Crane Inspection

LETOURNEAU, INC.
QUALIFIED CRANE INSPECTOR

TRAINING MANUAL
GENERAL TABLE OF CONTENTS
PREVENTIVE MAINTENANCE SCHEDULES AND CRANE

INSPECTION
NOTE
The contents of this Crane Inspectors
Training Manual include all publications or
excerpts from publications referenced in
the Preventive Maintenance Schedules.
However, it is recommended that the
inspector read, understand and follow all
instructions contained within the cranes
OPERATING AND SERVICE and REPAIR
AND OVERHAUL MANUALS prior to
performing any inspections or service
procedures to these cranes.
Module 1: Pre-Use or Daily Inspections and Service

Module 2: Monthly Inspections and Service
Module 3: Quarterly Inspections and Service
Module 4: Annual Inspections and Service
PUBLICATION OSM-5 WIRE ROPE USE, HANDLING AND

MAINTENANCE
PUBLICATION OSM-6 BRAKES
EXCERPTS FROM PUBLICATION OSM-4
Lubricating Oil Analysis
Power Loss Lowering System Inspection and Test

Procedures
PUBLICATION ROM-1 STRUCTURAL COMPONENTS
PCM 120 SS
PCM 350 SS
PUBLICATION LET-1 FIELD WELDING PROCEDURES
EXCERPTS FROM PUBLICATION ROM-6
Automatic Overload Protection System Test and

Calibration Procedures
EXCERPTS FROM PUBLICATION OSM-2 SAFETY
7-OSL, Crane TOC (MSWord)

Training Manual
06-26-02
Identification and Safety Label Group
Load Charts PCM 120/350 SS
Wire Rope Reeving Diagrams
COPYRIGHT 2002
LeTourneau, Inc.
Return to Main Page
PRE-USE OR DAILY WALK AROUND INSPECTIONS AND SERVICES

TO BE PERFORMED BY QUALIFIED OPERATOR
Okay
n
1.
Check hourmeter (located in Machinery House) for proper operation. Record

reading in space provided. Hourmeter reading:___________________
2.
Check overall condition of crane and support structure. Look for damage.
3.
Check safety and instructional signs. Replace any that are illegible, deteriorated
or missing.
4.
Visually check column, boom and swing components for cracked welds and
broken or missing bolts.
5.
SLOWLY operate all powered components to their travel limits to check for prop
er limit switch operation.
6.
Check wire rope for attachment, damage, deterioration and proper lubrication.
7.
Check all controls for proper operation.
8.
Check load moment indicator for proper operation.
9.
Check personnel warning horn for proper operation.
10.
Check all lighting for proper operation. (Include helicopter warning light if appli
cable).
11.
Check all brakes for proper stopping action.
12.
Check hydraulic lines to brakes for damage and leaks (where applicable).
13.
Check hydraulic brake unit high pressure filters service indicator (located in Ma
chinery House). Service when required.
14.
Check hydraulic brake power unit (located in Machinery House) breather filter
service indicator. Service when required.
15.
Check all drive motors for proper operation.
16.
Check swing gearbox and drivers for overheating and leaks.
17.
Check hook and block for proper attachment and condition of safety latch.
18.
Check all sheave pins and retainers.
19.
Check Machinery House ventilation system.
20.
Check fire extinguisher for proper charge, seal, and certification interval.
21.
Check the swing gear lubricant for shavings.
22.
Check for proper CW and CCW rotation and REPORT any unusual noises and
vibrations.
23.
Check load rating chart at operator's controls. It must be correct and visible.
24.
Check hoist driver for visible oil leaks.
25.
Visibly check loose gear to be used, such as slings, sling hooks and shackles.
26.
Lubricate components and correct deficiencies as required based on these in

spections.
9OSM4.2.1b(M1), Gorilla
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
Needs
Attention
n
MONTHLY
TO BE PERFORMED BY QUALIFIED OPERATOR OR QUALIFIED INSPECTOR
Okay
n
1.

2.
3.
or missing.
4.
5.
6.
7.
8.
9.
10.
cable).
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
vibrations.
23.
24.
25.
26.
Further check all control mechanisms for proper adjustment, excessive wear of
components, and contamination by foreign matter.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
Needs
Attention
n
PREVENTIVE MAINTENANCE REQUIREMENTS AND RECOMMENDATIONS
PUBLICATION OSM4
Okay
n
27.
Check boom hoist limit and anti-two block devices for proper operation. Care
should be exercised to prevent damage to crane components.
28.
Check all electrically operated functions for proper operation.
29.
Correct deficiencies as required based on these inspections.
Needs
Attention
n
MONTHLY INSPECTION AND LUBRICATION REQUIREMENTS

NOTE: Numbers in parentheses refer to lubrication points indicated on Figure 1.
STOW BOOM FOR SAFE ACCESS TO LUBE POINTS.
1.
Thoroughly inspect wire rope per the instructions in Publication OSM 5, located
in the Operating and Service Manual.
2.
Lubricate main hook sheaves. (1)
3.
Lubricate main hook swivel bearing. (1)
4.
Lubricate auxiliary hook bearings (optional). (2)
5.
Lubricate auxiliary sheaves (optional). (3)
6.
Lubricate boom sheaves (optional). (4)
7.
Lubricate floating block and equalizer sheave. (5)
8.
Lubricate boom selfaligning bushing (until new grease appears). (6)
9.
Lubricate swing roller bearings. (7)
10.
Lubricate swing gear and gearbox pinion. (8)
11.
Lubricate gantry sheave. (9)
12.
Lubricate swing bearing (PCM 350SS). (10)
13.
Lubricate spherical and thrust bearing (PCM 120SS). (10)
COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
6
4
7
8
1
2
10
PCM 350SS
10
4
3
6
4
7
1
2
PCM 120SS
CAUTION: PROPERLY STOW BOOM BEFORE LUBRICATING CRANE.

tag: lube points
FIGURE 1. LUBRICATING POINTS PCM 350 AND PCM 120
TA8997CG
1CGNGO1600, P1031
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
QUARTERLY
TO BE PERFORMED BY QUALIFIED INSPECTOR
Okay
n
Needs
Attention
n
NOTE: The quarterly inspections includes an inspection of electric motors, servic

ing drivers and swing gearbox and hydraulic brake system, structural inspection,
and operational tests of the crane. These inspections should only be conducted by
qualified and experienced inspectors.
1.

2.
3.
or missing.
4.
5.
6.
7.
8.
9.
10.
cable).
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
vibrations.
23.
24.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
25.
26.
27.
28.
29.
Needs
Attention
n
QUARTERLY INSPECTION AND LUBRICATION REQUIREMENTS

1.
Thoroughly inspect and lubricate wire rope per the instructions in Publication
OSM 5, located in the Operating and Service Manual.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
6
4
7
8
1
2
10
PCM 350SS
10
4
3
6
4
7
1
2
PCM 120SS

tag: lube points
TA8997CG
1CGNGO1600, P1031
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
Needs
Attention
n
DRIVERS
MAIN HOOK, BOOM, AUXILIARY HOOK (OPTIONAL):
1.
Take samples for lubricating oil analysis and refill. Service if iron content is 100
ppm or greater. Refer to LUBRICATING OIL ANALYSIS, Publication OSM4, for
additional information.
CRANE SWING COMPONENTS
SWING GEARBOX:
1.
Take sample for lubricating oil analysis and refill. Service if iron content is
100 ppm or greater. Refer to LUBRICATING OIL ANALYSIS, Publication OSM4,
for additional information.
HYDRAULIC BRAKE SYSTEM
1.
Take oil sample for analysis. Flush system and refill if water or solid particle con
tamination is 60 ppm or greater.
WIRE ROPE
WIRE ROPE - INSPECTION AND LUBRICATION REQUIREMENTS:

1.
2.
Inspect sheaves for wear, cracks, rope path alignment and bearing condition.
CABLE DRUM DEAD END INSPECTION:

1.
Check torque on wire rope dead end setscrews (140150 lbs. lubricated with
30W motor oil).
OPERATIONAL INDICATORS
1.
Check boom angle/radius indicators over full range for accuracy.

DC MOTOR BRAKES
SWING, BOOM, MAIN HOOK AND AUXILIARY HOOK (OPTIONAL):
1.
Check the condition of all motor brakes. Refer to Publication OSM6 in the OP
ERATING AND SERVICE MANUAL.
2.
Check all motor brakes for proper operation. Refer to Publication OSM6 in the
OPERATING AND SERVICE MANUAL.
3.
Check swing motor brake for proper adjustment. Refer to Publication OSM6 in
the OPERATING AND SERVICE MANUAL.
4.
Check for damage or leakage in hydraulic brake systems.
5.
Check speed sensors mounting, tightness and condition of leads.

COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
Okay
n
Needs
Attention
n
Okay
n
Needs
Attention
n
POWER LOSS LOWERING SYSTEM

1.
Inspect and test the power loss lowering system. Refer to POWER LOSS LOW
ERING SYSTEM, located in Publication OSM4 in the OPERATING AND SER
VICE MANUAL.
QUARTERLY ELECTRICAL P.M.
CAUTION
Be sure all electrical power is turned off and locked out before touching any
electrical connection or terminal. Due to the potential for injury, only
qualified experienced persons should enter the Machinery House.
ELECTRICAL CONTROLS GROUP:
1.
Check hook Controller condition. Insure card cover is secure and harness con
nections are tight.
2.
Check Boom Controller condition. Insure card cover is secure and harness con
nections are tight.
3.
Check Swing Controller condition. Insure card cover is secure and harness
connections are tight.
4.
Check all converter panels for tight connections and condition of components.
Remove any accumulated dust.
5.
Check circuit breakers.
6.
Blow out the cabinet with clean, dry compressed air.
7.
Check backup batteries for clean, tight terminal connections (located on top of
machinery house).
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
QUARTERLY DC MOTOR BRUSH INSPECTION

VERNIER GAUGE
POSITION BRUSH IN GAUGE SAME WAY

FOR ALL MEASUREMENTS.
BRUSH
NOT ALL LEADS SHOWN
HIGH POINT ON BRUSH

1CG1088, P01112
TA8010CG
MOTOR
BRUSH #
DIM.
REPLACED?
ANY SPECIAL
CONDITIONS
1.
1.
SWING
S1A MOTOR
2.
3.
4.
1.
2.
MAIN HOOK
N 9 MOTOR
N9
2.
3.
4.
1.
2.
BOOM
N9 MOTOR
2.
3.
4.
1.
4.
AUXILIARY HOOK
N9 MOTOR
2.
3.
4.
NOTES! 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE.
2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS.
3. SEE CHAPTER 4.0 OF TAKING CARE OF YOUR DC MOTOR" LOCATED IN SECTION 2, DC MOTORS, OF THE REPAIR
AND OVERHAUL MANUAL FOR CONDITIONS TO LOOK FOR.
COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
SIMPLIFIED AND EXAGGERATED ILLUSTRATION OF ARMATURE AND COMMUTATOR

TA8009CG
1CG1083, P01112
MOTOR
TRACK #
TIR
MAX. BARTOBAR
SURFACE CONDITION - SEE NOTE
1.
1.
SWING
S1A MOTOR
2.
3.
4.
1.
2
2.
MAIN HOOK
N9 MOTOR
2.
3.
4.
1.
3
3.
BOOM
N9 MOTOR
2.
3.
4.
1.
4.
AUXILIARY
HOOK
N9 MOTOR
2.
3.
4.
3. IN THE SURFACE CONDITIONS" COLUMN INDICATE OBSERVED CONDITION OF COMMUTATOR SURFACE CON
CERNING THE FOLLOWING: (a) CONDITION OF FILM, (b) SIGNS OF ARCING, (c) GROOVING, (d) OTHER CHARACTER
ISTICS. REFER TO TAKING CARE OF YOUR DC MOTOR" FOR AN INTERPRETATION OF THE OBSERVATIONS.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
QUARTERLY STRUCTURAL INSPECTIONS

Okay
n
Needs
Attention
n
CAUTION
Dye penetrant and magnetic particle tests shall be conducted on any welds
suspected of being cracked. Structural repairs MUST be made in
accordance with the guidelines in STRUCTURAL REPAIRS, Publication
ROM1, in the REPAIR AND OVERHAUL MANUAL and LeTourneau, Inc.,
Publication LeT1, FIELD WELDING PROCEDURES, located in the back of
Section 1 of the REPAIR AND OVERHAUL MANUAL. Before ANY structural
repairs are made to the crane, the certifying authority shall be notified and
his surveyor present when the repairs are performed. Any inspections and
tests required by the certifying authority after structural repairs are made
shall be completed and a new certificate issued BEFORE the crane is
returned to service.
AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS):
1.
Test the AOPS, Refer to AOPS TEST AND CALIBRATION PROCEDURE, lo

cated in Publication ROM6 in the REPAIR AND OVERHAUL MANUAL.
COLUMN GROUP - BASE:

1.
Closely inspect welds holding bolt plate to column.
2.
Closely inspect circumferential and vertical welds of column structure.
3.
Closely inspect welds at all gusset plates.
4.
Closely inspect welds on ladder assembly and holding ladder to column.
5.
Closely inspect for missing, loose or broken bolts.
COLUMN GROUP - UPPER:

1.
2.
3.
Closely inspect welds on platform assembly and holding platform to column.
4.
5.
6.
Closely inspect all bearings, wear bands and king pin condition.
BOOM:
1.
Closely inspect main boom hinge pins and attachment point welds.
2.
Closely inspect splice joints in top chords for cracks.
3.
Closely inspect welds at bridle cable ears and plates.
4.
Closely inspect for excessive wear at pins and ears.

COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
Okay
n
5.
Closely inspect welds in joints on bottom chords.
6.
Closely inspect welds at all diagonal pipes.
7.
Closely inspect condition and attachment of luffing ropes.
8.
Closely inspect boom sections attachment points for loose, broken or missing
bolts.
9.
Closely inspect boom light assemblies for proper attachment, broken lenses,
lose wiring and proper operation.
10.
Closely inspect limit switches for proper mounting and adjustment.
11.
Closely inspect catwalks and handrails for cracked welds and loose, broken or
missing bolts.
Needs
Attention
n
JIB BOOM (OPTIONAL):

1.
2.
3.
4.
5.
Closely inspect sheaves, pins and retainers.
SWING TABLE ROLLER ASSEMBLY:

1.
Closely inspect welds at boom and gantry attachment points.
2.
Closely inspect welds around the entire structure.
3.
Closely inspect welds at Machinery House mounting points.
4.
Closely inspect swing gearbox mounting.
5.
Closely inspect all pins and retainers.
6.
Closely inspect structure for loose, missing or broken bolts.
7.
Closely inspect swing bearing and gear for loose, broken or missing bolts.
LOWER BEARING AND SOCKET ASSEMBLY:

1.
Closely inspect for loose, missing or broken bolts or nuts.
2.
Closely inspect all welds on assembly.
3.
Closely inspect all bearings, bushings and oil seals.
SWING GEAR UNIT ASSEMBLY:

1.
Closely inspect gearbox mounting.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
2.
Closely inspect gearbox pinion for cracks.
3.
Closely inspect gearbox pinion adjustment. Should be .020" gap. Refer to the
REPAIR AND OVERHAUL MANUAL, Section 1, SWING GEAR UNIT, for informa
tion on Swing Gearbox adjustment.
4.
Closely inspect the gearbox lube level.
Needs
Attention
n
WINCH HOUSING ASSEMBLY:

1.
Closely inspect the mounting structure welds.
2.
Closely inspect for proper attachment of drivers and drive motors.
3.
Closely inspect cable drum structures for cracks, wear and proper attachment.
GANTRY ASSEMBLY:
1.
2.
Closely inspect for wear at attachment points.
3.
Closely inspect welds at attachment points.
4.
Closely inspect welds at main pipes and support pipes.
5.
Closely inspect boom stops.
GANTRY SHEAVE HOUSING ASSEMBLY:

1.
Closely inspect pins, retainers and capscrews.
2.
Closely inspect sheaves for wear.
3.
Closely inspect housing assembly welds.
4.
FLOATING SHEAVE HOUSING ASSEMBLY:

1.
2.
3.
4.
5.
Closely inspect wire rope for proper attachment.
HOOK AND BLOCK ASSEMBLY:
10
1.
2.
3.

COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
Okay
n
4.
5.
Closely inspect hook assembly for bends, cracks and overall condition.
Needs
Attention
n
AUXILIARY HOIST ASSEMBLY:

1.
2.
3.
4.
5.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
11
ANNUAL
TO BE PERFORMED BY QUALIFIED INSPECTOR
Okay
n
Needs
Attention
n
NOTE: The annual inspections includes an inspection of electric motors, servicing

drivers and swing gearbox and hydraulic brake system, structural inspection, and
operational tests of the crane. These inspections should only be conducted by
qualified and experienced inspectors.
1.

2.
3.
or missing.
4.
5.
6.
7.
8.
9.
10.
cable).
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
vibrations.
23.
24.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
25.
26.
27.
28.
29.
Needs
Attention
n
ANNUAL INSPECTION AND LUBRICATION REQUIREMENTS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
6
4
7
8
1
2
10
PCM 350SS
10
4
3
6
4
7
1
2
PCM 120SS

tag: lube points
TA8997CG
1CGNGO1600, P1031
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
Needs
Attention
n
DRIVERS - SERVICE REQUIREMENTS

MAIN HOOK, BOOM, AUXILIARY HOOK (OPTIONAL):
S Main Hook
1.
S Boom
Drain,, flush and refill drivers for:
S Auxiliary Hook
CRANE SWING COMPONENTS - SERVICE REQUIREMENTS
SWING GEARBOX:
1.
Drain, flush and refill swing gearbox.

HYDRAULIC BRAKE SYSTEM - SERVICE REQUIREMENTS
1.
Flush and refill hydraulic brake system.

