USTC 2500 jbt User manual

TM
A Manitowoc Company
3120933 Rev . 0 PRINTED IN U.S.A. January 15, 2001
Sales: [phone] Sales: [phone]
Sales Fax: [phone] Sales Fax: [phone]
Service: [phone] Service: [phone]
Service Fax: [phone] Service Fax: [phone]
USTC, Inc.
76 Bowman Road 3000 S. Austin Ave
York, PA 17404-8793 Georgetown, TX 78627-1609
2500/2700JBT Cranes
Service Manual
Courtesy of Crane.Market

FORWARD
The purpose of this manual is to provide the customer with the operating procedures essential
for the promotion of safe and proper machine operation for its intended purpose. It is impor-
tant to over-stress proper usage. All information in this manual should be READ and UNDER-
STOOD before any attempt is made to operate the machine.
SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION
AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICE IN THIS AREA IS THE
RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.
ALL PROCEDURES HEREIN ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTER-
ATION AND/OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN WITHOUT
WRITTEN APPROVAL FROM USTC, INC.
REMEMBER, EQUIPMENT IS ONLY AS SAFE AS THOSE WHO OPERATE IT!
Since safety of personnel and proper use of the machine are of primary concern, statements
are used throughout this manual to emphasize certain areas. The following definitions indicate
how a statement will appear in this manual.
Whenever this symbol is seen in this manual or on the machine, personnel safety is a concern.
Take time to read and understand these statements!
DANGER: INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT
AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
WARNING: INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT
AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.
CAUTION: INDICATES A POTENTIALLY HAZARDOUS SITUATIONS WHICH, IF NOT
AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO
ALERT AGAINST UNSAFE PRACTICES.
IMPORTANT: Indicates a situation which may cause machine damage if not correctly followed.
Note: Provides information which may be of special interest.
Courtesy of Crane.Market

3120933 Rev.0 USTC i
TABLE OF CONTENTS
SECTION 1 – SPECIFICATIONS
General ............................................................................................................................................ 1-1
Hydraulic System Safety ................................................................................................................ 1-1
Maintenance.................................................................................................................................... 1-2
Component Data ............................................................................................................................. 1-3
Hoist ........................................................................................................................................ 1-3
Gear Reduction Hub ............................................................................................................... 1-3
Swing Brake ........................................................................................................................... 1-3
Swing Motor ........................................................................................................................... 1-3
Swing Bearing ......................................................................................................................... 1-3
Control Valve .......................................................................................................................... 1-3
Hoist Valve.............................................................................................................................. 1-3
Hydraulic Pump ...................................................................................................................... 1-3
Hydraulic Filter ....................................................................................................................... 1-3
Hydraulic Tank........................................................................................................................ 1-3
Boom Specifications........................................................................................................................ 1-3
Jibs (Optional) ......................................................................................................................... 1-4
Outriggers And Stabilizers .............................................................................................................. 1-4
A-Frame Outriggers ............................................................................................................... 1-4
Out-and-Down Stabilizers ....................................................................................................... 1-4
Cylinders ......................................................................................................................................... 1-4
Telescope ................................................................................................................................ 1-4
Lift .......................................................................................................................................... 1-4
A-Frame Outrigger ................................................................................................................. 1-4
Out-and-Down Stabilizer Extend ............................................................................................ 1-4
Out-and-Down Stabilizer Jack ................................................................................................ 1-4
Pressure Settings ............................................................................................................................ 1-4
Capacities ........................................................................................................................................ 1-4
Performance Data .......................................................................................................................... 1-5
Hoist Performance .................................................................................................................. 1-5
Functional Speed Specifications .............................................................................................. 1-5
Weights ........................................................................................................................................... 1-5
Courtesy of Crane.Market

ii USTC January 15, 2001
TABLE OF CONTENTS (Cont.)
SECTION 2 – LUBRICATION
Machine Inspection Requirements .................................................................................................. 2-1
Preparation For Use ........................................................................................................................ 2-1
Lubrication ...................................................................................................................................... 2-1
Operator's Daily Checklist .............................................................................................................. 2-3
Periodic Inspection .......................................................................................................................... 2-4
SECTION 3 – TROUBLESHOOTING
General ............................................................................................................................................ 3-1
Troubleshooting Information ............................................................................................................ 3-1
SECTION 4 – BOOM AND HOIST
General ............................................................................................................................................ 4-1
Cable Inspection Procedures .......................................................................................................... 4-1
Hoist Cable ..................................................................................................................................... 4-2
Installation and Attachment Procedure .................................................................................. 4-2
Break-In Procedure ................................................................................................................ 4-3
Cable Reeving ................................................................................................................................. 4-3
Single-Part Line Reeving ........................................................................................................ 4-4
Two-Part Line Reeving .......................................................................................................... 4-5
Three-Part Line Reeving ........................................................................................................ 4-5
Four-Part Line Reeving .......................................................................................................... 4-5
Five and Six-Part Line Reeving .............................................................................................. 4-6
Wear Pads ....................................................................................................................................... 4-7
Side Wear Pads ...................................................................................................................... 4-7
Extend/Retract Boom Cables ......................................................................................................... 4-7
Cable Inspection Procedures .................................................................................................. 4-7
Hoist Layback ................................................................................................................................. 4-7
Extend/Retract Cable Adjustment Procedure ........................................................................ 4-8
Extend/Retract Cable Replacement .......................................................................................4-10
Boom Assembly ..............................................................................................................................4-10
Boom Removal .......................................................................................................................4-10
Boom Installation .................................................................................................................... 4-10
Boom Disassembly ................................................................................................................. 4-10
Boom Inspection .....................................................................................................................4-13
Boom Assembly ......................................................................................................................4-14
Courtesy of Crane.Market

