TECHNICAL BULLETIN

November 19, 1997

Subject: Cold Weather Operation Safety

To: All Weldco Hydra-Lift Crane Owners

Weldco Hydra-Lift Crane recommends that each crane owner advises each crane operator that all
capacity charted maximum crane ratings must be reduced by at least 1% for each degree Celsius
below zero outdoor temperature. For example, do not exceed 75% of any charted capacity when
operating cranes during -25°C outdoor weather. No attempt should be made to operate any Weldco
Hydra-Lift Crane at temperatures less that -35°C.

Components of cranes, such as the SAE100R series hoses do not have test requirements for
temperatures less than -35°C. All components of the crane, outriggers, etc., connected by such
hydraulic hoses are affected and apply to the caution stated. When conditions demand that a crane
must be operated during weather conditions between 0°C and -35°C, all operators are warned to be
extremely cautious and careful to avoid any sudden movements and to operate controls at very slow
speeds.

Copies of this bulletin should be given to each operator and permanent copies of the bulletin should
be attached to the manual for your crane and kept with the crane at all times.

9
TECHNICAL BULLETIN
January 24, 2001

Subject: Emergency Procedures - Operational Aids

To: All Weldco Hydra-Lift Crane Owners

When operational aids are inoperative or malfunctioning, the following requirements shall apply for
continued use or shutdown of the crane.

1. Steps shall be take to schedule repairs and recalibration immediately. The operational aids shall
be put back into service as soon as replacement parts, if required, are available and the repairs
and recalibration can be carried out. Every reasonable effort must be made to expedite the repairs
and recalibration.

2. When a Load Indicator

Indicator, Rated Capacity Indicator
Indicator, or Rated Capacity Limiter is inoperative or
malfunctioning, the designated person responsible for supervising the lifting operations shall
establish procedures for determining load weights and shall ascertain that the weight of the load
does not exceed the crane ratings at the radius where the load is to be handled.

3. When a Boom Angle or Radius Indicator is inoperative or malfunctioning, the radius or boom
angle shall be determined by measurement.

4. When an Anti-two-block Device

Device, Two-blocking Damage Prevention or Two-block Warning Device
is inoperative or malfunctioning, the designated person responsible for supervising the lifting
operations shall establish procedures, such as assigning an additional signal person, to furnish
equivlaent protection. This does not apply when lifting personnel in load line supported baskets.
Personnel shall not be lifted in load line supported baskets when anti-two-block devices are not
functioning properly.

5. When a Boom Length Indicator is inoperative or malfunctioning, the designated person

responsible for supervising the lifting operations shall esteblish the boom length at which the lift
will be made by actual measurement or marking on the boom.

6. When a Level Indicator is inoperative or malfunctioning, other means shall be used to level the
crane.

10
IMPORTANT NOTICE
BOOM LIGHTS WIRING
For convenience, your new Weldco Hydra-Lift® Crane is prewired for Boom Lights.
A 2 wire conductor (White 14ga. and Black 14ga.) complete with disconnect for future
serviceability is supplied and is ready for connection to the boom lights at the turret.
Refer to illustration below for circuit information. Continuous Rotation Crane shown.

Warning: System is protected by a 30 A breaker, lights cannot exceed

360 Watts total.

11
IMPORTANT NOTICE
BOOM LIGHTS WIRING
For convenience, your new Weldco Hydra-Lift® Crane is prewired for Boom Lights.
A 2 wire conductor (White 14ga. and Black 14ga.) complete with disconnect for future
serviceability is supplied and is ready for connection to the boom lights at the turret.
Refer to illustration below for circuit information. Non- Continuous Rotation Crane shown.

Warning: System is protected by a 30 A breaker, lights cannot exceed

360 Watts total.

12
IMPORTANT NOTICE
FREE FLOW INSTALLATION
Your new Weldco Hydra-Lift® Crane is pre-plumbed for free flow directly to tank to
prevent premature winch motor seal leakage. If you are installing your new Weldco
Hydra-Lift® Crane, you "MUST" provide free flow directly to tank. It is labelled on all
hydraulic schematics. It is plumbed from port# 40/102 on the bottom of the hydraulic
swivel directly to tank. See below.

Warning: Failure to provide a free flow to tank, will result in premature

winch motor seal leakage and/or hydraulic swivel seal leakage and/or
improper shifting of the 2 sp. winch and/or malfunction of the optional
"Hydra-Limit" capacity alert system.

ITEM PART # DESCRIPTION QTY

1 Adapter 90° 1
2 503-43-6506 Adapter Tee - #8-ORB x #8-JICM 1
3 506-43-4003 Adapter Reducer - #8-JICF x #6-JICM 1
4 Hose Assembly - #8 (length to suit) 1

13
WEDGE SOCKET INSTALLATION INSTRUCTIONS
Read and understand these instructions before installing the Wedge Socket.

WARNING
- Loads may slip or fall if the Wedge Socket is not properly installed and maintained.
- A falling load can seriously injure or kill.

ASSEMBLY
DEAD END LIVE END LIVE END DEAD END LIVE END
CLAMP SECTION
OF SAME
DIAMETER WIRE
ROPE TO DEAD
END
TAIL LENGTH
POSITION
CLIP TO
*STANDARD WIRE ROPE PREVENT
6 ROPE DIAMETERS (6" MINUMUM) WEDGE FROM
LOOSENING
IN SOCKET
**ROTATION RESISTANT WIRE ROPE
20 ROPE DIAMETERS (6" MINIMUM)
WEDGE
WEDGE
SOCKET

USE HAMMER TO SEAT WIRE ROPE INSTALLED BACKWARDS DEAD END CLIPPED
WEDGE AND ROPE AS ALIGN LIVE END
(ENTERING WRONG SIDE) TO LIVE END
DEEPLY AS POSSIBLE IN OF ROPE WITH
WEDGE SOCKET BEFORE EYE OF SOCKET
APPLYING FIRST LOAD
INCORRECT ASSEMBLY
IF WIRE ROPE IS INSTALLED BACKWARDS OR DEAD
END IS CLIPPED TO LIVE END A KINK WILL DEVELOP AND
CORRECT ASSEMBLY ROPE STRENGTH WILL BE REDUCED.

* Standard Wire Rope

Use only with standard 6 to 8 strand wire rope of designated size. Welding of the tail on standard rope is not
recommended.
** Rotation Resistant Wire Rope
Ensure that the dead end is welded, brazed or seized before inserting the wire rope into the wedge socket to
prevent core slippage or loss of rope lay.

OPERATING SAFETY
-Apply first load to fully seat the Wedge and Wire Rope in the socket. This load should be of equal or geater
weight than loads expected in use.
-Efficiency rating of the Wedge Socket termination is based upon the breaking strength of Wire Rope. The
efficiency of a properly assembled Wedge Socket is 80%.
- During use, do not strike the dead end section with any other elements of the rigging (Two-Blocking).
- Do not side load Wedge Socket.

INSPECTION/MAINTENANCE
- Always inspect socket, wedge and pin before using.
-Do not use parts showing cracks.
- Do not use modified or substitute parts.
-Repair minor nicks and gouges to socket or pin by lightly grinding until surfaces are smooth. (Do not
reduce original dimension more than 10%).
- Do not repair by welding.
- Inspect permanent assemblies annually, or more often in severe operating conditions.

14
Hydraulic Function Chart

HYDRAULIC FUNCTION SYMBOL # Appears on illustrations and hydraulic schematics to show Plumbing Functions.

3. MAIN BOOM - LOWER 63. TOOLS - RETURN

4. MAIN BOOM - RAISE 68. CURBSIDE HORIZONTAL OUTRIGGER - RETRACT
5. SWING - LEFT/CCW 69. CURBSIDE HORIZONTAL OUTRIGGER - EXTEND
6. SWING - RIGHT/CW 70. STREETSIDE HORIZONTAL OUTRIGGER - RETRACT
7. BOOM - RETRACT 71. STREETSIDE HORIZONTAL OUTRIGGER - EXTEND
8. BOOM - EXTEND 72. AUX. CURBSIDE HORIZONTAL OUTRIGGER - RETRACT
17 . WINCH - UP 73. AUX. CURBSIDE HORIZONTAL OUTRIGGER - EXTEND
18. WINCH - DOWN 74. AUX. STREETSIDE HORIZONTAL OUTRIGGER - RETRACT
21 . CURBSIDE OUTRIGGER - UP 75. AUX. STREETSIDE HORIZONTAL OUTRIGGER - EXTEND
22 . CURBSIDE OUTRIGGER - DOWN 76. MEDIUM WINCH - UP
23 . AUX. STREETSIDE OUTRIGGER - UP 77. MEDIUM WINCH - DOWN
24. AUX. STREETSIDE OUTRIGGER - DOWN 78. HIGH WINCH - UP
25 . AUX. CURBSIDE OUTRIGGER - UP 79. HIGH WINCH - DOWN
26 . AUX. CURBSIDE OUTRIGGER - DOWN 80. AUX. WINCH - UP
28. MOTION CONTROL VALVE DRAIN 81. AUX. WINCH - DOWN.
30 . STREETSIDE OUTRIGGER - UP 82. PRESSURE GAUGE - DIGGER
31. STREETSIDE OUTRIGGER - DOWN 83. PRESSURE GAUGE - BOOM FUNCTIONS
34 . ACCELERATOR 84. AUX. PRESSURE GAUGE
35 . PRESSURE (14 GPM) 85. WINCH HIGH/LOW SHIFT
36. TOPPING CYLINDER HOLDING VALVE FUSE LINE 86. ANTI-TWO BLOCK DUMP SIGNAL
37. FREE FLOW RETURN 87. PRESSURE (18 GPM)
40. WINCH MOTOR DRAIN LINE 102. HYDRA BLOCK “T” LINE / FREE FLOW TO TANK FROM
41 . PRESSURE (25 GPM) SENSING VALVE
42 . RETURN 103. HYDRA LIMIT “V” LINE / PRESSURE SENSING LINE
43 . PRESSURE (40 GPM) 104. HYDRA LIMIT “V’ LINE / RETURN TO TANK FROM
62. TOOLS - PRESSURE BLOCKING VALVE
106. PUMP SUCTION
15
16
General
Information

WARNING: Do not attempt to operate this equipment until you have:

(1) Studied and thoroughly understand this manual;
(2) Received personal instructions in its operation.
General
Information
The Weldco Hydra-Lift Series Cranes are designed for use where a versatile, mobile, truck-mounted
crane is needed. Normal mounting is directly behind the chassis cab. An operators control station is
located on either side of the truck frame (curb & street sides).

General Specification & Dimensions

HL 8TC HL 10TC HL 12TC
No. of Model Designations HL 8TC58 (STD) HL 10TC58 HL 12TC58
HL 8TC64 HL 10TC64 (STD) HL 12TC64
HL 8TC70 HL 10TC70 HL 12TC70 (STD)
Frame Mounting Space Req'd 45.4" 45.4" 45.4"
Number of Booms Three Three Three
all hydraulic
DIMENSIONS (based on
40" frame height), **Note: With
No Frame Spacer 6-5/8" subframe
*Overall road travel height 11.2' 11.2' **11.8'
*Maximum sheave height HL 8TC58 HL 10TC64 **HL 12TC70
Measured from Ground to 58.6' 65.6' 72.1'
Top of Sheave
*Boom vertical travel 95° (-15, + 80) 95° (-15, +80) 95° (-15, + 80)
*Retracted Boom Length HL 8TC58 HL 10TC64 HL 12TC70
Pivot Pin to Tip 21.5' 23.5' 25.5'
*Horizontal - Extendable HL 8TC58 HL 10TC64 HL 12TC70
Boom Reach - (Exc. jibs) 49.0' 55.0' 61.0'
Load Radius

HL 15/18TC70 HL 25/30/40TC70 HL 25/30/40TC100

Frame Mounting Space Req'd 42.8" 44.0" 44.0"
Number of Booms Three Three Four
all hydraulic
DIMENSIONS (based on
40" frame height),
6-5/8" Subframe
*Overall road travel height 12.1' 12.6' 12.6'
*Maximum sheave height 59' 59' 90'
Measured from Ground to
Top of Sheave
*Boom vertical travel 90° (-10, + 80) 90° (-10, +80) 90° (-10, + 80)
*Retracted Boom Length 25' 25' 28'
Pivot Pin to Tip
*Horizontal - Extendable 59' 59' 90'
Boom Reach - (Exc. jibs)
Load Radius
General Information - 1
General
Information
General Specification & Dimensions
HL 8TC HL 10TC HL 12TC HL 15TC

Maximum Lifting Capacity 8 Ton 10 Ton 12 Ton 15 Ton

in Tons (lbs) (16,000) (20,000) (24,000) (30,000)

Outrigger Spread
• Main 217.6" 217.6" 217.6" 220.8"
• Auxiliary (O-Opt./S-Std.) O - 120.4" O - 120.4" S - 120.4" S - 120.4"
• Out/Down (O-Opt./S-Std.) O - 196.3" O - 196.3" O - 196.3" O - 196.3"

Hydraulic System Data

• System Pressure 2950 PSI 2950 PSI 2950 PSI 2950 PSI

Relief Settings
• Winch 2500 PSI 2500 PSI 2500 PSI 2500 PSI
• Topping 1850 PSI 2150 PSI 2650 PSI 2800 PSI
• Swing 2000 PSI 2000 PSI 2000 PSI 2000 PSI

Reservoir Capacity 70 Gal. 70 Gal. 70 Gal. 70 Gal.