WIRE ROPE - INSPECTION AND LUBRICATION REQUIREMENTS
1.
2.
Inspect sheaves for wear, cracks, rope path alignment and bearing condition.
CABLE DRUM DEAD END INSPECTION
1.
Check torque on wire rope dead end setscrews (140150 lbs. lubricated with
30W motor oil).
OPERATIONAL INDICATORS
1.
Check boom angle/radius indicators over full range for accuracy.

DC MOTOR BRAKES
SWING, BOOM, MAIN HOOK AND AUXILIARY HOOK (OPTIONAL):
1.
Check the condition of all motor brakes. Refer to Publication OSM6 in the OP
ERATING AND SERVICE MANUAL.
2.
Check all motor brakes for proper operation. Refer to Publication OSM6 in the
3.
Check swing motor brake for proper adjustment. Refer to Publication OSM6 in
4.
Check for damage or leakage in hydraulic brake systems.
5.
Check speed sensors mounting, tightness and condition of leads.
COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
ANNUAL ELECTRICAL P.M.

Okay
n
Needs
Attention
n
CAUTION
Be sure all electrical power is turned off and locked out before touching any
electrical connection or terminal. Due to the potential for injury, only
qualified experienced persons should enter the Machinery House.
ELECTRICAL CONTROLS GROUP:
1.
Check hook Controller condition. Insure card cover is secure and harness con
nections are tight.
2.
Check Boom Controller condition. Insure card cover is secure and harness con
nections are tight.
3.
Check Swing Controller condition. Insure card cover is secure and harness
connections are tight.
4.
Check all converter panels for tight connections and condition of components.
Remove any accumulated dust.
5.
Check circuit breakers.
6.
Blow out the cabinet with clean, dry compressed air.
7.
Check backup batteries for clean, tight terminal connections (located on top of
machinery house).
CORROSION INHIBITORS:
1.
Replace corrosion inhibitors inside controller panel.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
ANNUAL DC MOTOR BRUSH INSPECTION

VERNIER GAUGE
POSITION BRUSH IN GAUGE SAME WAY

FOR ALL MEASUREMENTS.
BRUSH
NOT ALL LEADS SHOWN
HIGH POINT ON BRUSH

1CG1088, P01112
TA8010CG
MOTOR
BRUSH #
DIM.
REPLACED?
ANY SPECIAL
CONDITIONS
1.
1.
SWING
S1A MOTOR
2.
3.
4.
1.
2.
MAIN HOOK
N 9 MOTOR
N9
2.
3.
4.
1.
2.
BOOM
N9 MOTOR
2.
3.
4.
1.
4.
AUXILIARY HOOK
N9 MOTOR
2.
3.
4.
3. SEE CHAPTER 4.0 OF TAKING CARE OF YOUR DC MOTOR" LOCATED IN SECTION 2, DC MOTORS, OF THE REPAIR
AND OVERHAUL MANUAL FOR CONDITIONS TO LOOK FOR.
COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
SIMPLIFIED AND EXAGGERATED ILLUSTRATION OF ARMATURE AND COMMUTATOR

TA8009CG
1CG1083, P01112
MOTOR
TRACK #
TIR
MAX. BARTOBAR
SURFACE CONDITION - SEE NOTE
1.
1.
SWING
S1A MOTOR
2.
3.
4.
1.
2
2.
MAIN HOOK
N9 MOTOR
2.
3.
4.
1.
3
3.
BOOM
N9 MOTOR
2.
3.
4.
1.
4.
AUXILIARY
HOOK
N9 MOTOR
2.
3.
4.
3. IN THE SURFACE CONDITIONS" COLUMN INDICATE OBSERVED CONDITION OF COMMUTATOR SURFACE CON
CERNING THE FOLLOWING: (a) CONDITION OF FILM, (b) SIGNS OF ARCING, (c) GROOVING, (d) OTHER CHARACTER
ISTICS. REFER TO TAKING CARE OF YOUR DC MOTOR" FOR AN INTERPRETATION OF THE OBSERVATIONS.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
ANNUAL STRUCTURAL INSPECTIONS

Okay
n
Needs
Attention
n
CAUTION
Dye penetrant and magnetic particle tests shall be conducted on any welds
suspected of being cracked. Structural repairs MUST be made in
accordance with the guidelines in STRUCTURAL REPAIRS, Publication
ROM1, in the REPAIR AND OVERHAUL MANUAL and LeTourneau, Inc.,
Publication LeT1, FIELD WELDING PROCEDURES, located in the back of
Section 1 of the REPAIR AND OVERHAUL MANUAL. Before ANY structural
repairs are made to the crane, the certifying authority shall be notified and
his surveyor present when the repairs are performed. Any inspections and
tests required by the certifying authority after structural repairs are made
shall be completed and a new certificate issued BEFORE the crane is
returned to service.
COLUMN GROUP - BASE:
1.
2.
Closely inspect circumferential and vertical welds of column structure.
3.
4.
5.
COLUMN GROUP - UPPER:

1.
2.
3.
Closely inspect welds on platform assembly and holding platform to column.
4.
5.
6.
Closely inspect all bearings, wear bands and king pin condition.
BOOM:
1.
Closely inspect main boom hinge pins and attachment point welds.
2.
3.
Closely inspect welds at bridle cable ears and plates.
4.
5.
6.
7.
Closely inspect condition and attachment of luffing ropes.

COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
Okay
n
8.
Closely inspect boom sections attachment points for loose, broken or missing
bolts.
9.
Closely inspect boom light assemblies for proper attachment, broken lenses,
lose wiring and proper operation.
10.
Closely inspect limit switches for proper mounting and adjustment.
11.
Closely inspect catwalks and handrails for cracked welds and loose, broken or
missing bolts.
Needs
Attention
n
JIB BOOM (OPTIONAL):

1.
2.
3.
4.
5.
Closely inspect sheaves, pins and retainers.
SWING TABLE ROLLER ASSEMBLY:

1.
Closely inspect welds at boom and gantry attachment points.
2.
Closely inspect welds around the entire structure.
3.
Closely inspect welds at Machinery House mounting points.
4.
Closely inspect swing gearbox mounting.
5.
6.
Closely inspect structure for loose, missing or broken bolts.
7.
Closely inspect swing bearing and gear for loose, broken or missing bolts.
LOWER BEARING AND SOCKET ASSEMBLY:

1.
Closely inspect for loose, missing or broken bolts or nuts.
2.
Closely inspect all welds on assembly.
3.
Closely inspect all bearings, bushings and oil seals.
SWING GEAR UNIT ASSEMBLY:

1.
Closely inspect gearbox mounting.
2.
Closely inspect gearbox pinion for cracks.
3.
Closely inspect gearbox pinion adjustment. Should be .020" gap. Refer to the
REPAIR AND OVERHAUL MANUAL, Section 1, SWING GEAR UNIT, for informa
tion on Swing Gearbox adjustment.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
Okay
n
4.
Needs
Attention
n
Closely inspect the gearbox lube level.
WINCH HOUSING ASSEMBLY:

1.
Closely inspect the mounting structure welds.
2.
Closely inspect for proper attachment of drivers and drive motors.
3.
Closely inspect cable drum structures for cracks, wear and proper attachment.
GANTRY ASSEMBLY:
1.
2.
3.
Closely inspect welds at attachment points.
4.
Closely inspect welds at main pipes and support pipes.
5.
Closely inspect boom stops.
GANTRY SHEAVE HOUSING ASSEMBLY:

1.
2.
3.
4.
FLOATING SHEAVE HOUSING ASSEMBLY:

1.
2.
3.
4.
5.
Closely inspect wire rope for proper attachment.
HOOK AND BLOCK ASSEMBLY:
10
1.
2.
3.
4.
5.
COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4
Okay
n
Needs
Attention
n
AUXILIARY HOIST ASSEMBLY:

1.
2.
3.
4.
5.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
11
PUBLICATION OSM4
ANNUAL CRITICAL COMPONENT TESTING AND INSPECTION

Okay
n
Needs
Attention
n
NOTE: Testing and inspection of critical crane components shall be conducted in ac

cordance with the requirements of the certifying authority under which the crane is
operating. Refer to API RP 2D 8/1999.
HYDRAULIC BRAKE SYSTEM:
1.
Inspect and test the backup AC pump motor. Refer to Publication OSM6 in the
POWER LOSS LOWERING SYSTEM:

1.
Inspect and test the power loss lowering system. Refer to POWER LOSS LOW
ERING SYSTEM located in Publication OSM4 in the OPERATING AND SER
VICE MANUAL.
AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS):

1.
Test the AOPS, Refer to AOPS TEST AND CALIBRATION PROCEDURE, located
in Publication ROM6 in the REPAIR AND OVERHAUL MANUAL.
LOAD AND SPEED TESTING:

The following weight will be needed during the test procedure. NOTE: SWL is Safe Working Load on the
hook in pounds, which is the crane rating minus hook and block weight per API 2C.
PCM 120SS
PCM 350SS
RADIUS
SWL
RADIUS
SWL
Main Hook - Boom Up
22 ft.
98,400
30 ft.
146,800
Aux Hook - Boom Up
30 ft.
20,000
35 ft.
20,000
Okay
n
Needs
Attention
n
The following inspection or tests must be performed before doing any load testing.
12
1.
Verify that all controls are working properly.
2.
Verify that regenerative braking systems are functioning properly.
3.
Verify that all brake systems are functioning properly.
4.
Verify that all limit switches are adjusted and functioning properly.
5.
Inspect cable to verify proper reeving and that no rubbing or looseness of cable
is occurring.
6.
Verify boom raise and lower electrical stop limits.
7.
Replace brake system pressure filter.