3120933 Rev.0 USTC iii
TABLE OF CONTENTS (Cont.)
Telescope Cylinder ..........................................................................................................................4-16
Removal .................................................................................................................................. 4-16
Installation ...............................................................................................................................4-17
Fly Section .......................................................................................................................................4-17
Removal .................................................................................................................................. 4-17
Fly Section Installation ............................................................................................................4-18
Two-Speed Hoist Operation ............................................................................................................ 4-18
SECTION 5 – SWING DRIVE
General ............................................................................................................................................ 5-1
Counterbalance Valve ..................................................................................................................... 5-1
Swing Motor.................................................................................................................................... 5-2
Swing Brake.................................................................................................................................... 5-2
Adjustment .............................................................................................................................. 5-2
Disassembly ............................................................................................................................ 5-2
Installation ............................................................................................................................... 5-3
Gear Reducer Hub .......................................................................................................................... 5-4
Hub Disassembly .................................................................................................................... 5-4
Cleaning And Inspection ......................................................................................................... 5-4
Carrier Disassembly ............................................................................................................... 5-5
Primary Carrier Assembly ...................................................................................................... 5-5
Secondary Carrier Assembly .................................................................................................. 5-6
Hub Assembly ........................................................................................................................ 5-6
Swing Bearing ................................................................................................................................. 5-7
Bolt Replacement, Torque Procedure ..................................................................................... 5-7
Swing Bearing Wear Tolerance .............................................................................................. 5-8
SECTION 6 – ELECTRICAL
General ............................................................................................................................................ 6-1
Anti-Two-Block System Operation ................................................................................................. 6-1
Electrical System ............................................................................................................................ 6-2
Overload System ............................................................................................................................. 6-2
Load Moment Indicator .................................................................................................................. 6-2
Courtesy of Crane.Market

iv USTC January 15, 2001
TABLE OF CONTENTS (Cont.)
SECTION 7 – HYDRAULICS
Hydraulic System Safety ................................................................................................................ 7-1
Drift Test ......................................................................................................................................... 7-1
Telescope Cylinder.................................................................................................................. 7-1
Lift Cylinder ............................................................................................................................ 7-2
Pressure Testing .............................................................................................................................. 7-2
Main Relief Valve ................................................................................................................... 7-2
Telescope In Relief Valve ....................................................................................................... 7-3
Swing Inlet Relief Valve ......................................................................................................... 7-4
Hoist Relief Valve ................................................................................................................... 7-4
Burst-of-Speed and Telescope Out Relief Valve .................................................................... 7-5
Cylinders ......................................................................................................................................... 7-6
Holding Valves ........................................................................................................................ 7-6
Dissasembly ............................................................................................................................ 7-6
Cleaning and Inspection .......................................................................................................... 7-7
Assembly ................................................................................................................................ 7-8
Control Valve ..........................................................................................................................7-10
Hoist Valve.............................................................................................................................. 7-11
Manifold Valve ........................................................................................................................7-12
Hydraulic Filter .......................................................................................................................7-13
Courtesy of Crane.Market

3120933 Rev.0 USTC v
FIGURE LIST
2-1 Lubrication Points ....................................................................................................................... 2-2
4-1 Wire Rope Components ................................................................................................................ 4-1
4-2 Measuring Wire Rope .................................................................................................................. 4-2
4-3 Hoist Cable Spooling .................................................................................................................. 4-2
4-4 Cable Socket and Wedge Installation ......................................................................................... 4-3
4-5 Cable Reeving ............................................................................................................................. 4-4
4-6 Snatch Block ................................................................................................................................ 4-6
4-7 Hoist Layback .............................................................................................................................. 4-8
4-8 Internal Boom Cable Reeving ..................................................................................................... 4-9
4-9 Boom Removal ............................................................................................................................ 4-11
4-10 Inner-Mid, Outer-Mid and Fly Sections ..................................................................................... 4-13
4-11 Telescope Cylinder ..................................................................................................................... 4-16
5-1 Swing Drive Components ............................................................................................................ 5-1
5-2 Swing Motor Assembly ................................................................................................................ 5-2
5-3 Swing Brake Assembly ................................................................................................................. 5-3
5-4 Gear Reducer Hub Assembly ....................................................................................................... 5-5
5-5 Bearing Bolt Tightening Sequences ............................................................................................5-8
5-6 Swing Bearing Clearance Measurement .................................................................................... 5-9
5-7 Bearing Tolerance Check ............................................................................................................ 5-9
6-1 Anti-Two-Block Positions ............................................................................................................ 6-1
6-2 Electrical Schematic .................................................................................................................... 6-3
6-3 Electrical Power Distribution Diagram ...................................................................................... 6-4
6-4 Electrical Box Schematic ............................................................................................................ 6-5
6-5 Outrigger/Stabilizer Schematic .................................................................................................. 6-6
6-6 Overload Electrical Schematic ................................................................................................... 6-7
6-7 Outrigger/Stabilizer Wiring ........................................................................................................ 6-8
6-8 Outrigger/Stabilizer Switch Wiring ............................................................................................ 6-9
6-9 A2B with Slow-Down Circuit for Platform Installation WIring ................................................. 6-10
6-10 Radio Remote Control ................................................................................................................ 6-12
6-11 Clam Shell .................................................................................................................................. 6-13
7-1 Main Control Valve Pressure Relief Test Locations .................................................................... 7-3
7-2 Hoist Valve Relief Cartridges ...................................................................................................... 7-4
7-3 In-Line Relief Valve ...................................................................................................................... 7-5
7-4 Manifold Block Valve .................................................................................................................. 7-5
7-5 Typical Cylinder .......................................................................................................................... 7-7
7-6 Control Linkage Linkage ............................................................................................................ 7-9
7-7 Control Valve .............................................................................................................................. 7-10
7-8 Control Valve Section ................................................................................................................ 7-11
Courtesy of Crane.Market