Pump-Triple Gear-
• Flow (Pump) at 1800 RPM 14/18/25 14/18/25 14/18/25 14/18/25

HL 18TC HL 25TC HL 30TC HL 40TC

Maximum Lifting Capacity 18 Ton 25 Ton 30 Ton 40 Ton

in Tons (lbs) (36,000) (50,000) (60,000) (80,000)

Outrigger Spread
• Main 226.8" 258.8" 258.8" 299" F/B
• Auxiliary (O-Opt./S-Std.) S - 120.4" S - 120.4" NA Included
• Out/Down (O-Opt./S-Std.) O - 196.3" O - 196.3" S - 196.3" in Subframe

Hydraulic System Data

• System Pressure 2950 PSI 2950 PSI 2950 PSI 2950 PSI

Relief Settings
• Winch 2500 PSI 2800 PSI 2800 PSI 2800 PSI
• Topping 2800 PSI 2850 PSI 2850 PSI 2850 PSI
• Swing 2000 PSI 2000 PSI 2000 PSI 2000 PSI

Reservoir Capacity 70 Gal. 70 Gal. 70 Gal. 70 Gal.

Pump-Triple Gear-
Flow (Pump) at 1800 RPM 14/18/25 14/18/25 14/18/25 14/18/25

General Information - 2
General
Information
Group Orientation HL TC Series

General Information - 3
General
Information
Placard Location
Placards have been affixed to your new Weldco Hydra-Lift Crane in a number of re-
quired locations. These placards have been placed on the equipment not only to
guide you in it's operation, but also to warn you against certain practices which are
considered to be hazardous to either personnel or to equipment. On the pages which
follow, are actual photographs of the placards as well as a chart which shows their
location. Placards must be maintained in readable condition at all times. Individual
part numbers are included on the bottom right hand corner of each placard, in addition
each placard on the following pages is identified by part number, and major placards
are also identified by part number in your parts catalogue. Fourthly: the Hydra-Lift
parts depot stocks all the general safety placards in kit quantities for each crane. DO
NOT OPERATE YOUR CRANE WITHOUT READABLE PLACARDS.

Below is an example of a typical Decal Installation Drawing (See Parts Manual for the
Decal Installation specific for your crane)

General Information - 4
General
Information
General Placards

702-00-2455

General Information - 5
General
Information
General Placards

702-00-0700 701-00-1065

702-00-6151

702-66-1781

General Information - 6
General
Information
General Placards

702-58-0426

701-66-2041

General Information - 7
General
Information
General Placards

702-66-2059

702-50-2981

701-66-2040

General Information - 8
General
Information
General Placards

701-66-2042

General Information - 9
General
Information
General Placards

701-66-2039

General Information - 10
General
Information
General Placards

702-58-3953

702-58-0425

General Information - 11
General
Information
General Placards

702-00-2611

702-58-0427

General Information - 12
General
Information
General Placards

701-66-2038

General Information - 13
General
Information
General Placards - HL 8TC58 Capacity Chart (Standard)

General Information - 14
General
Information
General Placards - HL10TC64 Capacity Chart (Standard)

General Information - 15
General
Information
General Placards - HL 10TC70 Capacity Chart (Optional)

General Information - 16
General
Information
General Placards - HL 12TC70 Capacity Chart (Standard)

General Information - 17
General
Information
General Placards - HL 15TC70 Capacity Chart

General Information - 18
General
Information
General Placards - HL 18TC70 Capacity Chart

General Information - 19
General
Information
General Placards - HL 18TC92 Capacity Chart

General Information - 20
General
Information
General Placards - HL 25TC70 Capacity Chart

General Information - 21
General
Information
General Placards - HL 25TC100 Capacity Chart

General Information - 22
General
Information
General Placards - HL 30TC70 Capacity Chart

General Information - 23
General
Information
General Placards - HL 30TC100 Capacity Chart

General Information - 24
General
Information
General Placards - HL 40TC70 Capacity Chart

General Information - 25
General
Information
General Placards - HL 40TC100 Capacity Chart
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General Information - 26
General
Information
Supplementary Capacity Information

The following explanations and definitions should help in underrstanding the capacity
limitations of your Hydra-Lift Crane. Refer to these explanations when in doubt of the
meaning of any technical term applying to unit stability.

Tipping Condition (balance point) - A machine is considered to be at the point of tip-

ping when a balance is reached between the overturning moment of the load and the
stabilizing moment of the machine when on a firm, level supporting surface. The
machine can, and often will be, deflected resulting in an angular change of the centerline
of rotation.

Tipping Load - The load producing a tipping condition at a specified radius. Weights of
hook, hook blocks, slings, etc. shall be considered part of the load.

Load Radius - The radius of the load (horizontal distance) from the axis of rotation
before loading to the center of hoist line with the load applied.

CL ROTATION
BEFORE LOADING

CL ROTATION BOOM
AFTER LOADING DEFLECTED

WRONG RADIUS

WRONG RADIUS

CORRECT LOAD RADIUS

FRAME DEFLECTED

TIRE COMPRESSED

General Information - 27
General
Information
Supplementary Capacity Information

Rated Load (if Based on Tipping) - A load at a specified radius and as a specified
percentage of tipping load.

Rated Load (If Based on Strength) - A load at a specified radius where tipping is not
a factor but the maximum allowable strength of some component is reached. This
component could be hydraulic pressure, tire capacity, material stress, etc.

Listed Rated Load - The lower of the two preceding Rated Loads. An asterisk indi-
cates that strength (not tipping) is the limiting factor.

Practical Working Load - Listed rated loads are based on ideal laboratory conditions
and do not take into account many conditions experienced in the field. Therefore,
depending upon the conditions encountered, the operator is expected to allow an ad-
ditional safety margin and make a reduction from the listed ratings.

Some of the conditions which may be encountered in the field-

1. A load at a radius well within capacity is lowered rapidly and then abruptly stopped.
Tires, frame and boom will deflect and the total deflection could increase the load
radius to a point where the unit might tip over.

2. A long boom is extended at a high elevation angle with a light but large load (such
as a sheet of steel). A gusty wind could swing the load into the boom and exert
sufficient force to tip the unit over.

3. A capacity load is picked up from a stable crane position (such as over the rear of
the truck). This load is now swung to a less stable position (such as over the side
of the truck). This- results in tire and spring compression and increased frame
deflection. These deflections will increase the load radius and, as a result, the
capacity will be exceeded. (In such instances it will be necessary to keep the
radius constant by raising the boom).

Working Range - The range (reach) as shown shall not be exceeded. Exceeding the
range can result crane damage or tipping. Under no circumstances extrapolate (guess)
where no capacities are shown.

General Information - 28
General
Information
Supplementary Capacity Information

Personnel Handling - This unit should never be used to handle personnel unless
equipped with a factory approved personnel bucket. Personnel should NEVER be
permitted to ride the boom or loadline.

Boom stages - The boom stages are defined as follows:

Baseboom or First Stage - The boom section pinned to the turret; the largest
section.

2nd Stage - The next larger section; the first boom to hydraulically extend out of
base boom.

3rd Stage - The boom which hydraulically extends out from the 2nd stage boom.

4th Stage - The boom which hydraulically extends out of the 3rd stage boom.

WARNING: A STATED BOOM CAPACITY IS VALID ONLY WHEN SPECIFIC BOOM

STAGES ARE EXTENDED! THE STATED CAPAClTY IS NOT VALID IF THE SPECI-
FIED BOOM LENGTH, OR LOADED BOOM RADIUS IS OBTAINED IN ANY OTHER
MANNER!

For example, capacities listed for a fully extended jib must never be exceeded. Re-
tracting the hydraulic boom does not permit you to increase the loads in the jib beyond
any of the rated jib capacities.

General Information - 29
Training &
Operation
Training & Operation

Safe operation of your unit depends on you, the operator, the mechanical condition of
your unit and the assurance that the unit is not being used to lift loads in excess of the
maximum rated capacity. The following pages contain numerous safety precautions
that must be observed while performing work operations. This section must be read
carefully before operating the unit.

Pay special attention and periodically review all capacity placards, caution, danger or
warning decals shown in this manual. If there is a discrepancy as to message place-
ment or condition of these placards or decals, please contact you Weldco Hydra-Lift
dealer or the factory. If any placard is defaced, illegible or does not exist on your
machine, promptly have a new one installed and call it to the attention of all persons
who may be operating, working with of working near the machine.

Training & Operation - 1

Training & Operation

Important in the prevention of accidents is a positive attitude toward safety. It takes

only a little effort to anticipate a problem that might occur and what you would do to
overcome the problem. The habit of anticipating possible accidents automatically pre-
vents many of them from occuring. But, if there is one, your reaction time is much
shorter. A positive attitude towards safety makes a safer work crew.

Some procedures are so simple they often are overlooked. On the following pages are
some that should be double-checked before and during operation of the unit at the job
site.

Training & Operation - 2

Training & Operation

Be sure the outriggers are extended and firmly set on solid ground every time the unit
is operated.

Be sure that all members of the crew stand clear of the outriggers as they are being
lowered. You or a signal person must have the outrigger in sight every time the outrig-
gers are operated.

Training & Operation - 3

Training & Operation

Always look in the direction the boom is travelling as you operate the machine. Have
a crew member watch any areas that are blind to the operator so that the operator can
be warned in sufficient time to avoid an accident.

Always set the hand brake when the truck has been positioned at the work site. Posi-
tion wheel chocks before beginning operations.

Training & Operation - 4

Training & Operation

Check the winch brake. Keep the winches adjusted to protect the load, yourself and
other workers.

Always keep the work space of the truck bed clean. Put away unused tools, pick up
and stow gear when you are through. Cluttered work space can cause accidents.

Training & Operation - 5

Training & Operation

If your unit is equipped with quick disconnect fittings, keep the fittings out of the dirt.
Dirty disconnects can cause costly damage to pumps, motors and power tools. Al-
ways clean the disconnects before using.

Check for loose objects on the booms as you begin to operate. Loose objects such as
rocks, limbs or a tool left by another workman may fall and cause an injury.

Training & Operation - 6

Training & Operation

Double-check the work site before leaving. See that all tools are put away, the wheel
chocks are stowed and that the outriggers are fully retracted.

Even if you are only moving a short distance, it takes only a few seconds to stow the
boom before moving off. Low bridges, tree limbs or low wires you didn't notice before
can cause broken booms or broken wires and personnel injury.

Training & Operation - 7

Training & Operation

Check the outrigger valves and cylinders often. Notice if outriggers begin to creep
down from the stowed position overnight. If so, get them repaired immediately. Your
safety depends upon good maintenance and care of the equipment.

Don't experiment with your equipment at the job site. Study the manual, get checked
out by a trained operator and get the feel of the controls in a clear area before begin-
ning any jobs.
Training & Operation - 8
Training & Operation

Avoid any sudden stops of boom rotation. Start and stop slowly by moving the control
handles slowly. Sudden rotation starts or stops can damage the crane.

Inspect the winch loadline daily. There are several ways that a loadline can be
weakened. A weakened loadline could fail at any time, causing injuries. If the loadline
becomes damaged, replace it immidiately.

Training & Operation - 9

Training & Operation

Report all hydraulic leaks immediately. Then, check to insure that proper maintenance
is performed.

Avoid making side pulls with the load line. Always point the boom at the load being
pulled. Side pulls can damage the boom and turret.

Training & Operation - 10

Training & Operation

Use large flat pads under the outriggers when the ground is soft.

Your truck can't work if it can't get to the job, so check the condition of your truck
engine daily.

Training & Operation - 11

Training & Operation

Don't drive the truck with the load suspended.

After changing the hydraulic oil, be sure that all air is evacuated from the hydraulic
system by making two or three cycles with the system before putting the unit back in
service. (See "Purging Hydraulic System")

Training & Operation - 12

Training & Operation

Operate the controls smoothly to avoid sudden stops. Sudden stops impose unneces-
sary stress loads on the equipment which can damage the equipment and shorten its
working life.

When using the winch make sure that the rated machine capacity for a specific boom
attitude is never exceeded. Check the weights of all downhaul weights, hook blocks,
etc. and deduct them from the rated machine capacity shown on the capacity placard.

Training & Operation - 13

Training & Operation

Don't risk the possiblity of getting electrocuted by working with the unit close to energized
power lines. You must maintain a clearance of at least 10 feet between any part of the
machine, the loadline, and any electrical line or apparatus carrying up to 50,000 volts.
An additional 0.4 inch clearance is required for every additional 1000 volts or less.
Remember ALL Overhead lines are considered energized unless the power company
de-energizes the lines and visibly grounds them at the work site.