COPYRIGHT 2002
LeTourneau, Inc.
06/24/02
PUBLICATION OSM4

Time
Test boom luffing and swing speeds with no load

load.
Start
1.
Record time required to raise boom from horizontal to maximum boom up posi
tion.
2.
Record time required to lower boom from maximum up position to horizontal

position.
3
3.
Test swing speed with no load through 180

180 and compare to
specification.
4.
Verify that acceleration to full speed and regenerative braking to

0 speed is smooth.
5.
Verify that brake sets are smooth at the stopped position.
End
LEFT
RIGHT
Evaluate hook speeds:
CAUTION
Always use a minimum load of 2000 lbs. on the hook when running the hook at full speed to prevent
slack in cable spooling off of the drum.
Distance
1
1.
Boom Up, Main Hook with

2,000 lb. load
2
2.
Boom Up, Main Hook with

75,000 lb. load
3
3.
Boom Up, Aux Hook with

2,000 lb. load
4
4.
Boom Up, Aux Hook with

10,000 lb. load
Time
Speed
FPM
Motor
Volts
UP
DOWN
UP
DOWN
UP
DOWN
UP
DOWN
Okay
n
5
5.
Motor
Current
Evaluate smoothness of acceleration, deceleration, and stop

ping.
Needs
Attention
n
MAIN
AUX
Rated load testing:

1
1.
With boom full up, lift rated load. During this test it is recom
mended that the load not be raised over two feet from the deck
surface.
2
2.
Evaluate electrical and disc braking systems to assure that they

control and hold the load properly. Hold the load for five minutes.
06/24/02
COPYRIGHT 2002
LeTourneau, Inc.
MAIN
AUX
MAIN
AUX
13
PUBLICATION OSM5
OPERATING AND SERVICE MANUAL

LeTOURNEAU, INC. PCM CRANE
WIRE ROPE USE, HANDLING & MAINTENANCE
TABLE OF CONTENTS
TABLE OF CONTENTS
Page
LIST OF ILLUSTRATIONS (Con'd.)
SCOPE OF THIS PUBLICATION . . . . . . . . . . . . . . . 1
FIGURE
COMPONENTS OF WIRE ROPE . . . . . . . . . . . . . . . 2
Page
8.
WEDGE SOCKET ASSEMBLY

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .
15
9.
CORRECT INSTALLATION OF WEDGE

SOCKET ASSEMBLY . . . . . . . . . . . . . . . . . . .
15
10.
GO" - NOGO" METHOD OF DETER

MINING CORRECT WIRE ROPE SIZE . . . . .
16
11.
TIGHTENING TORQUE VALUES . . . . . . . . .
16
WIRE ROPE REPLACEMENT CRITERIA

AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WIRE ROPE REPLACEMENT CRITERIA . . . . . . . . 9
12.
INCORRECT INSTALLATION METHODS

OF WEDGE SOCKET . . . . . . . . . . . . . . . . . .
16
13.
WIRE ROPE MAINTENANCE . . . . . . . . . . . .
17
REPLACEMENT ROPE SELECTION CRITERIA . . 10
14.
WIRE ROPE SEIZING . . . . . . . . . . . . . . . . . .
20
WIRE ROPE REPLACEMENT PROCEDURES . . . . 10
15.
METHOD OF CLEANING WIRE ROPE . . . .
22
WIRE ROPE SLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SLING REPLACEMENT CRITERIA . . . . . . . . . . . . . 14
16.
METHOD OF LUBRICATING WIRE ROPE .
22
17.
WIRE ROPE LUBRICATION . . . . . . . . . . . . .
24
GENERAL PROCEDURES AND PRECAUTIONS . 2

TEST REPORTS AND WIRE ROPE
INSPECTION RECORDS . . . . . . . . . . . . . . . . . . . . . 3
WIRE ROPE INSPECTION PROCEDURES . . . . . . . . 5
WIRE ROPE INSPECTION TOOLS . . . . . . . . . . . . . 5
PROOF LOADING AND LABELING . . . . . . . . . . . . . 14

WIRE ROPE ATTACHMENT PROCEDURE . . . . . . . . 15
INSTALLATION SAFETY ADVISORIES . . . . . . . . . . 15
WEDGE SOCKET ASSEMBLY INSTALLATION . . . 15
OPERATIONAL SAFETY ADVISORIES . . . . . . . . . . 16
SHEAVES, ROLLERS AND DRUMS . . . . . . . . . . . . . . 17
SHEAVES, ROLLERS AND DRUM INSPECTION . 17
SEIZING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LUBRICATING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . 21
THE IMPORTANCE OF REGULAR WIRE
ROPE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 21
CHOOSING THE PROPER LUBRICANT . . . . . . . . 21
WIRE ROPE LUBRICATING PROCEDURES . . . . . 21
SCOPE OF THIS PUBLICATION

Publication OSM5, WIRE ROPE USE, HANDLING, AND
MAINTENANCE, is to assist maintenance personnel
and operators with the basics of inspection, mainte
nance and replacement of the wire rope on the crane.
As wire rope is a load bearing member of the crane, it is
ESSENTIAL to properly maintain it to ensure safe
operation.
NOTE
PCM350SS ELECTRIC DECK CRANE

WIRE ROPE SPECIFICATIONS . . . . . . . . . . . . . . . . . 25
In several places in this publication, the terms

qualified" or competent" person are used
with regards to inspection, repair and
certification of the crane and its components.
A qualified" or competent" person is defined
as follows: A person who, by possession of a
professional degree, certificate of profession
al standing or who by extensive knowledge,
training, and experience, has successfully
demonstrated the ability to solve or resolve
problems relating to the subject matter and
work.
LIST OF ILLUSTRATIONS
FIGURE
Page
1.
THE THREE BASIC COMPONENTS

OF WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . .
2.
ROPE MEASUREMENT . . . . . . . . . . . . . . . . .
3.
WIRE ROPE INSPECTION PROCEDURES .
4.
ROPE LAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.
WIRE ROPE TRANSFER PROCESS . . . . . .
10
6.
RATED CAPACITY SINGLELEG

WIRE ROPE SLINGS . . . . . . . . . . . . . . . . . . .
13
7.
RATED CAPACITY - BRIDLE SLINGS . . . .
13
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM5
NOTE
Mandatory rules of this publication per
ANSI/ASME are characterized by the word
SHALL." If a provision is of an advisory
nature, it is indicated by the word SHOULD"
and is recommended to be considered, the
advisability of which depends on the facts in
each situation.
Inspect regularly, following the PREVENTIVE MAIN

TENANCE SCHEDULES in the back of Publication
OSM4.
Never overload.
Minimize shock loading as overstressing of the rope

will occur.
NOTE
In order to ensure that there is no slack in the
rope at the start of loading, start the load
carefully and apply the power smoothly and
steadily.
COMPONENTS OF WIRE ROPE

Wire rope, also referred to as rope, consists of three
basic components, the core, the individual wires that
form the strands and the multiwire strands that are
helically laid around the core. Refer to Figure 1 for an
illustration of the components of wire rope.
Do not operate the machine if the ropes are frozen.
Take special precautions under the following

conditions:
1.
3.the conditions are abnormal or severe,
WIRE (2)
4.there is a hazard to personnel.
CENTER WIRE (3)

STRAND
WIRE ROPE
tag: 3 basic comp

FIGURE 1. THE THREE BASIC COMPONENTS
OF WIRE ROPE
1CG1227, P0815
TA8021CG
Protect rope from sharp corners or edges with pad

ding.
Avoid dragging the rope from under loads or over

obstacles.
Avoid dropping the rope from heights.
Avoid rolling loads with ropes.
Store all unused rope in a clean, dry place.
Never use wire rope which has been cut, badly

kinked or crushed.
Prevent loops in slack lines from being pulled tight

and kinking.
NOTE
GENERAL PROCEDURES AND PRECAU

TIONS
Wire ropes, like the machines and hoists on which they
are used, require careful use, handling and mainte
nance for satisfactory performance, long life and
adequate safety.
The following general precautions and procedures
should be observed to meet these requirements:
CAUTION
ALWAYS wear gloves when handling wire rope

to prevent hand injury.
the exact load is unknown,
2.there is a possibility of shock loading,
CORE (1)
CAUTION
If wire rope is replaced ensure that the correct repla

cement rope is used. Refer to the PARTS CATALOG
for the correct rope for your machine.
Once a kink has been made in a wire rope the

damage is permanent. A weak spot will always
remain no matter how well the kink seems to
have been straightened out. If a loop forms, do
not pull it out; unfold it.
D
Avoid reverse bends.
Repair or replace faulty guides and rollers.
Ensure the sheaves are aligned properly.
Replace sheaves having deeply worn or scored

grooves, cracked or broken rims, and worn or dam
aged bearings.
Repair faulty clutches.
Check for abnormal line whip and vibration.
Ensure that the rope is installed properly on the

drums.
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
Never wind more than the proper amount of rope on

a drum.
Never allow the rope to crosswind.
Ensure that the rope ends are properly seized.
Ensure that the ropes do not bind in sheaves.
apply a lubricant coating to the outside layer

of rope on the reel.
3. On a crane that is out of service for long period
of time, apply a lubricant to the outside layer of
the rope on the drum. Apply additional
lubricant to the accessible exposed rope in
the hoist system.
NOTE
4. Care should be taken during shipping and

handling of the reel and rope to prevent
damage to the rope. The loose end of the rope
on the reel should be secured properly to the
reel.
New wire rope requires a runin period before

operating at full load and full speed.
D
a.
Use thimbles in eye fittings at all times.

