:
PRESS and HOLDthe brakes and notify the operator to stop if
brakes begin overheating.
Hoist Joystick:
LOWER
For use (AUX HOIST ONLY) when a load is on the deck of a vessel that
is pitching up and down due to wave motion.
NORMAL
OFF
ON
ON
AUX
ENABLE
ON
ON
POWER
LOSS
OFF
BAT
FLASHING
AUX
ENABLE
BAT
ON
OPERATION
For use if the hook becomes entangled in a vessel
that is moving away from the crane.
POWER
NORMAL
LOSS
Master Switch:
Power On Light:
Emergency Hoist Release Switch:
Emergency Hoist Release Light:
ON
ON
ON
ON
BAT
FLASHING
ON
ON
KG KIPS
45359.7 100
40823.7 90
36287.7 80
120VAC
31751.7 70
22679.8 50
27215.8 60
18143.8 40
13607.9 30
9071.9 20
4535.9 10
0
REACH FEET
REACH CM
20
30
40
50
60
70
80
90
100
110
103108
762.0 914.4 1219.2 1524.0 1828.8 2133.6 2438.4 2743.2 3048.0 3352.8
10
MAIN HOIST (4)(2)(1)
LINE LIFT
MIN REACH 22.0 FT
MAX SWL 98,400 LBS.
BOOM
ANGLE
REACH
FEET
SWL (LBS.)
4 PART LINE
SWL (LBS.)
2 PART LINE
SWL (LBS.)
1 PART LINE
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
ELECTRICAL EQUIPMENT
AUTHORIZED PERSONNEL
ONLY
11
EQUIPMENT
OPERATED BY
REMOTE CONTROL
TA97366
COPYRIGHT 2002
LeTourneau, Inc.
21
PUBLICATION OSM2
!
API SPEC 2C
12
DATE MANUFACTURED
18
MANUFACTURERS MODEL NO.
DESIGN SERVICE TEMPERATURE
DEG.C.
ADDRESS
HAZARDOUS VOLTAGE
Can shock, burn, or cause death.
Turn power off before servicing motor.
13
LeTourneau, Inc.
HAZARDOUS VOLTAGE
P/N 4149157
19
BRAKE DISC ON
ELECTRIC MOTORS
MAY BE HOT. BRAKE
DISC WILL ROTATE IF
MOTOR IS ENGAGED
14
20
600 VOLTS
LeTourneau, Inc P/N 4234939
21
15
THIS EQUIPMENT IS
SUPPLIED BY MORE THAN
ONE POWER SOURCE
CRANE SN PC1
SWL 7.43 T 6.7
SWL 49.20 T 80.3
MANUFACTURED BY:
LeTourneau, Inc.
DATE
PC 120 SN
SWL
REACH
TONS
FEET
49.20
22
7.43
103
BOOM
ANGLE
80.3
6.7
22
LOW
HEADROOM
16
LeTourneau, Inc.
P/N 4237045
23
!
17
!
LADDERS:
FALLING HAZARD
Can cause serious
injury or death.
WATCH YOUR STEP.
WATCH FOR WIND
GUSTS.
P/N 4217858
22
TA97376
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM2
CRITICAL COMPONENTS
The following is a list of components of the crane which
should be considered as critical components." These
components are ones which affect the safety of the
crane from a structural and load hoisting standpoint.
These components should be of prime concern to the
deck operators supervisor, operator and maintenance
personnel with regards to certification, inspection,
maintenance and prompt repair per the appropriate
guidelines. Instructions for the maintenance and repair
of these components are included in the OPERATING
AND SERVICE MANUAL and the REPAIR AND OVER
HAUL MANUAL for the crane.
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
13
PUBLICATION OSM2
FORM H"
LOAD DIAGRAM
SEE CERTIFICATE NO. _____________________________ FOR THE APPROVED CONDITIONS FROM
THE ATTACHED LOAD CHART, WHICH HAVE BEEN SURVEYED AND TESTED AS A UNIT AFTER
INSTALLATION ONBOARD THE _____________________________.
AUX. HOIST SB
1 INCH WIRE ROPE
57.5 TONS BREAKING STR.
DYFORM 18 HSLR
ROTATION RESISTANT
SINGLE SHEAVE
BRIDLE PENDANTS
13/4 INCH WIRE ROPE
6 X 26 IWRC EIPS
168 TONS BREAKING STR.
TWO
SHEAVES
LUFFING
1 INCH WIRE ROPE
62.5 TONS BREAKING STR.
CONSTRUCTEX
THREE
SHEAVES
T.B., SWL
SINGLE
SHEAVE
R
D.B.