Training & Operation - 14

Training & Operation
Additional Tips
• Do not allow personnel to ride on winch cable hook or suspended load.

• Do not move loads over people.

• Do not lift a load until all personnel are clear.

• Do not transport personnel on boom or jib except with equipment furnished by

Weldco Hydra-Lift.

• Do not allow hook or load block to pull tight against boom tip when lowering or
extending boom or when winding cable in.

• Loadline must be properly attached to the winch drum and at least three wraps
must remain on the drum at all times.

• Do not modify this machine or add attachments unless approved by Weldco Hydra-
Lift.

• Keep the load close to the ground whenever possible.

• Do not operate the crane during electrical storms or when high wind condition
exist.

• Do not perform any maintenance on the crane unless authorised to do so.

• Do not attempt service or repair while the crane is operating.

• Do not operate the crane with oily or greasy hands.

• Do not disconnect hydraulic operating components when there is pressure in

them.

• Whenever possible, maintain at least a ten foot safety area between the crane tip
and the nearest obstruction.

• Do not load or unload other trucks or trailers while the driver remains in his cab.

Training & Operation - 15

Training & Operation
Training
All members of the crew must become thoroughly familiar with the operation of con-
trols, the correct operating procedures, maximum lifting capacities and safety precau-
tions applicable to your unit before operating. Operator training is important. Always
be prepared for any emergency. Learn the emergency procedures in this section and
be prepared to execute them if necessary. The preceding section contains numerous
safety precautions that must be observed while performing work operation. This sec-
tion must be read carefully and thoroughly understood before operating. If you have
any questions, contract your Weldco Hydra-Lift dealer.

All members of the crew must thoroughly understand the manufacturer's recommen-
dations for initiating operation.

The health, safety and well being of each member of the crew is of primary impor-
tance. Consequently, each member has an obligation to himself, and to his fellow
workers, to make sure safe operating procedures are followed. ALL OPERATING
REGULATIONS RECOMMENDED BY THE MANUFACTURER, THE EMPLOYER
AND BY MUNICIPAL, STATE, PROVINCIAL, AND FEDERAL AGENCIES MUST BE
OBSERVED.

Training & Operation - 16

Training & Operation

Become familiar with all the equipment checks given in this section and in Section III.
You should make daily equipment inspections and be able to recognize any potential
problem before beginning an assigned task. There is a high degree of reliability built
into your equipment, but there is always a possibility of mechanical failure or power
failure due to incomplete servicing or abnormal wear. An operator should never take
another's word. He should always thoroughly check the equipment himself.

Training & Operation - 17

Training & Operation

Each member of the work crew must become thoroughly familiar with each of the
operations described in the Emergency Operations segment of this manual. It is
essential that every member know how to lower or rotate the boom in the event of
hydraulic failure. Although you may never use these procedures, they must be reviewed
by the entire crew at the machine to enable each individual to visually identify each
operation.

Training & Operation - 18

Training & Operation

Each crew member must receive thorough instructions on the care and maintenance
of the machine thus enabling him to identify and anticipate any problems that may
occur. Knowing how the equipment operates will enable you to recognize when repairs
or adjustments are required.

Training & Operation - 19

Training & Operation
Operating Controls
Cab Controls
Power Take-Off (PTO)
Manual Shift Control - The PTO is engaged when the knob is pulled out and disengaged when the knob
is pushed in. The truck gear shift lever must be in neutral and the clutch depressed whenever the knob
is moved.
Air Shift Control - The PTO is engaged when the switch is moved to apply air to PTO and disengaged
when switch is in off position. The truck gear shift lever must be in neutral and clutch depressed when
switch is moved.
Electric Shift Control - Full torque electric shift PTO's are controlled by a switch. To operate, disen-
gage the clutch, shift to fourth or fifth gear, and operate the switch down to engage the PTO or up to
disengage the PTO. Return the gear shift to neutral and engage the clutch.
If the vehicle is equiped with automatic transmission, the power take-off may be engaged by placing the
transmission selector lever in any friving position and then engaging the PTO. The transmission selec-
tor lever must be returned to "N" for stationary vehicle operation. The power take-off may be disengaged
while in any transmission range provided that the load has first been removed from the PTO.
CAUTION: Make sure that the PTO is disengaged before driving away!
If the vehicle is equipped with automatic transmission, the power take-off may be engaged by placing the
transmission selector lever in any driving position and then engaging the PTO. The transmission selec-
tor lever must be returned to ”N” for stationary vehicle operation. The power take-off may be disengaged
while in any transmission range provided that the load has first been removed from the PTO.
Parking Brake
The truck parking brake must be firmly set and the wheel chocks firmly placed before beginning crane
operations.
GENERAL SAFETY INFORMATION
To prevent injury to yourself and/or damage to the equipment:
• Read carefully all owners manuals, service manuals, and/or other instructions.
• Always follow proper procedures and use proper tools and safety equipment.
• Be sure to receive proper training.
• Never work alone while under a vehicle or while repairing or maintaining equipment.
• Always use proper components in applications for which they are approved.
• Be sure to assemble components properly.
• Never use worn-out or damaged components.
• Always block any raised or moving device that may injure a person working on or under a vehicle.
• Never operate the controls of the power take-off or other driven equipment from any position that could
result in getting caught in the moving machinery.
COLD WEATHER OPERATION OF POWER P.T.O.'S
WARNING: During extreme cold weather operation [32° F (0° C) and lower], a disengaged Power Shift
power take-off can momentarily transmit high torque that will cause unexpected output shaft rotation.
This is caused by the high viscosity of the transmission oil when it is extremely cold. As slippage occurs
between the power take-off clutch plates, the oil will rapidly heat up and the viscous drag will quickly
decrease.

Training & Operation - 20

Training & Operation
Operating Controls
Cab Controls
PTO Cold Weather Operation (continued)

The power take-off output shaft rotation could cause unexpected movement of the driven equipment
resulting in serious personal injury, death, or equipment damage.
To avoid personal injury or equipment damage:
• Driven equipment must have separate controls.
• The driven equipment must be left in the disengaged position when not in operation.
• Do not operate the driven equipment until the vehicle is allowed to warm up.
ROTATING AUXILIARY DRIVESHAFTS
WARNING:
• Rotating auxiliary drive shafts are dangerous. You can snag clothes, skin, hair, hands, etc. This can
cause serious injury or death.
• Do not go under the vehicle when the engine is running.
• Do not work on or near an exposed shaft when engine is running.
• Shut off engine before working on power take-off or driven equipment.
• Exposed rotating driveshafts must be guarded.
USING SET SCREWS
WARNING: Auxiliary driveshafts may be installed with either recessed or protruding set screws. If you
choose a square head set screw, you should be aware that it will protrude above the hub of the yoke and
may be a point where clothes, skin, hair, hands, etc. could be snagged. A socket head set screw, which
may not protrude above the hub of the yoke, does not permit the same amount of torquing as does a
square head set screw. Also, a square head set screw, if used with a lock wire, will prevent loosening of
the screw caused by vibration. Regardless of the choice made with respect to a set screw, an exposed
rotating auxiliary driveshaft must be guarded.
IMPORTANT: SAFETY INFORMATION AND OWNERS MANUAL
Chelsea power take-offs are packaged with safety information decals, instructions, and an owner's manual.
These items are located in the envelope with the P.T.O. mounting gaskets. Also, safety information and
installation instructions are packaged with some individual parts and kits. Be sure to read the owner’s
manual before Installing or operating the P.T.O. Always install the safety information decals according
to the instructions provided. Place the owners manual in the vehicle glove compartment.
ENGINE SPEED CONTROLS
Proper engine operating speed can be maintained by means of foot throttles located on each side of the
mainframe at the control stations. Maintenance the remote throttle equipment regularly to avoid sticking
and binding of the linkage mechanisms. The throttle is pneumatic connected to the truck's existing air
supply.

Training & Operation - 21

Training & Operation
Operating Controls
Unit Controls -HL 8/10/12/15/18/25/30 TC Series

The unit is equipped with control stations on each side of the main frame. Placards
adjacent to the control handles indicate the direction to move the controls for various
unit functions. Each station is complete and provides complete control of boom rotation,
boom elevation, hoist, outriggers, engine foot throttle and the engine "start-stop" switch.
All control handles are positioned in the same order at both control stations. A single
hydraulic system pressure check gauge is centrally mounted below a clear plastic
cover which serves to protect the electrical switches.

Training & Operation - 22

Training & Operation
Operating Controls
Controls Functions -HL 8/10/12/15/18/25/30 TC Series

SWING: Operate lever to RIGHT or clockwise to rotate booms clockwise; operate

lever to LEFT or counterclockwise to rotate booms counterclockwise.

BOOM: Operate lever to LOWER to lower booms; operate lever to RAISE to raise
booms.

BOOM EXTENSION: Operate lever to EXTEND to extend the booms; operate

lever to RETRACT to retract the booms.

OUTRIGGERS: Operate lever to LOWER to lower outriggers; operate lever to

RAISE to raise the outriggers.

HOIST: Operate lever to LOWER to payout and lower loadline; operate lever to
RAISE to reel-in and raise the loadline.

FOOT THROTTLE: Depress the foot throttle to accelerate the truck engine speed.
Release to return to idle speed.

Training & Operation - 23

Training & Operation
Cab Layout WHL 30 / HL 40 TC Series

FOOT REST FOOT THROTTLE

CONTROL CONSOLE

HEATER OUTLET
NOZZLE

LH JOYSTICK
JOYSTICK HOLD- RH JOYSTICK
DOWN
CUPHOLDER

OPERATORS WINDSHIELD
SEAT WASHER RESERVOIR

HEATER FUEL CAB HEATER

TANK
PLAN VIEW

LOCKING CATCH

LMI INDICATOR
DEFROST FAN
PANEL/OPERATING
CONSOLE

VIEW LOOKING FORWARD

Training & Operation - 24
Training & Operation

FOOT THROTTLE: Controls speed of truck engine during crane operation.

CONTROL CONSOLE: Controls for Crane and Outrigger functions. (see pg 26, 27)

RH JOYSTICK: Controls Winch raise/lower, Winch speed and Boom extend/retract.

(see pg 28).

LH JOYSTICK: Controls Boom raise/lower, Boom swing and Horn. (see pg 28).

JOYSTICK HOLD-DOWN: Holds LH Joystick Pedestal in down position. Raise to

pivot pedestal back for entry or exit of Operators Seat.

OPERATORS SEAT: Moves foreward/backward, adjustable back.

CAB HEATER: On/Off, temperature control dial located on control console. See
manufacturers manual for operating, maintenance and troubleshooting instructions.

HEATER FUEL TANK: Holds Diesel fuel for heater.

HEATER OUTLET: Adjustable nozzle for heated air, located on operators right.

WINDSHIELD WASHER RESERVOIR: Reservoir/pump assembly for front and roof

wiper/washers.

DEFROST FAN: Two speed fan controlled from console. Speed control located on
Fan.

DOME LIGHT: On ceiling above operators seat. On/Off switch located on light
assembly.

LMI INDICATOR PANEL/OPERATING CONSOLE: Provides operator with

information regarding the angle of the boom, working radius, rated load and the total
calculated weight being lifted. See maufacturers manuals (in Electric/Hydraulic
Systems section) for operation and calibration information.

LOCKING CATCH/KEEPER PLATE: Locks roof hatch closed.

Training & Operation - 25

Training & Operation
Operating Controls
All crane functions can be operated from the cab with two low pressure joysticks and
switches mounted on the control console.

Control Console Functions WHL 30 / HL 40TC Series

FRONT WIPER/WASHER ROOF WIPER/WASHER

CONTROL CONTROL

BOOM LIGHT SWITCH FAN CONTROL SWITCH

CAB LIGHT SWITCH

ENGINE START/STOP
SWITCHES
CRANE/OUTRIGGER SELECT
SWITCH

EMERGENCY STOP BUTTON

FRONT OUTRIGGER
VERTICAL/HORIZONTAL
SELECT SWITCH

FRONT STREETSIDE FRONT CURBSIDE EXTEND/

EXTEND/RETRACT SWITCH RETRACT SWITCH

REAR STREETSIDE EXTEND/ REAR CURBSIDE EXTEND

RETRACT SWITCH RETRACT SWITCH

REAR OUTRIGGER
VERTICAL/HORIZONTAL
SELECT SWITCH

12VDC OUTLET HEATER CONTROL

MAIN CONSOLE
Training & Operation - 26
Training & Operation

FRONT WIPER/WASHER: Turn to operate wiper on front cab window. Push to wash.

ROOF WIPER/WASHER: Turn to operate wiper on roof hatch window. Push to wash.

FAN CONTROL: ON/OFF switch for defrost/ventilation fan.

BOOM LIGHTS: ON/OFF switch for boom mounted lights.

CAB LIGHTS: ON/OFF switch for cab mounted exterior lights.

ENGINE START: Push to START truck engine.

ENGINE STOP: Push to STOP truck engine.