LUBRICATION INSTRUCTIONS:
Lubricate regularly according to the PREVENTIVE

MAINTENANCE SCHEDULES in the back of Publication
OSC4 and the instructions in LUBRICATING WIRE
ROPE, this publication, page 21. Modify these recom
mendations for extreme conditions. Also, refer to wire
rope manufacturer's recommendations.
b.
TEST REPORTS AND WIRE ROPE IN

SPECTION RECORDS
Written, dated and signed operational test and inspec
tion reports should be kept and readily available for a
period of two years.
STORAGE PROCEDURES:
Wire rope placed in storage whether mounted on a

machine or not should be properly maintained. The
following procedures should be performed to prevent
rope damage and deterioration:
1. Stored ropes should be covered in a well
ventilated area and away from excessive heat.
2. Where covered storage is not available, the
rope and reel should be covered with water
proof material. For long periods of storage
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
NOTE
Wire rope removed from service should be
identified and marked as unfit for use on
cranes, slings or other load carrying devices.
NOTE
UNDER NO CIRCUMSTANCES shall any
machine be rerated in excess of the original
load ratings unless rating changes are
approved by LeTourneau, Inc. and a new load
chart is available.
LeTourneau, Inc.
PUBLICATION OSM5
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
WIRE ROPE INSPECTION PROCEDURES

Wire Rope is a structural component of the crane
requiring periodic replacement. Possible loss of
strength can result from wear, abuse and other forms of
deterioration. The wire rope must be carefully selected,
inspected and maintained. The qualified person who
determines whether replacement is necessary should
be knowledgeable in the inspection and maintenance of
wire rope.
No precise rules can be given for determination of the
exact time for replacement of rope, since many variable
factors are involved. Continued use depends largely
upon good judgement by the qualified person in
evaluating the strength remaining in the rope after
allowance for deterioration disclosed by inspection.
Continued rope operation depends upon this remaining
strength.
NOTE
b.
Wire ropes on the machine shall be inspected daily or

prior to use if the machine is not used daily. This visual
inspection should include moving and standing ropes,
end fittings and pins. The daily visual inspections should
be concerned with discovering gross damage, such as
listed below, which may be an immediate hazard:
WIRE ROPE INSPECTION TOOLS

Tools for the inspection of wire rope should include but
are not limited to the following:
1. Distortion of the rope such as crushing,

unstranding, birdcaging, main strand dis
placement, or core protrusion; loss of rope
diameter in a short rope length or unevenness
of outer strands provide evidence that rope
replacement should be considered. Refer to
Figure 2 for an illustration of the wire rope
measuring process.
D Awl
2. General corrosion
D Marlin spike
3. Number, distribution, and type of visible

broken (Refer to WIRE ROPE REPLACEMENT
CRITERIA AND PROCEDURES, this publica
tion page 9.)
D Steel tape
D Sheave groove gauges
4. Core failure in rotation resistant ropes. Partic

ular care shall be taken when inspecting
rotation resistant ropes because of their
susceptibility to damage from handling and
misuse and potential for deterioration when
used on equipment with limited design pa
rameters. Internal deterioration of rotation
resistant ropes may not be readily observable.
D Calipers
D Chalk
D Wiping cloth
D Gloves
a.
DAILY VISUAL INSPECTION
INSPECTION PROCEDURES:
ACTUAL DIAMETER
B. CORRECT
A.
C. INCORRECT
tag: rope measuremt

FIGURE 2. ROPE MEASUREMENT
1CG1229, P0815
1OSM5.1, 350SS
5/8/00
TA8023CG
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM5
NOTE
machine. Care should be exercised in inspecting the

rope at these points. Refer to Figure 3. Inspection
should include but not be limited to the following areas:
Rotation resistant wire rope is rope consisting

of an inner layer of strand laid in one direction
covered by a layer of strand laid in the
opposite direction. This has the effect of
counteracting torque by reducing the tenden
cy of the finished rope to rotate.
1. Equalizer sheaves or saddles, also referred to

as fixed guides, or other sheaves where wire
rope travel is limited.
2. End connections including socket or end
attachments to running ropes, boom pen
dants and other standing wire ropes. Refer to
Figure 2.
c. Particular care should be taken when inspecting

section of rope subject to rapid deterioration such as
flange points, crossover points, and repetitive pickup
points on drums.
d.
3. Sections of wire rope where the rope is

continually running over sheaves within the
various hoist systems. This inspection is of
particular importance where boom angle and
load block changes are frequent and limited
to short distances.
PERIODIC INSPECTION
A qualified person should inspect the wire rope at a

frequency based on such factors as: expected rope life
as determined by experience on the particular installa
tion or similar installations, severity of environment,
percentage or lifts at maximum rating, frequency rates
of operation, and exposure to shock loads. Inspections
need not be at equal calendar intervals and should be
more frequent as the rope approaches the end of its
useful life. However, this inspection shall be made at
least annually. A written, signed and dated inspection
report should be kept and readily available for two years
or until the wire rope is retired. The periodic inspection
shall cover the entire length of the rope. Any deteriora
tion resulting in appreciable loss of original strength,
such as described below, shall be noted and determina
tion made as to whether further use of the rope would
constitute a hazard:
4. At crossover and flange points of the wire rope

on hoist drums.
5. Special care should be taken in the inspection
of rotation resistant wire rope (see above).
j.
Wire ropes which have been idle for one month or more
should be inspected by a qualified person before being
placed into service. A written, signed and dated
inspection report should be kept and readily available
for two years or until the wire rope is retired.
NOTE
A long range inspection program should be
established to include records on examination
or ropes removed from service to establish a
relationship between visual observation and
actual condition of the internal structure.
e. The points listed in the daily visual inspections

above
f.
Reduction of rope diameter below nominal diame
ter due to loss of core support, internal or external
corrosion, or wear of outside wires
g. Severely corroded or broken wires at end connec
tions
h. Care shall be taken when inspecting rope sections
subject to rapid deterioration, such as the following:
1. Sections in contact with saddles, equalizer
sheaves, or other sheaves where rope travel is
limited;
2. Sections of the rope at or near terminal ends
where corroded or broken wires may pro
trude;
3. Sections subject to reverse bends;
4. Sections of rope which are normally hidden
during routine visual examination, such a
parts passing over sheaves.
i.
ROPE INSPECTION AT CONTACT POINTS
Heavy wear and /or broken wires occur in wire rope

sections in contact with certain components of the
6
WIRE ROPES NOT IN REGULAR USE
k.
INSPECT FOR LOCALIZED WEAR
Premature wear at one spot is common and can be

prevented if the cause is detected. Uneven wear can
be minimized by moving the rope at regular intervals so
that different stretches of it are at the critical wear points.
Changing layer and crossover points is merely a matter
of cutting a few feet of rope from the drum end and
refastening it. The cut should be long enough to move
the change of layer at least one full coil from its former
position and to move the crossover points onequarter
turn around the drum. Move the static section on an
equalizer sheave three sheave diameter lengths away
by cutting off the section on the drum end of the rope. To
distribute wear due to vibration, cut off a section next to
the dead end and refasten the rope.
l.
INSPECT FOR SLACK IN THE ROPE
Even with the utmost care during installation, it is

quite common to find that the dead turns on the drum
become somewhat slack in operation. This slackness
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
THE WIRES BREAK IN

THE VALLEY WHERE
STRAND TO STRAND
CONTACT OCCURS
VALLEY BREAKS
CHECK FOR INTERNAL DAMAGE AFTER DISCOVERING
BROKEN WIRES BETWEEN STRANDS.
BROKEN WIRES IN THE INDEPENDENT WIRE ROPE CORE

ARE NOT DISCERNIBLE FROM
EXTERIOR EXAMINATION OF THE ROPE.
tag: wir rop inspect
1CG1231, P0815
1OSM5.1, 350SS
5/8/00
FIGURE 3. WIRE ROPE INSPECTION PROCEDURES