S.W.L.
TWO
SHEAVES
THREE
SHEAVES
HOOK LOAD
20,000 LB
UNDER HOOK
SINGLE
SHEAVE
SINGLE
SHEAVE
Lw
HOOK LOAD
98,400 LB.
UNDER HOOK
MAIN HOIST DB, 1 INCH WIRE ROPE
70.03 B.S., DYFORM 34 LR, GR 2160
ROTATION RESISTANT
Lw
Lw
(1)
(2)
(3)
(4)
COPYRIGHT 2001
LeTourneau, Inc.
Insert1
Insert -2
PUBLICATION OSM-2
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM2
COPYRIGHT 2001
LeTourneau, Inc.
Insert3
PUBLICATION OSM2
COPYRIGHT 2001
Insert4
LeTourneau, Inc.
PUBLICATION OSM2
DEAD END
3
1 WIRE ROPE (9 x 40 CONSTRUCTEX)
460 LONG, 62.5 TONS B.S.
1
PCM120SS CRANE
BOOM UP CABLE REEVING SCHEMATIC
TA8928CG
COPYRIGHT 2001
LeTourneau, Inc.
Insert5
PUBLICATION OSM2
10 TON HOOK
1CG2465, P1030
TA8927CG
COPYRIGHT 2001
Insert6
LeTourneau, Inc.
WORKING
RADIUS
(FT.)
BOOM
ANGLE
(DEG.)
22.0
PERSONNEL
SAFE WORKING LOAD IN KIPS
4PART LINE
DYNAMIC
2.00
2PART LINE
STATIC
1.33
2PART LINE
DYNAMIC
2.00
1PART LINE
STATIC
1.33
1PART LINE
DYNAMIC
2.00
4PART LINE
2PART LINE
1PART LINE
80.3
98.40a
65.06h
48.40a
48.40a
23.40a
23.40a
32.32f
23.60a
11.00a
25.0
78.5
94.24f
62.29f
48.40a
48.40a
23.40a
23.40a
30.34f
23.60a
11.00a
30.0
75.6
79.10g
52.20g
48.40a
48.40a
23.40a
23.40a
25.30g
23.60a
11.00a
35.0
72.6
67.46g
44.44g
48.40a
48.40a
23.40a
23.40a
21.42g
23.41g
11.00a
69.5
58.95g
38.77g
48.40a
41.72g
23.40a
23.40a
18.58g
20.06g
11.00a
45.0
66.4
52.38g
34.39g
48.40a
36.66g
23.40a
23.40a
16.39g
17.53g
11.00a
50.0
63.2
47.08g
30.85g
48.40a
32.49c
23.40a
23.40a
14.63g
15.45c
11.00a
55.0
59.9
42.67g
27.91g
44.36c
29.04c
23.40a
23.40a
13.16g
13.72c
11.00a
60.0
56.5
38.88g
25.39g
40.05c
26.16c
23.40a
23.40a
11.89g
12.28c
11.00a
53.0
35.56g
23.19g
36.39c
23.73c
23.40a
23.40a
10.79g
11.06c
11.00a
70.0
49.2
32.58g
21.19g
33.26c
21.64c
23.40a
21.64c
9.79g
10.02c
11.02c
75.0
45.3
29.85g
19.36g
30.54c
19.83c
23.40a
19.83c
8.88g
9.11c
9.11c
80.0
41.0
27.29g
17.66g
28.13g
18.22g
23.40a
18.24c
8.03g
8.31g
8.32c
24.84g
16.02g
25.53g
16.49g
23.40a
16.85c
7.21g
7.44g
7.62c
31.0
22.41g
14.41g
22.97g
14.78g
23.40a
15.57g
6.40g
6.59g
6.99g
95.0
24.7
19.89g
12.73g
20.32g
13.01g
21.24g
13.62g
5.56g
5.71g
6.01g
100.0
16.1
16.94g
10.76g
17.25g
10.96g
17.89g
11.39g
4.58g
4.68g
4.90g
103.0
6.7
14.07d
8.90g
14.27d
9.04g
14.69d
9.32g
3.65g
3.72g
3.86g
40.0
COPYRIGHT 2001
LeTourneau, Inc.
