USTC 2500 jbt User manual

TM
A Manitowoc Company
3120933 Rev . 0 PRINTED IN U.S.A. January 15, 2001
Sales: [phone] Sales: [phone]
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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.
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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
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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
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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
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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
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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)
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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.
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