vi USTC January 15, 2001
TABLE LIST
1-1 Torque Chart ................................................................................................................................ 1-6
2-1 Lubrication Points and Intervals ................................................................................................ 2-2
3-1 Boom Assembly ............................................................................................................................ 3-2
3-2 Pedestal ....................................................................................................................................... 3-3
3-3 Chassis Components .................................................................................................................... 3-4
3-4 Hydraulic Components ................................................................................................................ 3-5
3-5 Electrical System ........................................................................................................................ 3-12
7-1 Pressure Settings ......................................................................................................................... 7-2
7-9 Hoist Control Valve .................................................................................................................... 7-11
7-10 Manifold Valve ............................................................................................................................ 7-12
7-11 Hydraulic Filter .......................................................................................................................... 7-13
7-12 Hydraulic Schematic .................................................................................................................. 7-14
7-13 Outrigger Schematic ................................................................................................................... 7-15
7-14 Two-Speed Hoist ......................................................................................................................... 7-16
7-15 Overload ..................................................................................................................................... 7-17
7-16 Out-and-Down Stabilizers with Center Stabilizer ..................................................................... 7-18
7-17 Front Center Stabilizer .............................................................................................................. 7-19
7-18 Clam Shell Circuit ...................................................................................................................... 7-20
7-19 Emergency Down ........................................................................................................................ 7-21
7-20 Hydraulic Schematic with Continuous Rotation ....................................................................... 7-22
7-21 Hydraulic Schematic with Continuous Rotation ....................................................................... 7-23
FIGURE LIST (Continued)
Courtesy of Crane.Market

SECTION 1 – SPECIFICATIONS
3120933 Rev. 0 USTC 1-1
GENERAL
This section contains the general safety precautions
which must be observed during maintenance of the
crane It is of utmost importance that maintenance
personnel pay strict attention to these warnings and
precautions to avoid possible injury to themselves or
others or damage to the equipment. A maintenance
program must be established by a qualified person
and must be followed to ensure that the machine is
safe to operate.
WARNING: MODIFICATION OF MACHINE
WITHOUT CERTIFICATION BY A
RESPONSIBLE AUTHORITY THAT THE
MACHINE IS AT LEAST AS SAFE AS
ORIGINALLY MANUFACTURED IS A SAFETY
VIOLATION.
The specific precautions to be observed during ma-
chine maintenance are inserted at the appropriate
point in the manual. These precautions are those that
apply when servicing hydraulic and larger machine
component parts.
The safety of the maintenance and operating person-
nel must be the first consideration when engaging in
the maintenance of equipment.
Always be conscious of weight. Never attempt to
move heavy parts without the aid of a mechanical
device. Do not allow heavy objects to rest in an
unstable position. When raising a portion of the
equipment, ensure that adequate support is provided.
WARNING: SINCE MACHINE
MANUFACTURER HAS NO DIRECT
CONTROL OVER FIELD INSPECTION AND
MAINTENANCE, SAFETY IN THIS AREA IS
THE RESPONSIBILITY OF THE OWNER/
OPERATOR.
HYDRAULIC SYSTEM SAFETY
It should be particularly noted that the machine’s
hydraulic systems operate at extremely high and
potentially dangerous pressures. Every effort should
be made to relieve any system pressure prior to dis-
connecting or removing any portion of the system.
Relieve system pressure by moving the boom control
levers several times with the engine stopped and
ignition on to direct any line pressure back into the
return line and to the reservoir. Pressure feed lines to
system components can then be disconnected with
minimal fluid loss.
Courtesy of Crane.Market