CRANE/OUTRIGGER SELECT: Rocker switch used to select either CRANE or

OUTRIGGER functions.
When CRANE functions are selected,Outrigger function switches will not work.
When OUTRIGGER functions are selected, Crane Joysticks will not work.

NOTE: See page 29 for Outrigger Controls.

EMERGENCY STOP: Cuts power to all control functions. PUSH to engage, PUSH
again to disengage.

FRONT OR REAR VERTICAL/HORIZONTAL SELECT: Momentary contact switch

used to select horizontal or vertical outrigger motion. Normally set to vertical.
For horizontal motion: Hold down switch in horizontal select position and toggle
extend/retract switch.

STREET/CURBSIDE EXTEND/RETRACT: Three position switch, normally neutral,

used to extend or retract outriggers.

HEATER CONTROL: Master control dial for cab heater. Controls ON/OFF, and
temperature. See manufactures information for operating/maintenance instructions.

12VDC OUTLET: Receptacle for 12 VDC power.

Training & Operation - 27

Training & Operation
Control Functions WHL 30 / HL 40 TC Series

LEFT JOYSTICK RIGHT JOYSTICK

Left Joystick
BOOM RAISE/LOWER: Operate joystick FORWARD to lower boom; operate joystick
BACKWARD to raise boom.

BOOM SWING: Operate joystick to RIGHT to rotate boom clockwise; operate joystick to LEFT to
rotate boom counterclockwise.

HORN: (Momentary): Push down either front or back of rocker switch to sound horn.

Right Joystick
WINCH RAISE/LOWER: Operate joystick FORWARD to lower the load; operate
joystick BACKWARD to raise the load.
BOOM EXTEND/RETRACT: Operate joystick RIGHT to extend the boom; operate
joystick LEFT to retract the load.

WINCH HI-SPD SWITCH (Momentary): Push down and hold either front or back of rocker switch
to shift winch to high speed. Winch speed returns to low when switch is released.

Training & Operation - 28

Training & Operation
Outrigger Controls WHL 30 / HL 40TC Series

FRONT OR REAR VERTICAL/HORIZONTAL SELECT: Momentary contact switch

used to select horizontal or vertical outrigger motion. Normally set to vertical.
For horizontal motion: Hold switch in horizontal select position and operate Control
Handles.

STREET/CURBSIDE EXTEND/RETRACT: Control motion of Outriggers.

NOTE: Outrigger controls function ONLY when "Crane/Outrigger Select" switch, on

Control Console, (see page 26, 27) is set to OUTRIGGER. Oil flow to valves is
blocked when select switch is set to CRANE.

VERTICAL/HORIZONTAL
SELECT SWITCH OUTRIGGER VALVE
CONTROL HANDLES

Boom Angle Indicator (all cranes)

Use the boom angle indicator in conjunction

with the unit's capacity placard to determine
the angle of the boom and the maximum load
that can be raised at each boom angle.
(Typical example shown)

CAUTION: When lifting loads at or near a load shown on the capacity placard, the
load radius should be measured with a tape.
Training & Operation - 29
Training & Operation
Operating Procedures
Preparation For Operation

Equipment Familiarization

The operator should become thoroughly familiar with the location and operation of
controls, the correct operating procedure, the maximum lifting capacities and safety
precautions applicable to the unit before operating. Always be prepared for and emer-
gency. Crew members should learn the emergency procedures in this section and be
prepared to execute them as necessary.

Equipment Checks

Perform the following checks before beginning daily operation.

• Inspect for any unusual conditions such as pools of hydraulic fluid lubricating oil under the
chassis, any outrigger which may have crept down or any signs of damage or improper
maintenance.

• Check the level of the following: engine oil, radiator coolant, hydraulic reservoir.

• Check the following for proper operation: brake lights, flashers, turn signals, headlight,
horn and windshield wipers.

• Check the "Stop-Start" circuit for proper operation.

• Start the truck engine and move the unit to an unobstructed area. Set the parking brake.
Engage the PTO and allow the hydraulic system to heat until the reservoir feels warm to
the touch. Extend the outriggers and operate the boom through two complete cycles to
check the operation of the controls and hydraulic cylinders. Check the operation of the
"Anti-Two-Block" system. Return the boom the road travel position and retract the outrig-
gers. Disengage the PTO store wheel chocks if so equipped.

• Check the loadline cable in accordance with instructions in the "Lubrication & Mainte-
nance Section".

• Inspect the hydraulic hoses and fittings to verify that they are in good condition and show
no signs of leaking. The hoses should be free from cuts and abrasion and there should be
no evidence of binding. Any damage or leaking should be repaired immediately.

Training & Operation - 30

Training & Operation
Operation
General Instructions

Always seek the best possible work site when parking a truck-mounted Hydra-Lift. An
ideal job site parking location would be firm, level, dry ground or pavement located in
close proximity to the work station. Avoid uneven, rocky or muddy terrain, steep grades
or locations with unnecessary overhead obstructions. Avoid locations with powerlines
overhead.

Maximum loads shown on the capacity chart are based on a level condition of the
machine. Lift capacities are greatly reduced if the machine is not level. When the unit
must be operated on a slope, use outrigger pads or boards to level the truck.

If work must be performed on an incline, always attempt to position the truck so that it
is facing downhill and on the downhill of the work site. Then, work out of the rear of the
truck. By positioning the truck below the work site, any accidental slippage will shift
the unit away from the work rather than into it.

If the truck must be parked across the grade of an incline, always work with the boom
on the uphill side of the truck. Even then, operation must be restricted to prevent
tipping due to the shortened fulcrum point of the outriggers., Always park so that the
maximum number of operations can be accomplished without repositioning the truck.

Federal OSHA and ANSI B30.5 regulations pertaining to truck-mounted cranes stipulate
as follows:

5-3.4.5 Operating Near Electric Power Lines

(a) Cranes shall be operated so that no part of (2) Caution shall be exercised when working
the crane or load enters into the danger zone near overhead lines because they can move
shown in Fig. 17. horizontally or vertically due to wind, moving the
danger zone to new positions.
EXCEPTIONS: (3) While in transit with no load and boom
The danger zone may be entered if the electrical lowered, the clearance shall be as specified in
distribution and transmission lines have been de- Table 1.
energized and visibly grounded at the point of work; (4) A qualified signal person shall be assigned
OR to observe the clearance when the crane moves
The danger zone may be entered if insulating to within a boom’s length of the limits specified in
barriers (not a part of nor an attachment to the Table 1. The operator is not in the best position to
crane) have been erected to prevent physical judge distance between the power line and the
contact with the lines. crane or its protuberances.
(1) For lines rated 50 kV or below minimum (b) If cage-type boom guards, insulating links,
clearance between the lines and any part of the or proximity warning devices are used on cranes,
crane or load (including handling appendages) such devices shall not be a substitute for the
shall be 10 ft (3 m). For higher voltages, see Table
1.
Training & Operation - 31
Training & Operation
requirements of (a) above, even if such devices (d) Any overhead wire shall be considered to
are required by law or regulation. In view of the be an energized line unless and until the person
complex, invisible, and lethal nature of the electrical owning such line or the electrical utility authorities
hazard involved, and to lessen the potential of false verify that it is not an energized line.
security, limitations of such devices, if used, shall (e) Exceptions to this procedure, if approved
be understood by operating personnel and tested by the owner of the electrical lines, may be granted
in the manner and intervals prescribed by the by the administrative or regulatory authority if the
manufacturer of the device. Compliance with (a) alternate procedure provides protection and is set
above is the recommended practice of this volume forth in writing.
in determining permissible proximity of the crane (f) Durable signs shall be installed at the
and its protuberances, including load, to electrical operator’s station and on the outside of the crane
power lines. warning that electrocution or serious bodily injury
(c) Before the commencement of operations may occur unless a minimum clearance of 10 ft (3
near electrical lines, the person responsible for the m) is maintained between the crane or the load
job shall notify the owners of the lines or their being handled and energized power lines. Greater
authorized representatives, provide them with all clearances are required because of higher voltage
pertinent information, and request their as stated in (a)(1) above. These signs shall be
cooperation. revised when local jurisdiction requires greater
clearances.

TABLE 1 REQUIRED CLEARANCE FOR NORMAL VOLTAGE IN OPERATION

NEAR HIGH VOLTAGE POWER LINES AND OPERATION IN TRANSIT WITH
NO LOAD AND BOOM OR MAST LOWERED

Normal Voltage, kV
(Phase to Phase) Minimum Required Clearance, ft (m)

Operation Near High Voltage Power Lines

to 50 10 (3.05)
Over 50 to 200 15 (4.60)
Over 200 to 350 20 (6.10)
Over 350 to 500 25 (7.62)
Over 500 to 750 35 (10.67)
Over 750 to 1000 45 (13.72)

Operation In Transit With No Load and Boom or Mast Lowered

to 0.75 4 (1.22)
Over 0.75 to 50 6 (1.83)
Over 50 to 345 10 (3.05)
Over 345 to 750 16 (4.87)
Over 750 to 1000 20 (6.10)

Training & Operation - 32

Training & Operation
This area should be avoided.

Danger Zone area

[Note (1)]

NOTE:
(1) For minimum radial distance of danger zone, see para. 5.3.4.5

FIG. 17 DANGER ZONE FOR CRANES AND LIFTED LOADS OPERATING

NEAR ELECTRICAL TRANSMISSION LINES.

Training & Operation - 33

Training & Operation
Operation

Initiating Operation

Place the unit in operation as follows:

1. If possible, position the unit at the job site so that all work operations can be
performed without repositioning the truck.
2. Set the truck parking brake securely and position wheel chocks.
3. With the gear shift in neutral, depress the clutch (if equipped with manual
transmission) and engage the power take-off. If equipped with an automatic
transmission, place the selector in "DRIVE" and engage the PTO, then, shift the
gear selector to "NEUTRAL".
4. Bring the hydraulic system up to operating temperature (oil reservoir warm to the
touch) by allowing the system to operate with all controls at neutral. After warm
up, return hand throttle in the chassis cab to idle and use the foot throttle on the
mainframe.
5. Positioning Outriggers
Always extend the outriggers to the ground to provide firm support of the truck
before operating. When operating on soft terrain where the supports tend to mire
into the ground, use pads or boards under the outriggers and tires to prevent
miring. Never set an outrigger on a curb. The load may cause the unit to tip due
to the shortened fulcrum point of the outriggers. Extend both main and auxiliary
outriggers if so equipped. Level the vehicle as much as possible referring to the
bubble level on the crane.
WARNING: NEVER RELY SOLELY ON THE TRUCKS BRAKES. ALWAYS USE
WHEEL CHOCKS.
CAUTION: DO NOT OPERATE THE BOOM UNTIL ALL OUTRIGGERS ARE
EXTENDED PROVIDING FIRM SUPPORT.
NOTE: Whenever possible, the truck should be level Lift capacities are greatly
reduced if the truck is not level
6. Check all controls (on both sides of the mainframe) for proper operation by oper-
ating each function through one complete cycle. This is particularly important
after the unit has been serviced or repaired. If abnormal operations are detected,
correct the situation before continuing.
7. During all operations, the controls should be metered when beginning or ending
a movement. This prevents sudden stops which impose severe shock loads on
the equipment.

Training & Operation - 34

Training & Operation
Operation

Engine Operating Speeds

For optimum unit performance, the hydraulic pump must be operated at its most effi-
cient speed. The optimum PTO speed for the hydraulic pump supplied with your Hy-
dra-Lift is 1800 RPM. PTO speeds higher that 1800 RPM will cause premature failure
of pumps, motor, rotation systems and cause overheating of the entire system. Make
sure that throttle STOPS are set up correctly to prevent PTO speeds higher than 1800
RPM.

Lifting Operations

Stability Load Limits

Before lifting a load, look at the capacity placard and make sure that the load is not
heavier than the load shown on the capacity chart for the desired boom length and
load radius.

EFFECT ON WARRANTY - Your unit warranty does not apply to any part of your unit
which has been subjected to misuse. Any part which fails because of overloading has
been subject to misuse within the meaning of the provision of the warranty.

All capacity ratings are given in direct relationship to the radius at which the load is
being handled. All radii are measured from the centerline of rotation to the loadline.
All variances of loads and radii of operation are shown on the load capacity placard
mounted on the mainframe. The placard is located near the operator’s platform for the
purpose of informing the operator when a load can or cannot be handled.

CAUTION: The boom must not be extended or lowered while the load line downhaul
weight is pulled tight against the tip sheave. Always payout sufficient loadline to pre-
vent the downhaul weight from contacting ("TWO BLOCKING") tip sheave.

Training & Operation - 35

Training & Operation
Winch Operations

General Rules

1. Always operate the HOIST control to payout the loadline while extending the boom.
This will maintain clearance between the boom tip and loadline hook.

2. Make certain the winch cable is not twisted or kinked and that the cable is properly
seated on the drum and in the sheaves.

3. During winch operations, meter all controls and apply power smoothly-no sudden
acceleration or deceleration.

4. When lifting a load approaching the rated maximum capacity, raise the load a few
inches and return the control to neutral to determine if the brake is working properly.