COPYRIGHT 2002
LeTourneau, Inc.
TA8002CG
PUBLICATION OSM5
arises from a certain amount of stretch which occurs in a

new rope under tension and periodically throughout the
life of the rope from release of the load. When this
slackness is noted, these turns should be rewound to
tighten them. If left uncorrected, a wedging action,
causing abrasion from the second layer, will occur and
broken wires in the dead turns will appear.
NOTE
Localized abrasion and fatigue can be dealt
with, without the necessity of discarding the
whole rope, by installing a longer rope than
necessary, initially, and cutting one end or the
other to expose a new section of rope to the
place where the deterioration occurs.
NOTES
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
WIRE ROPE REPLACEMENT CRITERIA AND PROCEDURES

Wire rope is an expendable item and is routinely
replaced in accordance with criteria set out in American
Petroleum Institute API RP 2D Recommended Practices
for Maintenance and Operation of Offshore Cranes. It
also has a variable load life characteristics which
significantly differ from the more or less permanent
components of the crane. Because of this and the many
other inherent properties peculiar to wire rope, it was
decided to set singular design factors taking into
consideration each type rope and rope service. The
design factors have been increased and based on
experience, are sufficiently large to account for minor
strength effects such as specified sheave sizes, tackle
dynamics and nominal versus minimum rope strength.
WIRE ROPE REPLACEMENT CRITERIA

The following general instructions should be used in the
inspection process for determination of the replace
ment interval of wire rope on the machine.
NOTE
When inspection indicates suspected loss of original

strength, the qualified person shall make a determina
tion relative to further use of the wire rope. Conditions
such as the following shall be reasons for questioning
continued use of the rope or for increasing the
frequency of inspection:
b. In running ropes, 12 randomly distributed broken
wires in 1 lay, or 4 broken wires in 1 strand in 1 lay.
c. In rotation resistant wire ropes, 4 randomly
distributed broken wires in one lay or 2 broken wires in 1
strand in 1 lay.
d. One (1) outer wire broken at the contact point with
the core of the rope indicated by an externally protrud
ing wire or loop of loose wires.
e. Wear of onethird the original diameter of outside
individual wires.

a.
The various rope conditions noted upon inspection

should be used to determine continued use or retire
ment of the rope in question. The following replacement
criteria examples are a list of wire rope applications for a
crane.
f.
Kinking, crushing, birdcaging, or any other dam
age resulting in distortion of the rope structure.
g.
BROKEN WIRE REPLACEMENT CRITERIA
Broken wire replacement criteria were developed by

testing with hardened steel sheaves. When broken
wires begin to appear, additional broken wires can be
anticipated in a short period. Once broken wires are
observed, inspections should be made at more fre
quent intervals.
NOTE
The term ROPE LAY or LAY LENGTH will be
used in later paragraphs of this publication. A
ROPE LAY or LAY LENGTH is the distance
measured parallel to the axis of the rope in
which a strand makes one complete helical
revolution about the core. Refer to Figure 4 for
an illustration of a ROPE LAY.
Evidence of heat damage from any cause.
h. Reductions from nominal wear diameter greater

than those shown below:
Maximum Allowable Reduc
tion from Nominal Diameter
Rope Diameter
Up to 5/16" (8 mm)
1/64" (.04 mm)
Over 5/16" to 1/2" (13 mm)
1/32" (0.8 mm)
Over 1/2" to 3/4" (19 mm)
3/63" (1.2 mm)
Over 3/4" to 11/8" (29 mm)
1/16" (1.6 mm)
Over 11/8" to 11/2" (38 mm)
3/32" (2.4 mm)
Refer to Figure 2 for an illustration of the wire rope

measuring process.
i.
Attention shall be given to end connections. Upon
development of more than 2 broken wires adjacent to a
socketed end connection, the rope shall be resocketed
or replaced. Resocketing shall not be attempted if the
resulting rope length will be insufficient for proper
operation.
NOTE
ONE ROPE LAY
FIGURE 4. ROPE LAY

1CG1228, P0815
1OSM5.1, 350SS
5/8/00
TA8001CG
COPYRIGHT 2002
These replacement criteria were developed on

steel sheaves. When sheaves of other
materials are used, the manufacturer of the
sheave should be consulted.
LeTourneau, Inc.
PUBLICATION OSM5
NOTE
WIRE ROPE REPLACEMENT PROCE

DURES
Inspection records should be maintained to

determine the time interval for retirement of
the wire rope. Records should be readily
available until the specific wire rope is retired.
All observed rope deterioration as listed
above should be recorded on these inspection
records.
These general instructions should be followed in the

replacement of the wire rope on the machine to prevent
damage:
a. Unreeling or uncoiling of wire rope should be done
as recommended by the rope manufacturer. Care
should be taken to avoid kinking or introduction of twist
into the rope. Use additional care when unreeling or
uncoiling rotationresistant rope.
REPLACEMENT ROPE SELECTION

CRITERIA
Replacement wire rope should be selected by using the
following criteria:
NOTE
Wire rope on the machine MUST be replaced
with same diameter, length, construction and
grade rope as the machine was originally
equipped. The replacement rope MUST not be
different unless approved by LeTourneau, Inc.
and all furnished load rating charts MUST be
reviewed and changed as required. Replace
ment wire rope shall be certified to original
specifications and the certificate kept on file in
the Control Book.
b. To avoid introduction of twist into the rope while

reeving, remove the rope from the same side of the reel
as it will operate on the drum, top to top or bottom to
bottom. When transferring wire rope from a storage reel
to a drum, the rope should travel from the top of the reel
to the top of the drum; or from the bottom of the drum.
This will avoid a reverse bend in the rope as it is being
installed. Installing a rope so that a reverse bend is put
into it causes the rope to become twisty," difficult to
handle and spool smoothly on the drum. This is
especially true of large diameter wire ropes. A braking
action should be applied to the reel at all times (use a
block of timber against the reel flange) in order to get a
good smooth wrap on the drum. Refer to Figure 5 for an
illustration of the transferring process.
WRONG
WRONG
(THIS REVERSES THE NATURAL CURVE IN THE WIRE.)
REEL
REEL
DRUM
DRUM
BRAKE
BRAKE
Never reel from top to bottom or from bottom to top.
RIGHT
RIGHT
(THIS RETAINS THE NATURAL CURVE IN THE WIRE.)
REEL
REEL
DRUM
DRUM
BRAKE
BRAKE
tag: wir rop transf

1CG1232, P0815, 1/28/98
10
Always reel from top to top or from bottom to bottom.
FIGURE 5. WIRE ROPE TRANSFER PROCESS

COPYRIGHT 2002
LeTourneau, Inc.
TA8000CG
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
c. For crane applications, care must be taken to

assure that the boom hoist system is reeved for the
specific crane configuration in use.
d. When reeving through the sheave system avoid
kinks or looping which could damage the rope.
e. Cut off all welded ends of the rope before installing
in a wedge socket or wedge in the drum.
f.
New rope, when first installed, should be broken in
by slowly lifting and lowering a light load several cycles
through the entire hoist mode.
bending the rope about small pipe or crane compo

nents which might induce kinks or curling.
i.
Wire rope clips should be installed in accordance
with wire rope or clip manufacturer's recommendations.
The saddle portion of the clip shall be applied to the live
rope segment and the Ubolt to the dead or shortened
end segment. The wire rope clip nuts should be
tightened after initial use of the wire rope and periodical
ly checked. This instruction does not apply to the use of
wire rope clips with wedge sockets.
g. Before cutting a rope, seize the rope at either side

of the cut location to prevent unlaying of the strands.
Seizing of the wire rope should be performed by or
supervised by a qualified person. Refer to SEIZING
WIRE ROPE, page 19, this publication.
h. Care should be taken during installation to avoid
contaminating, scraping or nicking the wire rope. Avoid
NOTE
The wire rope is retained to the cable drum
dead end with 3/4 UNC setscrews. These
setscrews tighten to 140150 lbs. torque with
the threads lubricated with 30W motor oil.
Torque should be checked every six months.
NOTES
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
11
PUBLICATION OSM5
NOTES
12
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
WIRE ROPE SLINGS

This instruction applies to singlepart wire rope slings.
Consult sling manufacturer's recommendations for
multipart rope slings.
CAUTION
RATED CAPACITY FOR SINGLELEG

SLING IN U.S. TONS (2,000 Lb.)
ROPE DIAM.
(INCH)
MS(1)
HT(2)
S(3)
1/2
2.2
2.0
2.3
5/8
3.4
3.0
3.6
3/4
4.9
4.2
5.1
7/8
6.6
5.5
6.9
8.5
7.2
9.0
11/8
10.0
9.0
11.0
11/4
13.0
11.0
14.0
13/8
15.0
13.0
17.0
11/2
18.0
16.0
20.0
13/4
25.0
21.0
27.0
32.0
28.0
34.0
Wire rope slings should not be field fabricated

except where necessary under special cir
cumstances. If circumstances require field
fabrication, proper equipment should be
available and qualified persons should
perform this function using accepted standard
practices. Zinc or resin poured sockets should
be fabricated in accordance with API RP 9B.
a.
SINGLELEG WIRE ROPE SLINGS
The data in Figure 6 shall be used to determine the rated

capacity of the various size singleleg wire rope slings of
improved plow steel (IPS), independent wire rope core
(IWRC) constructed with the terminals as noted.
Increase these values by 15 percent if extra plow steel
(EIPS) independent wire rope core (IWRC) rope is used
in the sling fabrication. Consult the wire rope manufac
turer for ratings of wire rope slings of construction and
grades other than those listed in this section.
MS(1)
HT(2)
MS(1)
FIGURE 6. RATED CAPACITY SINGLELEG