SECTION 1 – SPECIFICATIONS
1-2 USTC January 15, 2001
MAINTENANCE
WARNING: FAILURE TO COMPLY WITH
SAFETY PRECAUTIONS LISTED IN THIS
SECTION MAY RESULT IN MACHINE
DAMAGE, PERSONNEL INJURY OR DEATH
AND IS A SAFETY VIOLATION.
RNO SMOKING IS MANDATORY. NEVER
REFUEL DURING ELECTRICAL STORMS.
ENSURE THAT FUEL CAP IS CLOSED
AND SECURE AT ALL OTHER TIMES.
RREMOVE ALL RINGS, WATCHES AND
JEWELRY WHEN PERFORMING ANY
MAINTENANCE.
RDO NOT WEAR LONG HAIR UNRE-
STRAINED OR LOOSE FITTING CLOTH-
ING AND NECKTIES WHICH ARE APT TO
BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
ROBSERVE AND OBEY ALL WARNINGS
AND CAUTIONS ON MACHINE AND IN
SERVICE MANUAL.
RKEEP OIL, GREASE, WATER, ETC., OFF
STANDING SURFACES AND HAND
HOLDS.
RUSE CAUTION WHEN CHECKING A HOT,
PRESSURIZED COOLANT SYSTEM.
RNEVER WORK UNDER AN ELEVATED
BOOM UNTIL BOOM HAS BEEN SAFELY
RESTRAINED FROM ANY MOVEMENT
BY BLOCKING OR OVERHEAD SLING.
RBEFORE MAKING ADJUSTMENTS, LU-
BRICATING OR PERFORMING ANY
OTHER MAINTENANCE, SHUT OFF THE
ENGINE.
RBATTERY SHOULD ALWAYS BE DISCON-
NECTED DURING REPLACEMENT OF
ELECTRICAL COMPONENTS.
RKEEP ALL SUPPORT EQUIPMENT AND
ATTACHMENTS STOWED IN THEIR
PROPER PLACE.
RUSE ONLY APPROVED, NONFLAM-
MABLE CLEANING SOLVENTS.
Courtesy of Crane.Market

SECTION 1 – SPECIFICATIONS
3120933 Rev. 0 USTC 1-3
COMPONENT DATA
Hoist
Manufacturer ................................................. Braden
Model ............................................................ PD12C
Type ................................. Hydraulic Drive Planetary
Drum Diameter .......................... 9.75 in. (247.6 mm)
Drum Length ........................... 13.57 in. (344.7 mm)
Flange Diameter...................... 16.38 in. (416.1 mm)
Brake ............................................ Integral Multi-Disc
Maximum Rope Capacity ............... 400 ft. (121.9 m)
Rope Diameter ............................ 9/16 in. (14.3 mm)
Gear Reduction Hub
Manufacturer ............................................... Eskridge
Type ............................. Double Reduction Planetary
Ratio ................................................................... 36:1
Number of Teeth ................................................... 16
Pitch Diameter ................................. 4 in. (101.6 mm
Outside Diameter ............................ 4.40 (111.8 mm)
Swing Brake
Manufacturer ............................................... Eskridge
Type ................... Spring Applied; Hydraulic Release
Release Pressure ........................ 170 psi (11.73 bar)
Holding Torque ......................... 2400 lb-in. (271 Nm)
Swing Motor
Manufacturer ................................................... White
Type .................................................................. Gear
Displacement ................................ 6.0 in3(98.3 cm3)
Maximum Pressure ................... 1750 psi (120.8 bar)
Maximum Flow ......................... 13 gpm (49.2 L/min)
Swing Bearing
Manufacturer ...................................................... PSL
Type ............................................ Internal Tooth, Ball
Ball Bearing Circle .................. 29.96 in. (761.0 mm)
Ball Diameter ................................. 1.37 in. (35 mm)
Bolt Torque 472 lb-ft. (640 Nm) w/Loc-Wel Patch Dry
Control Valve
Manufacturer .......................... Commercial Intertech
Type .................................... Dual Inlet, Open-Center
Sections .................................................................. 7
Hoist Valve
Manufacturer .......................... Commercial Intertech
Type ..................................................... Open-Center
Sections .................................................................. 1
Hydraulic Pump
Manufacturer .......................... Commercial Intertech
Type ..................................................3-Section Gear
Rated Pump Speed .................................... 2400 rpm
1st Section Flow ........................ 39 gpm (148 L/min)
2nd Section Flow ......................... 24 gpm (91 L/min)
3rd Section Flow ........................... 8 gpm (30 L/min)
Hydraulic Filter
Type ..................................................... Inline Return
Filtration ...................................... 10 Micron Nominal
Flow Rating ............................... 60 gpm (227 L/min)
Hydraulic Tank
Manufacturer ................................................... USTC
Type .............................. All Steel with Lockable Cap
Capacity .............................................. 90 gal (341 L)
BOOM SPECIFICATIONS
Manufacturer ...................... Manitowoc Boom Trucks
Type ..................... 4-Section Proportional Telescope
Retracted Length ................................ 29 ft. (8.84 m)
Extended Length .............................. 94 ft. (28.65 m)
Boom Elevation .......................................... -8° to 80°
Extend Cable Type .................................. 5/8 in. RRL
Outer-Mid Length .......................... 609 in. (15.47 m)
Fly Length ..................................... 626 in. (15.90 m)
Retract Cable Type ............................................RRL
Outer-Mid Retract ......... 5/16 in. dia. 345 in. (8.76 m)
Fly Retract ...................... 3/8 in. dia. 349 in. (8.86 m)
Courtesy of Crane.Market