5. Never attempt to pull poles out of the ground using the winch. This will overload
and damage the winch and boom.

6. Do not make side pulls with the boom. This type of loading can damage the boom
and rotation mechanism.

7. When lifting a load, always make certain that three full wraps of rope remain on the
drum before using the winch.

8. Observe the limits outlined by the Reduced Capacity Chart whenever applicable.

STRAIGHT LINE PULLS

The boom can be used as a fairlead to pull loads in from anywhere within its boom arc
of 360' as long as the load is pulled in a straight line with the boom and loadline
parallel. The maximum load rating for this operation is 5000 lbs. with all booms re-
tracted.

CAUTION: The boom and loadline must form a straight line between the boom and
load with no bends or turns.

Do not reroute the cable beyond, below or to the side of the boom tip. Any such
rerouting automatically imposes a load on the boom tip and the turret rotation mecha-
nism. Either of these parts can be damaged if straight-line pulls are conducted under
these conditions.

Training & Operation - 36

Training & Operation
Winch Operations

Operation Procedures

1. On loads where the weight is not verified always test lift the load a few inches by
use of the topping (or lift) cylinder. As a general guide, if the load can be raised in
this manner the winch can be used to lift the load. This same test should be used
when increasing the lift radius once a load is suspended.

2. Anti-Two Blocking. Do not pull load line hook into sheave. Do not lower boom (on
turret mounted winches) into load line hook. Do not extend sheave into load line
hook. On units equipped with anti-two blocking devices, do not render the de-
vices inoperative. Test the device for proper functioning prior to daily operation.

3. Multi-Part Line

Load line Variation - when lifting loads up 7900 or more, always use a two-part
line (or multiple reeving). See Capacity Chart on Crane.

Two-Part Three-Part Three and Four Part

WARNING: Regardless of multi-parting, never lift more than capacity chart rating.

Training & Operation - 37

Training & Operation
2 Speed Winch Option

This winch is similar to the single speed winch but is powered by a tandem motor and
operated with the same control handle plus a toggle switch. For high speeds, light
load lifting, the toggle switch is used. Always use low speed with heavy loads. Braking
is automatic when the control valve returns to neutral or there is a loss of hydraulic
power.

Using Personnel Bucket

(An Optional Feature)

When aloft in a personnel bucket:

1. Always wear a body belt attached to the boom with a lanyard.

2. Never allow conductive material to hang from the personnel bucket, boom tip or
the bucket occupant. This includes power tool lines, ropes, wires, cables and
extension cords.

3. Stay clear of all electrical conductors when raising or lowering anything between
the ground and the boom tip.

4. Regard all conductors as electrically energized including neutrals, ground lines,

jumpers and guy wires.

Training & Operation - 38

Training & Operation
Hydra-limit Load Sensing
(An Optional Feature)

The Hydra-Limit Load Sensing System is designed to indicate structural overload con-
ditions caused by operator error. The sensing system monitors the differential pres-
sure in the boom lift cylinder, induced by the load on the boom, and determines whether
or not the boom is overloaded. If an overload should occur, the sensing system stops
the BOOM EXTENSION and BOOM LOWERING functions and, at the same time, the
WINCH RAISE flow is diverted to the reservoir. The BOOM RETRACT and WINCH
LOWER functions remain operable, as does the BOOM RAISE function. The oper-
able functions can move the load toward a safer condition.

When the load on the boom has been reduced to within rated capacity, the Load
Sensing System may be reset by momentarily moving the BOOM lever to the RAISE
position. Normal operation may then be resumed.

CAUTION: THE LOAD SENSING SYSTEM MUST NOT BE USED TO DETERMINE

MAXIMUM LIFTING ABILITY. THE CAPACITY PLACARD LOADS ARE MAXIMUM
LOADS AND MUST NOT BE EXCEEDED.

The Hydra-Limit Load Sensing System will not protect the machine under conditions
where stability is a determining factor. Consequently, the machine should always be
levelled on a firm supporting surface with the outriggers extended and the tires off the
surface for maximum stability.

CAUTION: THE LOAD SENSING SYSTEM WILL NOT PROTECT AGAINST OVER-
LOADS WHEN JIBS ARE IN USE, THE CAPACITY PLACARD LOAD LIMITS MUST
NOT BE EXCEEDED ALSO, THE LOAD SENSING SYSTEM WILL NOT PROTECT
THE BOOM AGAINST SIDE LOADS, LOADS THAT ARE DRAGGED ACROSS THE
GROUND, SHOCK LOADS, SUDDEN STOPS OR STARTS.

Training & Operation - 39

Training & Operation
Shutting Down

1. Return the boom to the road travel position.

2. Make sure that the loadline hook is tied down so that it can not swing freely.

3. Retract the outriggers

4. Return the engine throttle to the idle position, depress the clutch, and disengage
the power take-off.

5. Remove and stow the wheel chocks if applicable. Release the parking brake
before driving the truck.

Training & Operation - 40

Training & Operation
Emergency Operation

Emergency Rotation

The HL TC Series crane is equipped with a spring applied pressure released rotation
brake. This brake will only allow rotation if there is sufficient hydraulic pressure to
cause rotation gearbox to rotate the turret. In case of hydraulic failure this brake will
have to be HYDRAULICALLY released. Below is the procedure to rotate the turret:

Attach a tag line to the boom, and lower the boom as mush as possible while maintain-
ing enough height to clear the boom rest, exhaust stacks and any other vertical object.

Plumb a PORT-A-POWER or other hydraulic source into the brake port on the rotation
gearbox.

Remove counterbalance valve from the motor.

Pressurize the brake port to 600 PSI and rotate the boom over the boom rest with a tag
line.

Release hydraulic pressure and reattach the brake line.

Finish lowering the boom to the boom rest.

Once the boom is in the boom rest, use straps to secure the boom into the
boom rest for roading.

Emergency Lowering Of The Boom

The boom can be lowered by releasing the hold adjustment on the holding valve at the
base of the topping cylinder and actuating the boom control lever to the LOWER posi-
tion. Proceed as follows:

1. Loosen the locking jam nut securing the adjusting screw on the holding valve.

2. Very slowly turn the adjusting screw counterclockwise, approximately three turns.

Training & Operation - 41

Training & Operation
Emergency Operation

Emergency Lowering Of The Boom (continued)

Releasing Holding Valve

CAUTION: IF THE BOOM BEGINS TO DESCEND WHEN THE ADJUSTMENT

SCREW IS FIRST TURNED, IMMEDIATELY TURN THE SCREW CLOCKWISE TO
STOP BOOM MOVEMENT. A CYLINDER LINE IS BROKEN AND THE RATE OF
DESCENT MUST BE CONTROLLED WITH THE ADJUSTMENT SCREW. USE EX-
TREME CAUTION WHEN LOWERING IN THIS MANNER.

3. Actuate the boom control to LOWER and hold until the boom is in the stowed
position.

4. If the boom does not begin to descend, back off the holding valve adjusting screw
until it does. In extreme cases, it may be necessary to apply external forces to start
downward boom movement.

CAUTION: After lowering the boom in this manner, the boom cylinder holding valve
will be out of adjustment and it will be necessary to readjust it before returning to
service. Refer to "Holding Valve Adjustment" in Section III for adjustment instructions.
In addition, the cylinder will be void of oil making unit operation hazardous until all air is
evacuated from the system. Recharge the system as explained below.

Training & Operation - 42

Training & Operation
Recharging System

With the Crane in the stowed position (Boom fully retracted and in the Boom Rest, and
Outriggers fully retracted) fill the hydraulic reservoir with hydraulic oil to the Black Line of
the sight gauge. See Figure A. Place the unit in operation and recharge the cylinder as
follows:

1. Raise and lower the boom several times through a travel arc of approximately
60°.

2. Completely extend the boom.

3. Completely retract the boom.

4. Retract the boom and lower it to the stowed position.

5. Fully retract all Outrigger Cylinders.

WARNING

1. Do not attempt to refill Hydraulic Oil Reservoir when Cylinders are extended.

2. Do not operate Crane when Oil level is below the Red Line when Crane is in the
Stowed Position.

Figure A

Training & Operation - 43

Lubrication &
Maintenance
Lubrication &
Daily & Weekly
Maintenance
A regular schedule of maintenance is essential to keep your unit at peak operating
efficiency. Operators or service personnel responsible for the care of the unit should
be completely familiar with the type and frequency of maintenance and lubrication
operations to be performed. The following pages outline the daily and weekly mainte-
nance and lubrication required and the service interval.

Refer to Maintenance manual for monthly and periodic lubrication and maintenance
instructions.

Selecting Oil

The table below lists the minimum specifications for hydraulic oil suitable for use in
Weldco Hydra-Lift units. All major oil companies can supply well know brands to meet
requirements for insulated or non-insulated equipment.

Minimum Oil Specifications

*Ambient Temp. Range, °F 0-90 Below 32 32-90 Above 90

Max. Pour Point, °F -30 -15 +10 +10
Max. Viscosity,SSU @ 0°F 4000 4000 - -
Min. Viscosity,SSU @ 100°F 149-195 100-130 150-200 200-315
Min. Viscosity,SSU @ 210°F 48 41 43 47
Min. Viscosity Index 139 90 90 90

*Consult oil supplier for sustained operations during extreme high or low temperature
conditions.

Determining Oil Condition

The presence of dust, solvents and other contaminants in hydraulic oil will adversely
effect its condition and lead to its premature breakdown. Operating temperatures
above 180°F and/or water in the oil will cause an increase in its oxidation rate. As
hydraulic oil oxidizes, sludge and varnish forming materials will be deposited in the
pumps, valves, cylinders and lines and increase the rate of wear.

Lubrication & Maintenance - 1

Lubrication &
Daily & Weekly
Maintenance
To determine the condition of the hydraulic oil, obtain a sample from the system and
pour it into a clean glass. If it smells clean, it is probably in good condition. If it has a
burnt oil or racid smell, or if it is cloudy or dark in colour, the oil should be changed. If
water appears in the bottom of the glass after it stood for several minutes, there is
either an opening for water to enter the system or the unit has been subjected to
extreme temperature changes which cause condensation in the system.

Servicing System Filters

Simplified Hydraulic Schematic

The unit's hydraulic system is equipped with two filters to remove contaminates from
the oil. A 100-mesh suction strainer, located with the reservoir, filters out large particles
and a micronic cellulose filter, located in the return line, must be serviced at each oil
change. (See "Purging Hydraulic System"). Check the filters for excessive
contamination midway between changes and service if necessary.

Lubrication & Maintenance - 2

Lubrication &
Daily & Weekly
Maintenance
Return Line Filter

Change the filter cartridge whenever the filter condition indicator indicates red with the
pump running. To replace the filter cartridge, remove the six bolts securing the access
plate to the filter head. Remove the filter and discard. Clean the filter housing and dry.
Insert a new element in the filter housing. Replace the access plate and tighten the
bolts securely. Operate the system and check for oil leaks.

Note: When the filter is removed, about a quart of stale hydraulic oil will spill
out. A drain pan should be provided to catch the spill. This spillage should not
be returned to the reservoir.

Suction Strainer

Lubrication & Maintenance - 3

Lubrication &
Daily & Weekly
Maintenance
Purging The Hydraulic System
All the hydraulic oil in the system should be changed twice yearly or every 800 hours of
operation, which ever comes first, or after the failure of a pump or any other major
hydraulic component. By using the following procedure, approximately 95% of the old
oil can be purged from the pump by the flow of new oil entering the system from the
pump pressure line.

Before beginning, make certain there is enough oil available to refill the system with
enough extra to allow for some spillage. Two persons are required to perform this
procedure; one to engage and disengage the PTO while the other operates the main
controls. Maintain the truck engine speed at low RPM during the procedure to minimize
loss of new oil.

CAUTION: Watch the hydraulic oil level during this operation. Don't allow the
reservoir to drop below 1/3 full at any time during purging. Otherwise the pump
may cavitate due to loss of oil and become damaged.

1. Position the unit where the boom can be moved through its full travel. Extend the
outriggers and move the boom to its lowest position to place the topping cylinder
at the end of it's stroke. Fully retract the boom. Operate the winch to unwind
enough loadline to allow full boom extension plus approximately five extra feet.

2. Uncouple the suction line at the reservoir and allow the hose to drain. Remove
the reservoir drain plug. Clean the suction line strainer and reassemble. Install
the suction line back to the reservoir.

3. Remove the return line from the reservoir and direct the open line into a sump or
drain pan. Plug the port from which the line was removed.

4. Reinstall the reservoir drain plug and fill the reservoir with new hydraulic oil.

5. Start the engine and actuate the winch control valve to the raise position. Engage
the PTO. Retract the winch loadline the five feet previously allowed in order to
purge the hydraulic oil from the winch circuit. Disengage the PTO.

Lubrication & Maintenance - 4

Lubrication &
Daily & Weekly
Maintenance
Purging The Hydraulic System
6. At the inlet to the winch valve, disconnect from the tee connector, the hydraulic
line which runs from the pump to feed the winch valve. Cap the open port on the
tee connector. Then, using an extension hose, direct the flow from the pump into
the reservoir filler pipe.