WIRE ROPE SLINGS
CAUTION
No singleleg hitch should be used on slings

with a load that cannot be controlled. Always
rig the sling and load so as not to allow the
load or lifting device to rotate and unlay the
sling rope. Rotation or twisting of the load can
cause excessive stress on the attachment
connection and reduce the slings capacity or
pull out.
Mechanical sleeve attachment

Hand tucked splice attachment
Zinc or resin poured
ANGLE A
15
30
45
60
COSINE OF ANGLE A
0.966
0.866
0.707
0.500
Example: Twolegged bridle of 1 inch IPS, IWRC wire rope

with zinc poured socket attachments, at 45.
Rated Capacity = 9.0 tons x 2 x 0.707
b.
CHOKER SLINGS
Cosine of Angle A
Slings used in choker configurations have a rated

capacity of 70 percent or S(3) if the choke angle is 120
or greater.
c.
BRIDLE SLINGS
For bridle slings and basket hitches where both legs are
not vertical use the following computation of the sling
arrangement rated capacity. Rated Capacity equals
Single leg capacity (refer to Figure 7) times the number
of legs times the cosine of angle A.
1OSM5.1, 350SS
5/8/00
Number of Legs
Capacity from Fig
ure 6
Rated Capacity = 12.73 tons
tag: bridle slings

FIGURE 7. RATED CAPACITY - BRIDLE SLINGS
d.
SLING INSPECTION:
All loose slings should be visually inspected daily and a

detailed periodic inspection should be performed on a
COPYRIGHT 2002
LeTourneau, Inc.
13
PUBLICATION OSM5
regular basis with the frequency of inspection based on

the following:
Slings should not be made using wire rope clips.
1. Frequency of sling use
2. Severity of service conditions
3. Nature or type of lifts being made
4. Experience based on service life of slings
used in similar applications
NOTE
d.
Evidence of heat damage or exposure.
e.
Cracked, deformed or worn end attachments.
f.
Hooks that have been opened more than 15
percent of their normal throat opening or twist more than
10 degrees from the plane of the unbent hook.
g.
Severe corrosion of the rope or end attachments.
PROOF LOADING AND LABELING

Slings of all rope grades and construction terminated by
mechanical, hand tucked or poured attachments shall
be proof loaded by the sling manufacturer when
specified by the purchaser.
Inspections should be made by qualified

persons only. Deterioration which could
contribute to loss of the original strength shall
be noted and the sling retired if such loss is
considered excessive.
SLING REPLACEMENT CRITERIA

Reasons for replacing the wire rope sling include but are
not limited to the conditions below. If there is any
question relative to the integrity of the sling, it should be
retired.
a. In singlepart slings, ten (10) randomly distributed
broken wires in one lay length or five (5) broken wires in
one strand in one lay length.
b.
c. Kinking, crushing, birdcaging or any other dam

age resulting in distortion of the rope strand and core
configuration.
Severe localized abrasion or scraping.
The proof load for singleleg slings with mechanical or

poured attachments shall be twice the vertical rated
capacity. Slings with handtucked splice attachments
shall be proof loaded to the vertical rated capacity.
The proof load for multipleleg bridle slings shall be
applied to each of the individual legs.
Slings of all types, grade and construction should be
labeled showing sling manufacturer and the vertical
rated capacity when specified by the purchaser.
Slings of other than wire rope construction should be
used, inspected and tested in accordance with the sling
manufacturer's recommendations.
NOTES
14
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
WIRE ROPE ATTACHMENT PROCEDURE

The PCM Electric Deck Cranes use a Wedge Socket
Assembly with a cable clamp for attachment of the wire
rope to components other than the cable drums. It is
CRITICALLY IMPORTANT that the Wedge socket
Assembly be correctly installed. Incorrect installation
can result in bodily injury and/or damage to equipment.
D Repair minor cracks or gouges to socket or pin

by lightly grinding until surfaces are smooth. Do
not reduce original dimension more than 10%.
D Inspect permanent assemblies annually, or
more often in severe operating conditions.
D Use only with standard 6 to 8 strand wire rope of
designated size. For intermediate size rope,
use next larger size socket. For example, when
using 9/16" diameter wire rope, use a 5/8" size
Wedge Socket Assembly. Welding of the tail on
standard wire rope is not recommended. The
tail length of the dead end should be a minimum
of 6 rope diameters but not less than 6". Refer to
Figure 9.
INSTALLATION SAFETY ADVISORIES
D Loads may slip or fall if the wedge socket is

not properly installed.
D A falling load can seriously injure or result in
the loss of life.
D Read and understand these instructions
before installing the wedge socket.
TAIL
LENGTH*
D Do not side load the wedge socket.

D Apply first load to fully seat the wedge and
wire rope in the socket. This load should be
of equal or greater weight than loads
expected in use.
RIGHT
CORRECT INSTALLATION OF WEDGE SOCKET ASSEMBLY
WEDGE SOCKET ASSEMBLY INSTALLA

TION
*TAIL LENGTH
Standard 6 to 8 strand wire rope
Components of the Wedge Socket Assembly are shown

in Figure 8.
PIN
SOCKET
A minimum of 6 rope diameters,

but not less than 6"
FIGURE 9. CORRECT INSTALLATION

OF WEDGE SOCKET ASSEMBLY
COTTER KEY
1CG1959, P1073
WEDGE
FIGURE 8. WEDGE SOCKET

ASSEMBLY COMPONENTS
NOTE
TA9257CG
The general guidelines listed below should be followed

in the installation and maintenance of the Wedge Socket
Assembly:
D Always inspect socket, wedge and pin before
installing.
D Do not use any part showing cracks.
1OSM5.1, 350SS
5/8/00
TA9259CG
D To use rotation resistant wire rope (special wire

rope constructions with 8 or more outer
strands), 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. The tail length of the dead
end should be a minimum of 20 rope diameters
but not less than 6". Refer to Figure 9.
CABLE CLAMP
1CG1958, P1073
Rotation Resistant Wire Rope

A minimum of 20 rope diameters,
but not less than 6"
COPYRIGHT 2002
The wedge has GO" and NOGO" features to

determine correct wire rope size cast into the
wedge. Refer to Figure 10.
The proper size wire rope is determined when
the following criteria are met:
1. The wire rope shall pass through the GO"
hole in the wedge.
LeTourneau, Inc.
15
PUBLICATION OSM5
WRONG
ROPE
BACKWARD
FIGURE 10. GO" - NOGO" METHOD OF

DETERMINING CORRECT WIRE ROPE SIZE
1CG1960P1073
WRONG
WEDGE
BACKWARD
FIGURE 12. INCORRECT INSTALLATION

METHODS OF WEDGE SOCKET
TA9258CG
1CG1961, P1073
2. The wire rope shall NOT pass through the

NOGO" hole in the wedge.
Rope Size
3/8
7/16
1/2
9/16
5/8
3/4
Clip Size
3/8
7/16
1/2
9/16
5/8
3/4
*Torque Ft./Lbs.
45
65
65
95
95
130
7/8
11/8 11/4
7/8
11/8 11/4
225
225
225
TA9256CG
D Do not attach dead end to live end or install

wedge backwards. Refer to Figure 12.
D Use a hammer to seat wedge and rope as deep
into socket as possible before applying first
load.
360
*The tightening torque values shown are based upon the threads
being clean, dry and free of lubrication.
OPERATIONAL SAFETY ADVISORIES

D Apply first load to fully seat the wedge and wire
rope in the socket. This load should be of equal
or greater weight that loads expected in use.
FIGURE 11. TIGHTENING TORQUE VALUES

D Properly match socket, wedge and clip to wire
rope size. Refer to Figure 11.
D Align live end of rope with center line of pin.
Refer to Figure 9.
D Secure dead end section of rope. Refer to Fig
ure 9.
D Tighten nuts on clip to recommended torque.
Refer to Figure 11.
16
WRONG TAIL
CLIPPED TO
LIVE LINE
COPYRIGHT 2002
D During use, do not strike the dead end section

with any other elements of the rigging (two
blocking).
NOTE
Efficiency rating of the wedge socket termina
tion is based upon the catalog breaking
strength of wire rope. The efficiency of a
properly assembled wedge socket is 80%.
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
SHEAVES, ROLLERS AND DRUMS

During regular inspections and when ropes are
changed on a crane a number or areas effecting
performance and rope life should be checked and
corrected. This inspection or check should include but
not be limited to the following:
SHEAVES, ROLLERS AND DRUM INSPEC