SECTION 1 – SPECIFICATIONS
1-4 USTC January 15, 2001
Jibs (Optional)
Non-Extendable Length ...................... 26 ft. (7.92 m)
Extendable Length .............. 26-46 ft. (7.92-14.02 m)
OUTRIGGERS AND STABILIZERS
A-Frame Outriggers
Extended Width (Pin to Pin) ... 258.00 in. (6553 mm)
Overall Stowed Width ................ 95.6 in. (2228 mm)
Extension per side ...................... 90.0 in. (2286 mm)
Pad Dimensions ... 17.63 x 11.50 in. (447 x 292 mm)
Below Ground Penetration ........... 8.00 in. (203 mm)
Out-and-Down Stabilizers
Extended Width (Jack Centerline) 164.8 in. (4.23 m)
Overall Stowed Width ................... 96 in. (2438 mm)
Extension per side ........................ 38 in. (965.2 mm)
Pad Diameter .................................. 14 in. (356 mm)
Below Ground Penetration ......... 12.31 in. (320 mm)
CYLINDERS
Telescope
Bore .............................................. 6.00 in. (152 mm)
Stroke ..................................... 261.00 in. (6629 mm)
Rod Diameter ............................... 4.97 in. (126 mm)
Nut Torque .................................................. Weld-On
Lift
Bore .............................................. 8.00 in. (203 mm)
Stroke ....................................... 58.44 in. (1484 mm)
Rod Diameter ............................... 4.00 in. (102 mm)
Nut Torque .............1900-2400 lb-ft. (2576-3254 Nm)
A-Frame Outrigger
Bore .............................................. 4.00 in. (102 mm)
Stroke ....................................... 56.13 in. (1426 mm)
Rod Diameter ................................. 2.75 in. (70 mm)
Nut Torque ............. 1125-1375 lb-ft. (1525-1864 Nm)
Out-and-Down Stabilizer Extend
Bore ................................................ 2.00 in. (51 mm)
Stroke ....................................... 76.00 in. (1930 mm)
Rod Diameter ................................. 1.25 in. (32 mm)
Nut Torque .......................................50 lb-ft. (68 Nm)
Out-and-Down Stabilizer Jack
Bore .............................................. 5.00 in. (127 mm)
Stroke ......................................... 22.25 in. (565 mm)
Rod Diameter ................................. 3.50 in. (89 mm)
Nut Torque .............1600-2000 lb-ft. (2169-2712 Nm)
PRESSURE SETTINGS
Main Relief+............................... 3500 psi (241.3 bar)
Lift Up ........................................ 3500 psi (241.3 bar)
Lift Down ................................... 3500 psi (241.3 bar)
Telescope In+............................. 2500 psi (172.3 bar)
Telescope Out+.......................... 3300 psi (227.5 bar)
Outriggers ................................. 3500 psi (241.3 bar)
Stabilizers.................................. 3500 psi (241.3 bar)
Swing+....................................... 2100 psi (144.8 bar)
Hoist+......................................... 3200 psi (220.6 bar)
Burst-of-Speed+......................... 2000 psi (137.9 bar)
+ Adjustable Relief Valve
CAPACITIES
Hydraulic Tank ..................................... 90 gal (340 L)
Hoist (94 ft. Boom) ............................. 3.5 qt. (3.3 L)
Gear Reducer Hub ............................ 1.25 qt. (1.2 L)
Courtesy of Crane.Market

SECTION 1 – SPECIFICATIONS
3120933 Rev. 0 USTC 1-5
PERFORMANCE DATA
Hoist Performance
IMPORTANT: Line pull ratings are based on hoist
capabilities. Refer to Hoist Specification Decal on
machine to determine permissible line pull of wire
rope.
CAUTION: MINIMUM OF 5 WRAPS TO
REMAIN ON DRUM AT ALL TIMES.
IMPORTANT: Non-swivel hookblock must be used
with low rotation wire rope.
Functional Speed Specifications
LIFT UPLIFT UP
LIFT UPLIFT UP
LIFT UP – Lowest to Maximum Elevation _____sec.
Minimum: 30 sec.
Maximum: 40 sec.
LIFT DOLIFT DO
LIFT DOLIFT DO
LIFT DOWNWN
WNWN
WN – Maximum to Minimum Elevation ____ sec.
Minimum: 25 sec.
Maximum: 35 sec.
TELESCOPE OUTTELESCOPE OUT
TELESCOPE OUTTELESCOPE OUT
TELESCOPE OUT –Retracted to Fully Extended __ sec.
Minimum: 70 sec.
Maximum: 95 sec.
TELESCOPE INTELESCOPE IN
TELESCOPE INTELESCOPE IN
TELESCOPE IN – Extended to Fully Retracted __ sec.
Minimum: 70 sec.
Maximum: 100 sec.
SWING LEFT 360°SWING LEFT 360°
SWING LEFT 360°SWING LEFT 360°
SWING LEFT 360° – Boom 60°Elevation ______ sec.
Minimum: 40 sec.
Maximum: 50 sec.
SWING RIGHT 360°SWING RIGHT 360°
SWING RIGHT 360°SWING RIGHT 360°
SWING RIGHT 360° – Boom 60°Elevation ______ sec.
Minimum: 40 sec.
Maximum: 50 sec.
HOIST UPHOIST UP
HOIST UPHOIST UP
HOIST UP – Boom 60°Elevation ______ sec.
Minimum: 30 sec.
Maximum: 45 sec.
HOIST DOHOIST DO
HOIST DOHOIST DO
HOIST DOWNWN
WNWN
WN – Boom 60°Elevation ______ sec.
Minimum: 30 sec.
Maximum: 45 sec.
WEIGHTS
94 ft. Boom ................................. 9500 lbs. (4309 kg)
Hoist ............................................... 470 lbs. (213 kg)
Lift Cylinder .................................... 804 lbs. (365 kg)
Pedestal ....................................... 1925 lbs. (873 kg)
Turntable Assembly ...................... 1300 lbs. (590 kg)
26 ft. Jib ......................................... 975 lbs. (442 kg)
26-46 ft. Jib .................................. 1500 lbs. (680 kg)
Courtesy of Crane.Market