IMPORTANT: This will permit the fresh hydraulic oil from the pump to return to
the reservoir without being lost during purging of the other circuits.

7. Operate the control valve to raise the boom. Engage the PTO. When the boom
reaches its maximum height, disengage the PTO to stop the pump.

IMPORTANT: If the control lever is held open after boom movement stops, new
oil will be expelled through the relief valve.

8. Repeat the procedure to fully extend the boom.

9. Operate the control valve to rotate the boom. Engage the PTO and allow the
boom to rotate over the rear of the truck. Disengage the PTO.

10. Operate the outrigger control levers to the retract position. Engage the PTO and
raise the outriggers cautiously. Disengage the PTO.

CAUTION: When performing Step 10, always raise the outriggers slowly. If
stability becomes a problem, it may be necessary to rotate the boom further to
balance the chassis weight.

11. After all components have been purged, uncap the tee connector in the winch
circuit and reconnect the line from the pump to the tee connector.

12. Change the filter element in the return line and reconnect the return line to the
hydraulic reservoir. Add sufficient oil to return the reservoir to full.

13. Operate the controls to place the unit in road travel position.

Lubrication & Maintenance - 5

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Holding Valve Adjustment

1. Place the unit in operation and extend the outriggers. Raise the boom to a
horizontal position and rotate it to the rear of the truck. Fully extend the booms.

2. Connect the loadline to maximum capacity test load (See Capacity Placard) and
operate the winch control to suspend the load approximately three feet above the
ground.

3. Shut down the hydraulic system. Operate the boom control to LOWER. If the
boom descends the holding valve is in need of adjusment.

Adjusting Holding Valve

CAUTION: A secondary support system for the boom should be provided during
this entire adjustment. This support system could be in the form of a sling
extended from an overhead crane, a steel structure designed for this purpose,
or heavy timbers placed in such a manner as to prevent the boom from lowering
to the extent that the workmen's safety would not be endagered.

Lubrication & Maintenance - 6

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Holding Valve Adjustment

4. Two men are required to perform the adjustment; one stationed at the control
levers and the other at the holding valve. With the boom raised as previously
described loosen the locking jam nuts securing the adjustment screw and back
off the adjusting screw one or two turns (counterclockwise). Operate the boom
topping lever to LOWER and hold fully actuated. When the boom begins to
descend, turn the adjusting screw clockwise until movement stops. Do not turn
beyond this point as a tighter adjustment will unnecessarily restrict boom movement
during operation.

5. Tighten the lock nuts securely while holding the adjustment screw to maintain the
adjustment.

NOTE: If difficulty is encountered in achieving proper adjustment, it may be due

to dirt or foreign matter in the valve. Normally any accumulation of dirt will
occur at the pressure inlet port and can be reached by removing the swivel fitting
connecting the hose to the valve. Clean with compressed air.

Maximum Hydraulic System Pressures:

HL 8TC / 10 TC / 12TC / 15TC / 18TC / 25TC / 30TC / 40TC Series - controlled by
three main relief valves, and one work port relief cartridge.

Main Relief Valves

HL 8TC HL 10TC HL 12TC HL 15/18TC HL 25/30/40TC
Swing control 2000 PSI 2000 PSI 2000 PSI 2000 PSI 2000 PSI
Winch control 2500 PSI 2500 PSI 2500 PSI 2500 PSI 2800 PSI
Main control 2950 PSI 2950 PSI 2950 PSI 2950 PSI 2950 PSI

Work Port Relief valves

Topping 1850 PSI 2150 PSI 2650 PSI 2800 PSI 2850 PSI

Lubrication & Maintenance - 7

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Directional Control Valve

The HL TC Series Hydraulic control valves, comprise of a Gresen V42 for the Winch
hydraulic circuit and Gresen V20 the remaining hydraulic circuits. The V20 has an
end-inlet with a relief valve, Model #WHA set to 2000 psi. (See figure 1) Valve spool
#1 controls the swing circuit, followed by a mid-inlet with a relief valve set to 2950 psi.
Valve spool #4 has a port relief valve, Model #RP20. (See figure 2) It operates the
Topping Cylinder. Check the Work Port Relief Valve setting chart for the proper setting
related to your crane model. The 5 remaining spools operate, Boom Extend (#3),
Mainframe Outriggers (#5 and #6) and Auxiliary Outriggers (#7 and #8). All the working
ports are SAE #10 ORB except boom extend (spool #3) and all the remaining ports are
SAE #12 ORB. The V42 valve has a inlet with a relief valve Model #RP60-A set to
2500 psi. (Similar to figure 2) All the port sizes are SAE #16 ORB.

Figure 1 Figure 2

Lubrication & Maintenance - 8

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Relief Valve Adjustment

To assure the proper pressure setting, relief valves in the main control valve must be
checked and adjusted before adjusting the winch valve. Any other adjustment sequence
will result in incorrectly adjusted system pressures and faulty equipment operation. To
adjust, proceed as follows:

Swing Relief (set at 2000 psi, all models)

1. Remove one of the hydraulic hoses connected to the Rotation Gearbox and cap.
Disconnect the other hose and tee in a length of high pressure hydraulic hose
long enough to place a hydraulic gauge 0-3000 psi in a readable position.
2. Place the unit in operation, engage the PTO and accelerate the truck engine to
attain correct pump speed. Operate swing control and hold. NOTE: If no pressure
is shown, reverse control handle and hold. Pressure should build up to specified
pressure and relieve. If the valve relieves at any other pressure, an adjustment
must be made.
3. If the pressure is incorrect, adjust as follows:
Remove the acorn nut and loosen the lock nut. While keeping the function under
pressure, with a screw driver turn the adjustment screw clockwise to increase
pressure and counterclockwise to decrease until the proper setting is attained.
4. Once adjusted properly, tighten the locknut without turning the adjustment and
replace the acorn nut. Remove the tee and gauge, reconnect the hydraulic lines
in their proper locations.

Swing Relief Pressure

Setting Location

Lubrication & Maintenance - 9

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Relief Valve Adjustment

Main Relief (set at 2950 psi, all models)

This relief setting has a gauge connected from the factory and placed in the center of
the control console. Pressure should be monitored and adjusted when required. To
adjust, proceed as follows:
1. Place the unit in operation, engage the PTO and accelerate the truck engine to
attain correct pump speed. Operate an outrigger to RETRACT position and hold.
Pressure should build up to specified pressure and relieve. If the valve relieves
at any other pressure, an adjustment must be made.
2. If the pressure is incorrect, adjust as follows:
Remove the acorn nut and loosen the lock nut. While keeping the function under
pressure, with a screw driver turn the adjustment screw clockwise to increase
pressure and counterclockwise to decrease until the proper setting is attained.
3. Once adjusted properly, tighten the locknut without turning the adjustment and
replace the acorn nut.

Main Relief Pressure

Setting Location

Lubrication & Maintenance - 10

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Relief Valve Adjustment

Topping Relief (Setting varies for each model)

1. Ensure the Boom is resting on the Boom Rest or on a firm surface. Remove one
of the hydraulic hoses connected to the Topping Cylinder and cap. Disconnect
the other hose and tee in a length of high pressure hydraulic hose long enough to
place a hydraulic gauge 0-3000 psi in a readable position.
2. Place the unit in operation, engage the PTO and accelerate the truck engine to
attain correct pump speed. Operate the topping function and hold. NOTE: If no
pressure is shown, reverse control handle and hold. Pressure should build
up to specified pressure and relieve. If the valve relieves at any other pressure,
an adjustment must be made.
3. If the pressure is incorrect, adjust as follows: Note: this procedure may require
two people since the adjustment will be made through an access below the
control console. Remove the cover on the relief valve and loosen the lock nut.
While keeping the function under pressure, with an hex wrench turn the adjustment
screw clockwise or counterclockwise until the proper setting is attained.
4. Once adjusted properly, tighten the locknut without turning the adjustment and
replace the cover. Remove the tee-hydraulic line and gauge assembly and
reconnect the hydraulic lines to their proper locations.

Topping Relief Pressure

Setting Location

Lubrication & Maintenance - 11

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Relief Valve Adjustment

To assure the proper pressure setting, relief valves in the main control valve must be
checked and adjusted before adjusting the winch valve. Any other adjustment sequence
will result in incorrectly adjusted system pressures and faulty equipment operation. To
adjust, proceed as follows:

Winch Valve Relief (set at 2500 psi, 12000 lbs 1 & 2 Speed,
2800 psi 15000 lbs 2 speed)

1. Remove one of the hydraulic hoses connected to the Winch Motor and cap.
Disconnect the other hose and tee in a length of high pressure hydraulic hose
long enough to place a hydraulic gauge 0-3000 psi in a readable position.
2. Place the unit in operation, engage the PTO and accelerate the truck engine to
attain correct pump speed. Operate Winch control and hold. NOTE: If no pressure
is shown, reverse control handle and hold. Pressure should build up to specified
pressure and relieve. If the valve relieves at any other pressure, an adjustment
must be made.
3. If the pressure is incorrect, adjust as follows: Note: this procedure may require
two people since the adjustment will be made through an access below the
control console. Remove the cover on the relief valve and loosen the lock nut.
While keeping the function under pressure, with an hex wrench turn the adjustment
screw clockwise or counterclockwise until the proper setting is attained.
4. Once adjusted properly, tighten the locknut
without turning the adjustment and replace the
cover. Remove the tee-hydraulic line and
gauge assembly and reconnect the hydraulic
lines to their proper locations.

Winch Relief Pressure

Setting Location

Lubrication & Maintenance - 12

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Extension Cylinder Holding Valve Adjustment
Single Cartridge System
1. Place the unit in operation and extend the outriggers. Raise the boom to the
horizontal position and rotate it to the rear of the truck. Fully extend the boom.
2. Connect the loadline to a maximum capacity load. (See Capacity Placard) Raise
the booms to a 60° angle.
3. Shut down the hydraulic system. Operate the boom control to RETRACT. If the
boom retracts, its holding valve need adjustment as follows:
a. Loosen the lock nut securing the extension cylinder holding valve adjustment
screw.
b. Slowly tighten the adjustment screw until the boom retraction stops.
CAUTION: Do not tighten the adjustment screw further as this will impede normal
system operation.
c. While holding the adjustment screw to maintain adjustment, retighten the lock
nut.

Boom Holding Valve

Adjustment Screw

Lubrication & Maintenance - 13

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Extension Cylinder Holding Valve Adjustment
Double Cartridge System
1. Place the unit in operation and extend the outriggers. Raise the boom to the
horizontal position and rotate it to the rear of the truck. Fully extend the boom.
2. Connect the loadline to a maximum capacity load. (See Capacity Placard) Raise
the boom to a 60° angle.
3. Shut down the hydraulic system. Operate the boom control to RETRACT. If the
boom retracts, its holding valve need adjustment as follow:
a. Loosen the lock nut securing the extension cylinder holding valve adjustment
screw.
b. Slowly tighten the adjustment screw until the boom retraction stops.
CAUTION: Do not tighten the adjustment screw further as this will impede normal
system operation.
c. While holding the adjustment screw to maintain adjustment, retighten the lock
nut.
4. Start hydraulic system, fully retract
and lower the boom as low as
possible, keeping the load in tension.
5. Shut down the hydraulic system.
Operate the boom EXTEND. If the
boom extends, its holding valve
needs adjustment. Follow 3a, 3b and
3c.