65.0
85.0
90.0
36.3
NOTES
D
D
D
D
Insert7
4PART LINE
STATIC
1.33
PUBLICATION OSM2
LeTOURNEAU PCM120SS
MAIN HOIST CAPACITY CHART-100 FT. BOOM
WORKING
RADIUS
(FT.)
BOOM
ANGLE
(DEG.)
25.0
PERSONNEL
SAFE WORKING LOAD IN KIPS
4PART LINE
DYNAMIC
2.00
2PART LINE
STATIC
1.33
2PART LINE
DYNAMIC
2.00
SINGLE LINE
STATIC
1.33
SINGLE LINE
DYNAMIC
2.00
4PART LINE
2PART LINE
SINGLE LINE
80.4
98.40a
57.13
48.40a
48.40
23.40a
23.40
32.30f
23.40e
11.00e
30.0
78.0
84.40c
46.42
48.40a
48.40
23.40a
23.40
29.40f
23.40e
11.00e
35.0
75.6
70.15c
39.25
48.40a
42.74
23.40a
23.40
27.09f
23.40e
11.00e
73.1
59.45c
34.06
48.40a
36.65
23.40a
23.40
25.19f
23.40e
11.00e
45.0
70.5
51.14c
30.1
48.40a
32.09
23.40a
23.40
23.58f
22.24f
11.00e
50.0
68.0
44.48c
26.95
44.48c
28.53
23.40a
23.40
22.20f
20.97f
11.00e
65.4
39.03c
24.36
39.03c
25.65
23.40a
23.40
20.99f
19.85f
11.00e
60.0
62.7
34.49c
22.18
34.49c
23.24
23.40a
23.40
19.91f
18.86f
11.00e
65.0
59.9
30.65c
20.29
30.65c
21.19
23.40a
23.00
18.94f
17.95f
11.00e
57.1
27.36c
18.64
27.36c
19.39
23.40a
20.91
18.04f
17.13f
11.00e
75.0
54.2
24.50c
17.16
24.50c
17.80
23.40a
19.10
17.22f
16.35f
11.00e
80.0
51.2
22.00c
15.81
22.00c
16.36
22.00c
17.52
16.44f
15.63f
11.00e
85.0
48.0
19.80c
14.57
19.80c
15.04
19.80c
16.05
15.69f
14.93f
11.00e
90.0
44.7
17.83c
13.41
17.83c
13.81
17.83c
14.67
14.97f
14.26f
11.00e
95.0
41.1
16.08c
12.31
16.08c
12.64
16.08c
13.37
14.26f
13.59f
11.00e
100.0
37.2
14.49c
11.24
14.49c
11.52
14.49c
12.13
13.55f
12.93f
11.00e
105.0
33.0
13.06c
10.19
13.06c
10.42
13.06c
10.93
12.83f
12.24f
11.00e
110.0
28.2
11.75c
9.11
11.75c
9.30
11.75c
9.71
11.75c
11.51f
10.55f
115.0
22.5
10.56c
7.96
10.56c
8.11
10.56c
8.43
10.56c
10.56c
9.80f
120.0
14.7
9.46c
6.58
9.46c
6.69
9.46c
6.91
9.46c
9.46c
8.84f
6.1
8.33d
5.23
8.33d
5.30
8.33d
5.45
8.33g
8.33g
7.80f
40.0
LeTourneau, Inc.
55.0
COPYRIGHT 2001
70.0
123.0
NOTES
D
D
D
D
Insert9
D
D
D
D
D
D
D
D
D
4PART LINE
STATIC
1.33
PUBLICATION OSM2
LeTOURNEAU PCM120SS
MAIN HOIST CAPACITY CHART-120 FT. BOOM
PUBLICATION OSM2
LeTOURNEAU, INC.
PCM 120SS CRANE W/120' BOOM
AUXILIARY HOIST SYSTEM
DYNAMIC, STATIC AND PERSONNEL
LOAD RATING CHART, SINGLE LINE LIFT
API Spec 2C, Fifth Edition (1995)
WORKING
RADIUS (FT.)
BOOM
ANGLE (DEG.)