SECTION 1 – SPECIFICATIONS
1-6 USTC January 15, 2001
Table 1-1. Torque Chart
TORQUE
DRY OR
LOCTITE
263
(LBf-IN)
TORQUE
LOCTITE
262
(LBf-IN)
TORQUE
LUB
(LBf-IN)
TORQUE
LOCTITE
242
OR 271
(LBf-IN)
(LBf-FT) (LBf-FT) (LBf-FT) (LBf-FT) (LBf-FT) (LBf-FT) (LBf-FT) (LBf-FT)
VALUES FOR ZINC PLATED FASTENERS ONLY
Note: These torque values do not apply to cadmium plated fasteners.
TPI
SAE GRADE 5 BOLTS & GRADE 2 NUTS SAE GRADE 8 BOLTS & GRADE 8 NUTS,
& SOCKET HEAD CAP SCREWS
SIZE
4
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
40
48
32
40
32
36
24
32
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
380
420
580
610
900
940
1120
1285
2020
2320
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
8
9
16
18
30
31
43
49
96
120
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200
(LBf-FT)
6
7
12
13
22
23
32
36
75
86
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640
135
105
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300
540
600
820
920
1260
1320
1580
1800
2860
3280
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
12
13
23
25
41
43
60
68
144
168
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
1280
1440
1820
2000
2380
2720
3160
3560
160
185
9
10
17
19
31
32
45
51
108
120
18
20
35
35
55
60
80
90
110
130
170
180
280
320
460
500
680
740
960
1080
1360
1500
1780
2040
2360
2660
30
30
50
55
80
90
120
135
165
190
240
265
420
465
660
725
990
1100
1400
1575
2000
2200
2625
3000
3475
3925
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974
22
25
40
45
63
70
96
108
139
154
180
204
301
336
485
534
687
796
1030
1155
1453
1610
1907
2165
2530
2844
BOLT DIA
(IN)
TENSILE
STRESS
AREA
(IN†)
CLAMP
LOAD
(LB)
TORQUE
DRY OR
LOCTITE
263
(LBf-IN)
TORQUE
LOCTITE
242
OR 271
(LBf-IN)
CLAMP
LOAD
(LB)
TORQUE
LOCTITE
262
(LBf-IN)
TORQUE
LUBE
(LBf-IN)
Courtesy of Crane.Market

SECTION 1 – SPECIFICATIONS
3120933 Rev. 0 USTC 1-7
CLAMP
LOAD
(LB)
TORQUE
AS RECEIVED
w/ LOC-WEL
PATCH
(LB
f
-FT)
14
15
28
30
50
55
77
82
120
127
170
182
231
242
400
440
645
700
950
1000
1365
1520
1925
2070
2550
2685
3345
3600
22
25
40
45
63
66
96
105
145
150
170
190
290
320
480
510
660
730
1000
1110
1400
1510
1860
1940
2430
2610
21
24
38
43
61
66
93
178
203
317
354
512
563
775
839
1065
1203
1535
1689
2011
2295
2672
2995
25
32
50
55
81
91
124
105 140
236
270
423
472
682
751
1022
1118
1448
1531
2047
2265
2681
3060
3562
3994
SOCKET HEAD SCREWS
Note: These torque values do not apply to cadmium plated fasteners.
TPI
SIZE
4
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
40
48
32
40
32
36
24
32
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
3180
3640
5240
5800
7750
8780
10630
11870
14190
15990
18200
20300
22600
25600
33400
37300
46200
50900
60600
66300
76300
85600
96900
107300
115500
131500
140500
158000
13
14
25
27
45
50
70
75
110
115
155
165
210
220
365
400
585
635
865
915
1240
1380
1750
1880
2320
2440
3040
3270
BOLT DIA
(IN)
TENSILE
STRESS
AREA
(IN†)
TORQUE
AS RECEIVED
w/o LOC-WEL
PATCH
(LB
f
-FT)
TORQUE
LOCTITE
262
(LB
f
-IN)
UNBRAKO 1960 SERIES
SOCKET HEAD
TORQUE
LUBRICATED
w/ LOC-WEL
PATCH
(LB
f
-FT)
TORQUE
DRY
w/ LOC-WEL
PATCH
(LB
f
-FT)
KERR-LAKESIDE
SOCKET HEAD
Courtesy of Crane.Market