Boom EXTEND Holding Valve

Adjustment Screw

Boom RETRACT Holding Valve

Adjustment Screw

Lubrication & Maintenance - 14

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Hydra-limit Load Sensing System Adjustment (Option)
1. Confirm that the TOPPING work port relief for RAISE is properly set according to
page 7.
2. The sensing valve and gauge port are located on the bottom of the lift cylinder.
Connect an accurate 0-3000 psi gauge to the gauge port.
TO MAIN BOOM RAISE
TO MAIN
BOOM LOWER SENSING
VALVE
CAP "A"

GAUGE PORT
PLUG

TO HYDRA-LIMIT GAUGE PORT LOCATION

PRESSURE SENSING (Tubing removed for clarity)

HYDRA-LIMIT
DIRECT TO TANK

CAUTION: BE SURE THE BOOM LIFT CYLINDER IS FULLY RETRACTED, OR

THAT THE BOOM IS SUPPORTED BEFORE REMOVING THE CAP ON THE GAUGE
PORT. IF THE CYLINDER IS NOT COMPLETELY RETRACTED, OIL WILL ESCAPE
WHEN THE CAP IS REMOVED AND THE BOOM WILL COME DOWN.
3. Select a test load which matches the rated capacity chart. Extend the boom to
position it at the radius specified for that load.
4. Using the winch control only, lift the test load until the pressure gauge reads 50
PSI LESS than the topping work port relief valve setting. *The topping work
port relief setting ALWAYS has to be 50 PSI MORE than the Hydra-Limit
setting to allow the boom to be raised out of an overload condition. The
sensing valve should trip at this pressure and stop the winch. If the sensing valve
trips before this pressure is reached, the winch will stop pulling.
...continued

Lubrication & Maintenance - 15

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Hydra-limit Load Sensing System Adjustment (Option)
4. Continued from page 15
Operate the winch control lever to WINCH LOWER until the loadline goes slack.
Operate the boom raise lever to RAISE momentarily to reset the load sensing
system. (The boom does not have to move.)
5. Remove cap "A" on the sensing valve. (See Illustration) Turn the socket head
screw clockwise 1/6 of a turn to increase the trip pressure. Then, replace cap "A"
and repeat step 4.
6. Repeat step 5 until the sensing valve trips at proper pressure.
7. If, during step 4, the pressure on the gauge reaches proper pressure before the
sensing valve trips, stop the winch and operate the winch control to WINCH
LOWER. When the loadline goes slack, remove cap "A" and turn socket head
screw counterclockwise 1/2 turn. Replace cap "A" and repeat steps 4, 5 and 6.
When the sensing valve is properly set, repeat step 4 several times to check the
repeatability of the setting.
8. Adjust the electrical alarm pressure switch to engage the audible alarms at a
pressure 50 PSI LESS than the final setting above for the Hydra-Limit sensing
valve. *It is important that the audible alarm WARNS the operator of the
impending overload shut-down BEFORE it happens so he can efficiently
react to the warning.
CAUTION: MAKE SURE THAT THE BOOM IS FULLY RETRACTED, OR THAT
THE BOOM IS SUPPORTED BEFORE REMOVING THE GAUGE ON THE PORT.
IF THE CYLINDER IS NOT COMPLETELY RETRACTED, OIL WILL ESCAPE WHEN
THE GAUGE IS REMOVED AND THE BOOM WILL COME DOWN.
9. Raise the boom once more until the sensing valve trips and stops. The winch
raising and boom extension and lowering functions will be disabled. Lower the
winch and reset the Hydra-Limit load sensing system by moving the boom lever
to RAISE position momentarily.
NOTE: If the sensing valve does not trip in Step 9 above, repeat Steps 1 and 2 of the
procedure for Opening the Velocity Valve. Then repeat Step 9 until the Hydra-Limit
sensing system starts working.
10. Remove the pressure gauge from the holding valve gauge port. Replace the cap
on the gauge port.

Lubrication & Maintenance - 16

Lubrication &
Daily & Weekly
Maintenance
Minor Repairs & Adjustments
Opening The Velocity Valve

1. Lower the winch until the loadline goes slack.

2. Lower the boom until the topping cylinder bottoms out.
3. Now, slowly start raising the boom. If the pressure gauge starts responding to
the boom tip load, lower the boom to the 50 foot load radius position and go to
Step 4 in the procedure for setting the sensing valve.
If the pressure gauge does not respond to the load on the boom, repeat the
above Steps 1, 2 and 3 until the gauge starts responding to the boom load.

IMPORTANT: Maintenance of the winch should be a continuous process during

operations with the operator being constantly alert to detect unusual sounds,
excessive oil leakage, extreme heat and changes in the lifting characteristics of
the winch.

Lubrication & Maintenance - 17

Lubrication &
Daily & Weekly
Maintenance
Wire Rope Maintenance
Inspection

Three scheduled inspection - daily, monthly and quarterly - should be made of all rope
in daily service. These scheduled inspections vary in the degree of thoroughness as
outlined below and should be made at intervals recommended or sooner should the
general appearance of a particular rope indicate the need for more frequent or more
thorough inspection. All rope which has been idle for a period of a month or more due
to a shut-down or storage of a machine on which it is installed, shall be given a thorough
inspection before it is placed in service. This inspection should cover all types of
deterioration.

All running rope in continuous service should be inspected once each working day.
This inspection is made before the rope is used for the first time on any particular day.
It should cover the eye and that portion of the rope used most extensively in daily
operation. The eye should be inspected thoroughly for abrasion, corrosion, broken
wires and loose or broken servings. Inspect the remainder of the rope length normally
used for daily operation for points showing kinks, sharp bends, or any evidences of
damage or excessive wear.

During the monthly inspections, the entire length of wire rope should be inspected. A
thorough inspection should be made of the eye and the length of rope normally used in
daily operations. Examine the remainder of the rope for kinks, crushed or otherwise
damaged points.

The quarterly inspection requires a thorough inspection of the entire rope length. This
inspection will usually indicate greater wear at the eye end of the rope. Therefore, to
remain in service, it should be reversed on the drum so that the wear will more nearly
equalize along the entire length.

Lubrication & Maintenance - 18

Lubrication &
Daily & Weekly
Maintenance
Wire Rope Maintenance
Rope Replacement

It is extremely difficult to determine the exact time to replace wire rope since many
variable factors are involved. Proper determination of a wire rope depends upon the
good judgement of an experienced person in evaluating the remaining strength in a
used rope after allowing for the deterioration disclosed be inspection. The following
reasons are sufficient for considering rope replacement.

1. Six randomly distributed broken wires in one rope lay or three broken wires in one
strand in one rope.

2. Wear of one-third the original diameter of outside individual wires.

3. Kinking, crushing, bird caging or any other damage resulting in distortion of the
rope structure.

4. Reductions from nominal diameter of more than 1/32".

The right way to measure rope diameter is to

measure the rope's widest diameter.

Lubrication & Maintenance - 19

Lubrication &
Daily & Weekly
Maintenance
Wire Rope Maintenance
Maintenance Procedures

Care is required in the handling of wire rope to prevent damage to the rope or the
individual wire which will affect the overall strength and performance of the rope. The
formation of kinks should always be prevented as this displaces the strands of wire
from their original position and relation to each other causing severe bending and
unequal tensions in the stands. This distortion and wire displacement cannot be
corrected, even under high tension, and a permanent weak spot remains in the rope.
Displaced or raised wires indicate a previous kink, but will not show the extent of the
damage to the inner rope wires.

Wire rope should never be pulled over a non-operating support such as a spindle bar,
a pin or a inoperative sheave. This practice cause severe abrasion to the other strand
wires. A properly operating sheave or snatch block is essential to safety and to the
long service life of the rope.

The use of worn sheaves with flat grooves should be avoided since they do not provide
sufficient support to prevent the distortion and flattening of the rope as it passes over
the sheave. Sheaves having nicked or broken flanges are likely to be cut or otherwise
damage the rope and should not be used.

An even distribution of wire rope coils over the hoist drum is essential to smooth operation
and to prevent rope from cutting down through or crushing other coils on the drum with
resultant damage to the rope and difficulty in unreeling rope.

Lubrication & Maintenance - 20

Lubrication &
Daily & Weekly
Maintenance
Planetary Winch Oil Level

To check or fill Winch Drum with oil, remove O-Ring fill plug. The oil must be level to this opening.
Refill gear box with EP 90 WT gear lubricant or equivalent.
To check or fill Rotation Gearbox with oil, remove Breather and Fill plug. The oil must be level to
this opening. Refill gear box with EP 90 WT gear lubricant. On HL 500 only, remove NPT fill plug and fill
to the top of the pipe. Grease Rotation Gearbox Bearing with 2-3 shots of EP2 every 2 weeks.

PLANETARY ROTATION GEARBOX OIL LEVEL

HL TC SERIES (PINION GEAR UP) HL500 (PINION GEAR DOWN)

Lubrication & Maintenance - 21

Lubrication Chart

Location Recommended Procedure Frequency

Lubricant
1. Hydraulic Oil Reservoir Hydraulic Oil Check & Fill Weekly
Change Semi-Annually
2. Oil Filter None Change or Clean After first 40 Hrs,
the Quarterly
3. Reservoir Breather None Clean Monthly
4. Magnetic Oil Plug None Clean Quarterly
5. Loadline - Wire Rope Open Gear Lube Brush or Spray Semi-Annually
6. Boom Pivot Pin Chassis Grease Grease Gun Monthly
7. Lift Cylinder Pins Chassis Grease Grease Gun Monthly
8. Rotation Gearbox Chassis Grease Grease Gun Every 2 Weeks
Upper Bearing
9. Rotation Bearing Chassis Grease Grease Gun Monthly
10. Pump Drive U-Joint Chassis Grease Grease Gun Monthly
11. Winch Drive EPGL for Std. Winch After 100 Operating Hrs
Refer to Winch Manual
for Oil Recommendation Check & Fill Weekly
on Winch Change Semi-Annually
12. Control Linkage SAE-10W Oil Can Monthly
13. Rotation Gearbox & Brake EPGL Change After 100 Operating Hrs
Check & Fill Weekly
Change Semi-Annually
14. Rotation Bearing Gear Teeth Open Gear Lube Grease Gun Monthly
15. Boom Extension Chassis Grease Brush or Roller Weekly
Sides Chassis Grease Brush or Roller Weekly
Bottom Never-Seez Brush or Roller Weekly
16. Outriggers Chassis Grease Grease Gun & Monthly
Brush or Roller
17. Wire Rope Cables & Boom Open Gear Lube Brush or Spray Anytime Boom is
Dissassembled
18. Sheave Pins Chassis Grease Grease Gun Weekly
Boom and Jib
19. Extension Cable Sheaves Chassis Grease Grease Gun Monthly
20. Pin Joints Penetrating Oil Spray Monthly
Lubrication & Maintenance - 22
Inspection
Log
Inspection
Log
Inspection Year: _____ Model: _______________ Serial Number: ________________

Truck Model: ______________________________ VIN: _________________________

Owner: ___________________________________ Unit Number:

A regular schedule of maintenance is important to keep your unit in proper operating

condition. Operators and service personnel responsible for the care of the unit must
be completely familiar with inspection requirements, maintenance procedures,
lubrication requirements and proper machine operation characteristics. Complete and
detailed information is outlined in your Owners/Operators Manual. If your manual is
missing, order a replacement from your dealer or Weldco Hydra-Lift product support.

This manual has been prepared to serve only as a guide to making the required
inspections and when performing maintenance on Weldco Hydra-Lift products. This
manual is not intended to replace any operational checks required by a Manufacturer's
Owners Manual or a local or provincial safety board.

Federal regulations require that written, dated, and signed inspection records be
maintained.

Unit Model ___________________________

Serial No. _____________________________

Customer Fleet No. ____________________

Revised July, 2001 Inspection Log - 1

Inspection
Log
Inspection Reference
Main.
Code Inspection Maintenance Code
1 Is item properly installed on machine.
2 Check for proper working order.
3 Check for proper service/level.
4 Check for proper reading while operating engine.
5 Check for excess dirt, grease, or foreign matter.
6 Check for proper operation while operating machine.
7 Check for proper adjustment.
8 Check for cracks or leaks.
9 Check for excessive wear.
10 Check torque.
11 Clean and replace.
12 Change oil filters.
13 Check for cracked or broken structures and welds.
14 Service as required by engine manufacturer.
15 Lubricate.
16 Check connectors and wiring for proper alignment and insulation.

Date of
Inspection or Completed Desciption of Problem, Service, Adjustment or Repairs Performed
Repair by

Inspection Log - 2 Revised July,2001

Inspection
Log
Daily Inspection Month: __________________

Maint. Code 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Engine oil level 3,14
Hydraulic oil level 3
Radiator coolant level 4
Loose parts 1,2,7
Damage to structures 8,13
Cracked welds 13
Lights and horn 6
Safety equipment 2,6,7,16
Gauges 4,6
Tires and suspension 3,8,9
Proper lubrication 15
Hose or gearbox leaks 5,8
Control operation 2,6,7
Truck park brake 2
Proper fasteners 1
Anti-two block system 2,6,16
Initials

Maint. Code 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Engine oil level 3,14
Hydraulic oil level 3
Radiator coolant level 4
Loose parts 1,2,7
Damage to structures 8,13
Cracked welds 13
Lights and horn 6
Safety equipment 2,6,7,16
Gauges 4,6
Tires and suspension 3,8,9
Proper lubrication 15
Hose or gearbox leaks 5,8
Control operation 2,6,7
Truck park brake 2
Proper fasteners 1
Safety covers 1
Initials

Completion Code:
•If the item is acceptable - use a check Repair or replace all
•If the item requires service - use an "S"
•If the item is not acceptable - use an "N" non-acceptable items before use.
Revised July, 2001 Inspection Log - 3
Inspection
Log
Inspection Reference
Main.
Code Inspection Maintenance Code
1 Is item properly installed on machine.
2 Check for proper working order.
3 Check for proper service/level.
4 Check for proper reading while operating engine.
5 Check for excess dirt, grease, or foreign matter.
6 Check for proper operation while operating machine.
7 Check for proper adjustment.
8 Check for cracks or leaks.
9 Check for excessive wear.
10 Check torque.
11 Clean and replace.
12 Change oil filters.
13 Check for cracked or broken structures and welds.
14 Service as required by engine manufacturer.
15 Lubricate.
16 Check connectors and wiring for proper alignment and insulation.