STATIC LIFT
SWL (KIPS) 1.33
DYNAMIC SWL
(KIPS) 2.00
PERSONNEL
LIFT
SWL (KIPS)
30.0
79.9
20.00a
13.33
9.80e
35.0
77.5
20.00a
13.33
9.80e
40.0
75.2
20.00a
13.33
9.80e
45.0
72.8
20.00a
13.33
9.80e
50.0
70.3
20.00a
13.33
9.80e
55.0
67.8
20.00a
13.33
9.80e
60.0
65.3
20.00a
13.33
9.80e
65.0
62.7
20.00a
13.33
9.80e
70.0
60.1
20.00a
13.33
9.80e
75.0
57.4
20.00a
13.33
9.80e
80.0
54.5
20.00a
13.33
9.80e
85.0
51.6
20.00a
13.33
9.80e
90.0
48.5
19.28c
13.33
9.80e
95.0
45.3
17.49c
13.33
9.80e
100.0
41.8
15.87c
13.33
9.80e
105.0
38.1
14.41c
13.23
9.80e
110.0
34.1
13.08c
12.15
9.80e
115.0
29.5
11.85c
10.96
9.80e
120.0
24.0
10.72c
9.70
9.80e
125.0
16.7
9.66c
8.23
9.63f
128.0
9.6
9.04c
6.93
8.81f
NOTES
D This load chart meets API Spec. 2L, Fifth Edition (1995). Safe Working Load (SWL) = Load which may be
carried below the hook. API Static Rated Load = SWL plus 500 lb. overhaul ball.
D Ratings followed by a" are limited by the auxiliary hoist line limit.
D Ratings followed by c" are limited by the foundation limit.
D Ratings followed by e" are limited by the auxiliary hoist line limit.
D Ratings followed by f" are limited by the boom limit.
D Main Hoist Line - 1" dia. Bridon Dyform 34 LR, GR 2160, rotation
resistant. B.S. = 70.03 tons.
D Aux. Hoist Line - 1" dia. Bridon Dyform 18 HSLR rotation resistant. B.S. = 57.5 tons.
D Bridle Line - 13/4" dia., 6 x 26 Class, IWRC, EEIPS, B.S. = 168 tons.
D BoomUp Line - 1" dia., Bridon CONSTRUCTEX = 62.5 tons
COPYRIGHT 2001
Insert10
LeTourneau, Inc.
PUBLICATION OSM2
CRITICAL COMPONENTS
The following is a list of components of the crane which
should be considered as critical components." These
components are ones which affect the safety of the
crane from a structural and load hoisting standpoint.
These components should be of prime concern to the
deck operators supervisor, operator and maintenance
personnel with regards to certification, inspection,
maintenance and prompt repair per the appropriate
guidelines. Instructions for the maintenance and repair
of these components are included in the OPERATING
AND SERVICE MANUAL and the REPAIR AND OVER
HAUL MANUAL for the crane.
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
13
14
ON
SS8
BLK
WARNING
BLK
PB3
HORN
BLK
PB9
ACKNOWLEDGE
LEFT
SWING
LT9
POWER ON
BAT
SS1
BLK
OFF
1CG2458, P0222
LeTourneau, Inc.
COPYRIGHT 2002
MASTER
RIGHT
LT3
GREEN
ON
DRIVE SYSTEM
FAIL
RUN
RED
LT4
SWING BRAKE
ENGAGE
LT8
WARNING
BOOM LOWER
LIMIT OVERRIDE
POWER LOSS
HOIST LOWER
SPEED/TEMP
RED
PB8
RED
LT3
AMB
RED
LIGHTS
OFF
LT1
SET
SS3
BRAKE
LT34
RED
LT23
SS2
LT7
AUX
BOOM
SLACK WIRE
ROPE
LT5
LIMIT
SWITCHES
HOIST SELECT
MAIN
RAISE
LOWER
LT24
AMB
LT6
AMB
HOIST BRAKE
HYD. PRESS.
GREEN
AUX
EMERGENCY
HOOK RELEASE
ENABLE
RED
RUN
HOIST
GREEN
MAIN
SS7
ON
RED ONCONSTANT
TENSION
OFF
SS6
OFF
BAT
RUN
EMERGENCY
STOP
PB2
RED
LT2
GREEN
TA95806
11
10
WALL M
WALL G
12
13
14
PUBLICATION OSM2
TA97346
COPYRIGHT 2002
LeTourneau, Inc.