SECTION 1 – SPECIFICATIONS
1-8 USTC January 15, 2001
Courtesy of Crane.Market

SECTION 2 – INSPECTION
3120933 Rev. 0 USTC 2-1
MACHINE INSPECTION REQUIREMENTS
It should be noted that Occupational Safety and Health
Administration (OSHA) regulations state that all cranes
of the type covered by this manual be inspected and
maintained on a regular, daily basis in accordance with
recommendations made by the equipment manufacturer.
In addition, a thorough annual inspection must be per-
formed and a complete record of the inspection dates and
results be maintained. These legal requirements are from
OSHA Regulations 29CFR Parts 1910.180 and 1926.550.
They are also specified in American National Standards
Institute (ANSI) standard B30.5-1994 - Safety Code For
Cranes, Derricks, Hoists, Jacks and Slings.
USTC, Inc. recommends that inspection procedures
outlined in this and other manuals pertaining to this unit
be followed and that a written record be maintained and
available for review by Department of Labor personnel
should the need arise. Further requirements are depen-
dent upon state and local ordinances which govern the
particular area in which the equipment operates.
WARNING: DO NOT MODIFY IN ANY WAY
OR USE UNAUTHORIZED PARTS ON THE
MACHINE WITHOUT THE EXPRESS WRITTEN
CONSENT OF USTC, INC.
PREPARATION FOR USE
To ensure that the equipment is ready for operation at all
times, it should be inspected systematically so that de-
fects may be discovered and corrected before any result in
serious damage or failure. Defects discovered during
operation should be noted for future correction to be
made as soon as operation has ceased. Stop operation
immediately when a deficiency is noted which would
damage equipment if operation were continued.
All visual inspections necessary to keep the unit in a state
of operational readiness is the responsibility of manage-
ment personnel. Most requirements are relatively simple,
involving common sense coupled with a series of visual
inspection guidelines.
WARNING: SINCE THE MACHINE
MANUFACTURER HAS NO CONTROL OVER THE
FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA IS THE RESPONSIBILITY
OF THE OWNER/OPERATOR.
LUBRICATION
The lubrication points to be covered periodically are
illustrated and defined in Figure 2-1.
USTC, Inc. recommends using high quality hydraulic oil,
such as AW68. If operating in cold climates, AW46 may
be substituted.
Courtesy of Crane.Market

SECTION 2 – INSPECTION
2-2 USTC January 15, 2001
Figure 2-1. Lubrication Points
2
1
18
3
4
6
57
12
9
13
11
10
15 15
17 16
8
14
DESCRIPTION NOTES
1 Hook Bearing MPG 50 1
2 Hookblock Sheave MPG 50 1
3 Lower Boom Nose Sheaves MPG 50 1
4 Upper Boom Nose Sheave MPG 50 1
5 Fly Extend Cable Sheave MPG 50 1 Align holes in mid and fly.
6 Boom Assembly MPG 500 Extend boom. Brush on wear pad travel
area.
7 Fly Cable Retract Sheave MPG 50 2 Align access hole in base boom.
8 Boom Pivot Bushing MPG 50 2
9 Hoist Oil Level –Check w/ boom at 0°by using the Note A 100/1000 Change oil after first 100 hours and every
large oil level plug located in center of support. 1000 hrs. thereafter.
10 Upper Lift Cylinder Pin MPG 50 1
11 Lower Lift Cylinder Pin MPG 50 1
12 Swing Bearing MPG 50 2 Apply MPG, rotate turntable 90°and
Pinion and Swing Bearing Teeth 500 return, reapply MPG and rotate 90°in
opposite direction.
13 Swing Gear Box EPGL 250/1000 Change oil after first 250 hrs. and
every 1000 hrs. thereafter. Oil level to
be 1 1/2" from top of hub.
14 Jib Sheave (Optional) MPG 50
15 Outrigger/Stabilizer Wear Pads MPG 500 Extend beam. Brush on wear pad travel area.
16 Hydraulic Oil Reservoir HO 10/2000 Check level every 10 hrs. Change oil annually.
17 Hydraulic Oil Filter 50/250 Change filters after first 50 hrs. and
every 250 hrs thereafter.
18 Hoist Wire Rope PL 100 Brush on.
NS Platform Pivot (Optional) MPG 200 2
NS Platform Door Hinges MPG 200 2
NS LMI Dynamometer (If Equipped) MPG 50 2
NS Not Shown
A Use Texaco®Meropa 150 or Equivalent
INDEX NO.
FITTINGS
HOURS
LUBRICANT
TABLE 2-1. Lubrication Points and Intervals
Courtesy of Crane.Market