Date of
Inspection or Completed Desciption of Problem, Service, Adjustment or Repairs Performed
Repair by

Inspection Log - 4 Revised July,2001

Inspection
Log
Weekly & Monthly Inspection Month: _________________

Weekly Inspections
Maint. Code Week 1 Week 2 Week 3 Week 4 Week 5
Battery water level 3
Holding valve operation 2,4,6
Mounting bolt torque (during first month only) 10
Owners manual is with unit 1

Date:
Inititals:

Monthly Inspections
Maint. Code
Cylinders and valves 2,5,6,8
All structural members for damage 13
All welds for breaks and cracks 13
Completion Code:
All pins for proper installation 1,9,10,13
•If the item is acceptable - use a check
Control, safety & capacity placards 1,5 •If the item requires service - use an "S"
Boom wear pad bolt tightness 1,10 •If the item is not acceptable - use an "N"
All items under daily & weekly inspections
Repair or replace all
non-acceptable items before
use.

Comments:
Crane Hour Meter

Date: ____________________ Signature: ____________________________________________________________

Revised July, 2001 Inspection Log - 5

Inspection
Log
Inspection Reference
Main.
Code Inspection Maintenance Code
1 Is item properly installed on machine.
2 Check for proper working order.
3 Check for proper service/level.
4 Check for proper reading while operating engine.
5 Check for excess dirt, grease, or foreign matter.
6 Check for proper operation while operating machine.
7 Check for proper adjustment.
8 Check for cracks or leaks.
9 Check for excessive wear.
10 Check torque.
11 Clean and replace.
12 Change oil filters.
13 Check for cracked or broken structures and welds.
14 Service as required by engine manufacturer.
15 Lubricate.
16 Check connectors and wiring for proper alignment and insulation.

Date of
Inspection or Completed Desciption of Problem, Service, Adjustment or Repairs Performed
Repair by

Inspection Log - 6 Revised July,2001

Inspection
Log
Periodic Inspection Month: _________________

Maint. Code Comments:

All items listed under daily inspections
All items listed under weekly inspections
All items listed under monthly inspections
Bolts and fasteners in all areas 1,10
All pins, bearings, shafts, and gears for wear, cracks or distortion 2,5,8,9,13
this includes all pivot, outriggers and sheave pins & bearings
Hydraulic systems for proper operating pressure 7
Lift, outrigger and stabilizer cylinder drift 2,8
All cylinders for:
Damaged rods 2,6,8,9,13
Dented barrels 2,6,8,9,13
Drift from internal oil leaks 8
Leaks at seals, welds or holding valves 8
Hydraulic hose and tubing for damage or abrasion 8,9
All electrical wires and connections 16
Mainframe and stabilizer mounting bolt torque 10
Rotation bearing (turret) and gearbox mounting bolt torque 10

Other:
Stability test of unit - Yearly
Boom tear down and inspection - Every three years 2,5,6,7,9,
10,13,15,17

A periodic inspection is required every three months except for items listed in other.

Date: ____________________ Signature: ________________________________________________________

Completion Code:
•If the item is acceptable - use a check
•If the item requires service - use an "S"
•If the item is not acceptable - use an "N"

Repair or replace all

non-acceptable items before use.

Revised July, 2001 Inspection Log - 7

Inspection
Log
General Torque Data
The general purpose torque shown in the chart applies to lightly lubricated SAE Grade 8 fasteners,
medium carbon alloy steel Q & T.

SAE GRADE 8

Recommended
BOLT Torque Values
SIZE FT./LBS

1/4 - 20 UNC 10.5

5/16 - 18 UNC 22
3/8 - 16 UNC 37
7/16 - 14 UNC 60
1/2 - 13 UNC 92
9/16 - 12 UNC 132
5/8 - 11 UNC 180
3/4 - 10 UNC 296
7/8 - 9 UNC 473
1 - 8 UNC 714

THE FOLLOWING RULES APPLY TO THE CHART

1. Consult Hydra-Lift's specific recommendations when available. *

2. The chart may be used with both coarse and fine thread fasteners lightly lubricated.
3. Increase torque by 20% when multiple tapered tooth (shakeproof) lockwashers are used.
4. The torque values are given in foot-pounds.
5. Inch-pound equivalent may be obtained by multiplying by 12.
6. Kilogram-meter equivalent may be obtained by multiplying by 0.1383.
7. Newton-meter equivalent may be obtained by multiplying by 1.356.
8. Hardened washers should be used with Grade 8 or better bolts.

* Do not use above torque values for boom extention or retraction cable
adjustments. These cables all have Left Hand Threads and are only adjusted as per
specific instructions.

* Do not use above torque values for checking torque on anchor bolts used to
attach crane to chassis.

* See specific instructions for torquing sequences and values for installation of
slewing rings (Rotation Bearing)
Inspection Log - 8 Revised July,2001
Inspection
Log
HL 15TC/18TC/20TC Rotation Bearing Torque Data

Rotation Bearing Torquing Procedure

1. Ensure top and bottom of inner race and top of mainframe top plate and bottom of turret base
plate is clean and free of burrs.

2. Install Bearing with "load plug" of inner race in the position shown and "soft zone" (marked "G") on
outer race is in the position shown.

3. Tighten bolts to approximately 50 ft-lbs in sequence shown.

4. Re-torque all bolts to approximately 200 ft-lbs and finally to 300 ft-lbs.

5. Check bearing rotation, it should rotate freely by hand. No shimming is permitted.

6. Rotate eccentric ring until the following backlash clearance is achieved.

a) Pass a piece of paper (.003"-.004") through gear mesh. Paper should not be cut but should be
marked consistently across full gear width.
b) Pass a computer card (.007"-.009") through gear mesh. Card should be consistently cut across
full gear width.

Revised July, 2001 Inspection Log - 9

Inspection
Log
HL 25TC/30TC Rotation Bearing Torque Data

Bearing Installation/Torquing Procedure -

Bearing to Mainframe

1. Ensure mating surfaces are clean and free

of burrs.
2. Install Bearing with load plug in the po-
sition shown.
3. For turret installation, mark bearing "soft
zone" location on TOP side of outer race
(manufacturers mark: "S" or "G" on under-
side of outer race)
4. Tighten bolts to approximately 100 ft-lbs
in sequence shown.
5. Re-torque all bolts to approximately 400
ft-lbs and finally to 475 ft-lbs.
6. Check bearing rotation, it should rotate
freely by hand. No shimming is permit-
ted.
Inspection Log - 10 Revised July,2001
Inspection
Log
HL 25TC/30TC Rotation Bearing Torque Data

Eccentric Ring/Gearbox Installation

1. Apply Anti-Seize compound to areas shown.

2. Insert Eccentric Ring with thin side at the 10
o'clock or 2 o'clock position. Adjusment holes
must face up.
3. Install Gearbox. Tighten bolts (150 - 200 ft-lbs).
Use Locktite 242.
Check Gearbox oil level before running.

Backlash Adjustment

1. Rotate high spot of bearing (marked with paint in tooth space), to mesh with pinion.
2. Check backlash as follows:
a) Pass a piece of paper (.003"-.004") through gear mesh. Paper should not be cut but should be
marked consistently across full gear width.
b) Pass a card (.007"-.009") through gear mesh. Card should be consistently cut across full gear
width.
3. If adjustment is required, loosen gearbox mounting bolts and rotate eccentric ring. Tighten bolts
(150 - 200 ft-lbs) and check backlash.
4. When backlash is correct apply Locktite 242 to gearbox mounting bolts and torque to 150 ft-lbs.
Final torque to 200 ft-lbs.
5. Install and tighten Eccentric Ring Set Screw and Jam Nut. Apply Locktite 242.
6. Install Gearbox Push Bolts and Jam Nuts.Apply Locktite 242.

Bearing Installation/Torquing Procedure -

Turret to Bearing

1. Ensure mating surfaces are clean and free

of burrs.
2. Check Bearing "soft zone" (marked when
installing bearing to mainframe) on outer
race is positioned 90° to boom centreline.
3. Tighten bolts to approximately 100 ft-lbs
in sequence shown.
4. Re-torque all bolts to approximately 400
ft-lbs and finally to 475 ft-lbs.

Revised July, 2001 Inspection Log - 11

Inspection
Log
WHL 30TC Rotation Bearing Torque Data
SWING DRIVE
MOTOR/GEARBOX

GEARBOX MOUNTING BOLT

ECCENTRIC RING
GEARBOX PUSH BOLT
AND JAM NUT

BEARING/TURRET
MOUNTING BOLT

ROTATION BEARING

BEARING/MAINFRAME
MOUNTING BOLT

Bearing Installation/Torquing Procedure -

Bearing to Turret

1. Ensure mating surfaces are clean and free

of burrs.
2. Install Bearing with load plug in the po-
sition shown.
3. Note location of bearing "soft zone".
(manufacturers mark: "S" or "G" on outer
race)
4. Tighten bolts to approximately 100 ft-lbs
in sequence shown.
5. Re-torque all bolts to approximately 400
ft-lbs and finally to 475 ft-lbs.
6. Check bearing rotation, it should rotate
freely by hand. No shimming is permit-
ted.

Inspection Log - 12 Revised July,2001

Inspection
Log
WHL 30TC Rotation Bearing Torque Data

Eccentric Ring/Gearbox Installation

1. Apply Anti-Seize compound to areas shown.

2. Insert Eccentric Ring with thin side at the 10
o'clock or 2 o'clock position. Adjusment holes
must face down.
3. Install Gearbox. Tighten bolts (250-300 ft-lbs).
Use Locktite 242.
Check Gearbox oil level before running.

Backlash Adjustment

1. Rotate high spot of bearing (marked with paint in tooth space), to mesh with pinion.
2. Check backlash as follows:
a) Pass a piece of paper (.003"-.004") through gear mesh. Paper should not be cut but should be
marked consistently across full gear width.
b) Pass a card (.007"-.009") through gear mesh. Card should be consistently cut across full gear
width.
3. If adjustment is required, loosen gearbox mounting bolts and rotate eccentric ring. Tighten bolts
(250-300 ft-lbs) and check backlash.
4. When backlash is correct apply Locktite 242 to gearbox mounting bolts and torque to 250 ft-lbs.
Final torque to 300 ft-lbs.
5. Install Gearbox Push Bolts and Jam Nuts.Apply Locktite 242.

Bearing Installation/Torquing Procedure -

Turret to Mainframe

1. Ensure mating surfaces are clean and free

of burrs.
2. Position bearing "soft zone" at 90° to
Boom Centreline.
3. Tighten bolts to approximately 100 ft-lbs
in sequence shown.
4. Re-torque all bolts to approximately 400
ft-lbs and finally to 475 ft-lbs.

Revised July, 2001 Inspection Log - 13

Inspection
Log
HL 40TC Rotation Bearing Torque Data

Bearing to Subframe
Torquing Pattern

Turret to Bearing
Torquing Pattern

Inspection Log - 14 Revised July,2001

Inspection
Log
HL 40TC Rotation Bearing Torque Data

Rotation Bearing Torquing Procedure

1. Ensure top and bottom of inner race and top of subframe top plate and bottom
of turret base plate is clean and free of burrs.

2. Install Bearing with "load plug" of outer race in the position shown and "soft zone"
(marked "S") on inner race is in the position shown.

3. Tighten bolts to approximately 100 ft-lbs in sequence shown.

4. Re-torque all bolts to approximately 400 ft-lbs and finally to 714 ft-lbs.
5. Check bearing rotation, it should rotate freely by hand. No shimming is permitted.

6. Rotate high spot of bearing (as marked with paint in tooth space), to mesh with
pinion.

Revised July, 2001 Inspection Log - 15

Inspection
Log
Boom Extension & Retraction Cable Adjustment
CAUTION • All boom cables are equipped with Left Hand Threads
Make Sure all personnel are trained to know this before
any adjustments are attempted.
CAUTION • All boom cables are installed in pairs - any adjustments
must be done ""EQUALLY
EQUALLY
EQUALLY"" on each pair of Extension Ca-
bles or each pair of Retract Cables so that each cable is
adjusted to the same amount of tightness.

Procedure:
1. Fully retract the extension cylinder until relief pressure occurs.
2. Adjust the 3/8"Ø retract cables at bottom tip end of 2nd stage boom until stinger boom endplate
is gapped at only 1/2" from tip end of 2nd stage.
3. Adjust the 7/8"Ø extend cables until stinger boom begins to travel out, and increases the gap
from 1/2" to 3/4".
4. Check all cables for equal tightness.
5. Extend and retract all booms fully.
6. Retighten cables as per steps 2 & 3 if necessary.
7. Lock both pairs of cables in final adjustment with Left Hand Jam Nuts.

Mainframe Anchor Bolt Torques

CAUTION • Always lock anchor bolts final setting with jam nuts.
• Never weld jam nuts to anchor bolt - The anchor bolt
could fail due to welding and cause injury and or death.
30 Ton 1-1/8" anchor bolts ...................... 600 ft/lbs
25 Ton 1" anchor bolts .............................. 450 ft/lbs
18 Ton 1" anchor bolts .............................. 450 ft/lbs
15 Ton 1" anchor bolts .............................. 450 ft/lbs

Inspection Log - 16 Revised July,2001