15
14
15
14
16
18
WALL B
19
17
18
19
PUBLICATION OSM2
18
16
TA95816
COPYRIGHT 2002
LeTourneau, Inc.
10
14
18
20
21
22
46
10
46
22
23
TA98696
COPYRIGHT 2002
LeTourneau, Inc.
17
23
23
23
23
TA98706
COPYRIGHT 2002
LeTourneau, Inc.
19
PUBLICATION OSM2
WARNING
For use during crane power loss situations to lower load at a constant speed.
Emergency Hoist Release Switch: OFF
Before activating :
Constant Tension Switch:
OFF
(1) Inspect Power Loss Lowering Card, thermocouples
Master Switch:
BAT
and temperature transmitters as per OSM-4.
FLASHING
Power On Light:
(2)Place a man in the machinery house to monitor
Brake Switch:
ENABLE
Power Loss Hoist Lower Button:
PRESS and HOLDthe brakes and notify the operator to stop if
brakes begin overheating.
Hoist Joystick:
LOWER
POWER
LOSS
For use (AUX HOIST ONLY) when a load is on the deck of a vessel that
is pitching up and down due to wave motion.
NORMAL
OFF
ON
ON
AUX
ENABLE
ON
ON
OFF
BAT
FLASHING
AUX
ENABLE
BAT
ON
OPERATION
For use if the hook becomes entangled in a vessel
that is moving away from the crane.
POWER
NORMAL
LOSS
Master Switch:
Power On Light:
Emergency Hoist Release Switch:
Emergency Hoist Release Light:
ON
ON
ON
ON
BAT
FLASHING
ON
ON
8
4
KG KIPS
68039.5 150
63503.5 140
58967.6 130
120VAC
54431.6 120
CAPACITY
49895.6 110
45823.7 100
40823.7
90
36287.7
80
31751.7
70
27215.8
60
22679.8
50
18143.8
40
13607.9
30
9071.9
20
VENDOR:
4535.9
10
VENDOR:
VENDOR:
FEET 30 35 40
CM
50
60
70
80
90
100
110
120
130135
914.4 1219.2 1524.0 1828.8 2133.6 2438.4 2743.2 3048.0 3352.8 3657.6 3962.4
4114.8
REACH
10
5
LETOURNEAU PCM350 CRANE
WITH 123.5 FT. BOOM
BOOM
ANGLE
REACH
FEET
SWL (LBS.)
6 PART LINE
SWL (LBS.)
4 PART LINE
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
___
____
_____
_____
_____
1CG24631, P02221
ELECTRICAL EQUIPMENT
AUTHORIZED PERSONNEL
ONLY
SWL (LBS.)
2 PART LINE
11
EQUIPMENT
OPERATED BY
REMOTE CONTROL
LeTourneau, Inc.
TA98686
21
PUBLICATION OSM2
!
12
API SPEC 2C
FIFTH EDITION 1995
DATE MANUFACTURED
18
MANUFACTURERS MODEL NO.
DESIGN SERVICE TEMPERATURE
DEG.C.
ADDRESS
HAZARDOUS VOLTAGE
Can shock, burn, or cause death.
Turn power off before servicing motor.
13
LeTourneau, Inc.
HAZARDOUS VOLTAGE
P/N 4149157
19
BRAKE DISC ON
ELECTRIC MOTORS
MAY BE HOT. BRAKE
DISC WILL ROTATE IF
MOTOR IS ENGAGED
14
20
600 VOLTS
LeTourneau, Inc P/N 4234939
21
15
THIS EQUIPMENT IS
SUPPLIED BY MORE THAN
ONE POWER SOURCE
CRANE SN PC3
SWL 17.95 T 0.0
SWL 73.40 T 79.5
MANUFACTURED BY:
LeTourneau, Inc.
DATE
PC 350 SN
SWL
REACH
TONS
FEET
73.40
30
17.95
129
BOOM
ANGLE
79.5
0.0
22
LOW
HEADROOM
16
LeTourneau, Inc.
P/N 4237045
23
!
17
!
LADDERS:
FALLING HAZARD
Can cause serious
injury or death.
WATCH YOUR STEP.
WATCH FOR WIND
GUSTS.
P/N 4217858
22
TA98676
COPYRIGHT 2002
LeTourneau, Inc.