SECTION 2 – INSPECTION
3120933 Rev. 0 USTC 2-3
OPERATOR'S DAILY CHECKLIST
This paragraph provides a listing of those inspection
procedures which must be performed before placing the
unit in operation each day. Careful attention should be
paid during actual operation of the unit to observe any
conditions which might occur between regular inspec-
tions that could possibly be a safety hazard.
Proper inspection of the crane is also of extreme impor-
tance and reference must be made to the appropriate
vehicle components.
WARNING: DO NOT OPERATE MACHINE
UNTIL CORRECTIVE MEASURES HAVE BEEN
TAKEN AND ALL MALFUNCTIONS HAVE BEEN
CORRECTED.
1. Visually inspect machine for loose or missing parts,
foreign objects, hydraulic leaks from lines or
components and structural damage.
2. Ensure that tires are inflated to the proper pressure.
Refer to tire sidewall or contact tire manufacturer
for proper tire inflation pressure.
3. With all systems shut down and machine in stowed
or travel position, check oil level in hydraulic fluid
reservoir. If necessary, fill to FULL mark on tank
sight gauge.
Note: On new or recently overhauled machines or after
changing hydraulic oil, operate all systems a minimum
of two complete cycles and recheck oil in reservoir.
CAUTION: NEVER HANDLE CABLES OR
WIRE ROPE WITH BARE HANDS. BROKEN OR
FRAYED STRANDS CAN CAUSE SEVERE CUTS.
ALWAYS WEAR PROTECTIVE GLOVES IF IT IS
NECESSARY TO HANDLE CABLE OR WIRE
ROPE.
4. Inspect cable for defects as follows:
a. Corrosion.
b. More than one broken wire in any one strand.
c. More than one broken wire near an attach
fitting.
d. Excessive wear or broken wires in cable sections
under sheaves where cable travel is limited.
e. Evidence of noticeable reduction in original
cable diameter after allowance for normal stretch
and diameter reductions of newly rigged cable.
f. Excessive abrasion, scrubbing and peeling of
outer wires, pitting, deformation, kinking, bird
caging or other damage resulting in physical
changes to the cable structure.
g. Cracked, bent, worn or improperly installed
wedge socket.
5. Inspect hook for security of attachment, proper
swivel lubrication and for nicks, cracks, gouges,
deformation or evidence of any other damage.
Check for proper operation of hook safety latch.
6. Inspect the hookblock for security of attachments,
proper lubrication and for nicks, cracks, gouges,
deformation or evidence of any other damage.
7. Check wedge socket for proper size and proper
cable installation.
8. Ensure all components requiring lubrication are
serviced as necessary (i.e., wear pads, wire rope,
sheaves, etc.).
9. Ensure that all control placards are located adjacent
to the corresponding control device, and safety,
warning and instruction placards are securely
attached and legible.
10. Inspect steps, handholds, deck, operator platform
and controls to ensure they are free of oil, grease,
mud, water, debris and foreign objects (tools,
material, rags, etc.). Check entire machine for
debris which may interfere with operation.
11. Using all applicable safety precautions start engine
and, with PTO engaged, check indicator on top of
hydraulic filter mounted adjacent to oil tank for
condition of element. Change element as required.
12. With the unit operating and before starting actual
job site applications, inspect the following;
a. Smooth and proper operation of all crane and
outrigger functions. Check that Outrigger-in-
Motion Alarm system is working properly.
b. Check that boom and jib cable sheaves rotate
freely and ensure that they are in good condition.
c. Inspect all control levers, switches and accelera-
tor pedal for proper installation and operation.
d. Check for proper operation of all lights and
reflectors.
Courtesy of Crane.Market

SECTION 2 – INSPECTION
2-4 USTC January 15, 2001
e. Check anti-two-block device for proper operation.
The hookblock must stop when it contacts the
anti-two-block counterweight while winching up
or telescoping out. Telescope out, hoist up and
boom down must not function when in an anti-
two-block condition.
f. Check anti-two-block device for proper operation.
The load handling device must stop when it
contacts the anti-two-block counterweight while
hoisting up or telescoping out.
g. If equipped with Overload Audio/Visual Warning
or Overload Cut-off, test the system by activating
the toggle switch labeled “Capacity Alert Test
Switch”located on the console. When the test
switch is activated, the warning light must flash,
the warning horn sound and the following crane
controls must be disabled: Hoist Up, Telescope
Out, Boom Up, and Boom Down.
Next, lift and hold the “Override Switch for Lift Up
Only” and attempt to lift the boom from its current
position. If the boom elevates, the system is
working properly.
WARNING DAMAGE TO EQUIPMENT OR
PERSONNEL MAY OCCUR IF THE FOLLOWING IS
NOT ADHERED TO.
Note: The overload warning, overload cut-off and the
LMI systems are an operational aid only and shall not be
a substitute for good operator judgement, experience,
and use of safe crane operating procedures. The
responsibility for the safe crane operation shall remain
with the crane operator who shall ensure that all
warnings and instructions supplied are fully understood
and observed.
h. If equipped with an LMI, refer to the manufactur-
ers operation manual for daily and pre-operational
checks to be performed. The manual is supplied
with the crane and should be kept with the crane
at all times.
PERIODIC INSPECTION
Note: This machine requires annual inspections by an
authorized dealer. A decal, located on the turntable
behind the cab affords a place to record (stamp)
inspection dates. Notify dealer if inspection is overdue.
The crane must be thoroughly inspected periodically so as
to detect in a timely manner the possibility of damaged or
improperly installed parts. Frequency of inspection will to
a large extent depend upon crane activity and severity of
service but under no circumstances should the interval for
the below listed inspections exceed one month. These
inspections should also include those listed in the Daily
Inspection Checklist.
The appropriate truck manual should be consulted for
those inspection procedures which pertain to the carrier
and the recommendations of the manufacturer must be
strictly adhered to.
1. Inspect crane for any signs of deformation, damage
and attaching hardware for security and missing
items. Particular attention should be paid to areas of
high potential stress, such as crane/truck frame
attach points and outriggers.
2. Inspect outrigger assemblies for evidence of leakage
and security, pressure lines for evidence of abnor-
mal chafing.
3. Inspect power-take-off assemblies for security, wear
and damage.
4. Inspect main hydraulic pumps and lines for
damage, evidence of leakage and security of
attachment.
5. Check hydraulic fluid reservoir and lines for
damage, evidence of leakage and security of
attachment. Check filter indicators for element
condition. Clean or replace elements as necessary.
6. Check control levers in cab and linkage under
operator platform for visible damage, loose or
missing parts and proper lubrication. Assure that
levers function properly.
7. Check control switches at outrigger control station
and in cab for visible damage, loose or missing
parts, security, electrical connections for corrosion
and tightness, and wiring for proper routing.
Assure that switches function properly.
Courtesy of Crane.Market