TION
g. Rope end attachment checked for compatibility of

rope size.
h. Rope spooling on drum checked for correct
spacing and cross over and winding.
i.
Grooved drums checked for condition, size and
alignment of grooves.
a. Sheaves should be checked with a groove gauge

for wear and checked for corrugation, the rope imprint in
the groove surface. Refer to Figure 13 for and
illustration of the sheave inspection process.
b. Sheaves should be checked for broken or chipped
flanges.
c.
f.
Drum flange should be checked for cracks, chips
or other deterioration.
Sheaves should be checked for cracks in the hub.
d. Sheaves should be checked for freedom of

rotation without drag.
e. Sheaves and shafts should be checked for bearing
or shaft wear.
CHECK FLANGES FOR WEAR,

CHIPS AND CRACKS
j.
Smooth drums checked for surface conditions to
ensure that there are no cracks or corrugation from the
rope.
MAINTENANCE OF SHEAVES, ROLLERS AND
DRUMS
Proper maintenance of the equipment over which the
ropes operate has an important bearing on rope life.
Worn grooves, poor alignment of sheaves and worn
parts resulting in shock loads and excessive vibration
will have a deteriorating effect.
Sheaves and grooved rollers should be checked
periodically for wear in the grooves, which may
cause pinching and abrasion of the ropes. If the
CHECK SHEAVE
GROOVES FOR
WEAR.
CHECK BEARINGS FOR

WOBBLE, LUBRICATION
& EASE OF ROTATION
A SHEAVE BADLY CORRUGATED BY
THE ROPE'S "PRINT", A CONDITION
WHICH COULD SERIOUSLY DAMAGE
THE WIRE ROPE.
IMPROPER
A PROPER FITTING SHEAVE GROOVE

SHOULD SUPPORT THE ROPE OVER 135150 DEGREES OF ROPE CIRCUMFERENCE.
CHECK GROOVES
FOR PROPER SIZE
OBSERVE THE GROOVE SO THAT IT
MAY BE CLEARLY SEEN WHETHER
THE CONTOUR OF THE RADIUS GAUGE
MATCHES THE CONTOUR OF THE
BOTTOM OF THE RADIUS GAUGE.
tag: wire rope maint
FIGURE 13. WIRE ROPE MAINTENANCE

1CG701, P0150
1OSM5.1, 350SS
5/8/00
TA7635CG
COPYRIGHT 2002
LeTourneau, Inc.
17
PUBLICATION OSM5
groove bears the imprint of the rope, it should be

machined clean or replaced. The same should be done
with drums showing similar effects. Sheaves with
oversized grooves do not properly support the rope and
must be replaced. A radius gauge should be used to
check the alignment of the rope in the grooves ( Refer to
Figure 13).
Poor alignment of sheaves will result in wear on the
rope and wear on the sheave flange. This should be

corrected immediately as a distorted groove will also
result.
Sheave and roller bearings should be checked for
free operation. Sticking will cause unnecessary wear.
Excessive wear in the sheave bearings can cause
rope fatigue from the vibration.
NOTES
18
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
SEIZING WIRE ROPE

Seizing is as process in which wire ropes are bound and
secured prior to a cut being made. While there are
numerous ways to cut wire rope, in every case certain
precautions must be observed. For one thing, proper
seizings are always applied on both sides of the place
where the cut is to be made. In a wire rope, carelessly or
inadequately seized ends may become distorted and
flattened, and the strands may loosen. Subsequently,
when the rope is put to work, there may be an uneven
distribution of loads to the strands, a condition that will
significantly shorten the life of the rope.
There are two widely accepted methods of applying
seizing (Refer to Figure 14 for Method A" and Method
B"). The seizing itself should be a soft, or annealed,
wire or strand. The seizing wire diameter and the length
of the seize will depend on the diameter of the wire rope.
But the length of the seizing should never be less than
the diameter of the rope being seized. For preformed
ropes, one seizing on each side of the cut is normally
sufficient. But for those that are not preformed, a

minimum of two seizings is recommended (Method
B"). Seizings should be spaced six rope diameters
apart.
SEIZING THE ROPE

Figure 14 lists seizing lengths and seizing wire diame
ters suggested for use with some commonly used wire
ropes.
METHOD A": Lay one end of the seizing wire in the
groove between two strands and wrap the other end
tightly in a close helix over a position of the groove, using
a seizing iron (a round bar 1/2" to 5/8" diameter x 18"
long) as shown in Figure 14. Seizing widths should not
be less than the rope diameter.
METHOD B": The procedure illustrated in Figure 14 is
the second of the two (A and B) accepted methods for
placing seizing on wire rope.
NOTES
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
19
PUBLICATION OSM5
3
6
1
METHOD A"
METHOD B"
SEIZING - SUGGESTED DIAMETERS AND LENGTHS

Rope Diameters
Seizing Wire Diameters*
Seizing Lengths
inches
mm
inches
mm
inches
mm
1/85/16
3.58.0
.032
0.813
1/4
6.0
3/89/16
9.514.5
.048
1.21
1/2
13.0
5/815/16
16.024.0
.063
1.60
3/4
19.0
11-15/16
26.033.0
.080
2.03
1-1/4
32.0
1-3/81-11/16
35.043.0
.104
2.64
1-3/4
44.0
1-3/42-1/2
45.064.0
.124
3.15
2-1/2
64.0
2-9/163-1/2
65.089.0
.124
3.15
3-1/2
89.0
*The wire rope manufacturer should be consulted for seizing wire diameters of rope not included in this chart.
tag: wir rop seiz
1CG1240, P0815
20
FIGURE 14. WIRE ROPE SEIZING

COPYRIGHT 2002
LeTourneau, Inc.
TA6029
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
LUBRICATING WIRE ROPE

The lubrication new ropes receive during manufacture
is adequate for initial storage and early stages of the
rope's working life, but a regular lubrication program is
essential to gain the maximum service life from the rope.
The following instructions provide guidelines for the
proper lubricating of the wire rope on the machine.
Used crankcase oil should NEVER be used to

lubricate a wire rope. It contains tiny metal
chips which abrade the rope, it is acidic, and it
has few of the characteristics that a good rope
lubricant should have.
THE IMPORTANCE OF REGULAR WIRE

ROPE LUBRICATION
NOTE
Lubricants recommended by LeTourneau, Inc.
are listed in Publication OSM4, PCM CRANE
LUBRICATION SPECIFICATIONS, this manu
al. Lubricate the wire rope at regular intervals
in accordance with the PREVENTIVE MAINTE
NANCE SCHEDULES in the back of publica
tion OSM4. For off shore cranes, a rust
preventive lubricant such as Mobil Mobilar
ma 798" or Texaco Crater X" or equivalent is
recommended.
Lubricating a rope is as important as greasing any

other piece of machinery. If a planned program of
regular lubrication is not carried out, then the rope will
deteriorate as follows:
D
Corrosion and pitting will occur, causing a loss of

steel area and, therefore, a loss in strength of the
rope.
The wires will become brittle from excessive corro

sion and will break easily.
Since each wire in the rope moves relative to the

others during operation, they are subject to fric
tional wear. Lack of lubrication will increase the wear
rate, causing a marked reduction in strength from
loss of steel area.
Pits also cause internal nicking of the wires, which

results in loss of strength.
Ropes not in regular service or those not consid

ered as operating ropes are vulnerable to weather
ing out of the lubrication. Moisture seeps in, and
both core and wires deteriorate.
CHOOSING THE PROPER LUBRICANT

Wire rope should be lubricated with a lubricant which
provides excellent protective covering properties pro
ducing a nontacky but firm and flexible coating. This
lubricant should also be water repellent, have excellent
resistance to very high and very low temperatures, good
lubricating properties and free of mineral acids.
WIRE ROPE LUBRICATING PROCEDURES

a.
Corrosion resistance.
Water repellent.
Penetrating ability.
Chemically neutral.
High pressure flow characteristics.
Adhesiveness and an affinity for steel.
Temperature stability.
1OSM5.1, 350SS
5/8/00
ROPE CLEANING TECHNIQUES
The rope must be clean and dry before the lubricant

is applied because effective lubrication occurs only
when the dressing comes in contact with bare metal.
If this is not done, the lubricant will fall off, allowing
moisture to work into the rope to cause corrosion.
Excessive moisture gradually leaches out the internal
lubricant.
CAUTION
ALWAYS wear gloves when handling wire rope

to prevent hand injury.
The old lubricant can be removed by stationary or
powerdriven wire brushes or by compressed air jets
(Figure 15). It is advisable to use a light penetrating
cleaner to soften the builtup material before removing
it. The lubricant supplier should be contacted regarding
the proper cleaning oil to use.
CAUTION
Do not use gasoline or kerosene to clean wire

rope as too much of it will remove the internal
lubricant.
Good wire rope lubricants have the following character

istics:
D
CAUTION
b.
LUBRICANT APPLICATION TECHNIQUES
In view of the small space existing between wires in the

strand and strands in the rope, do not expect externally
applied lubricant to completely penetrate the rope.
The main object in external lubrication is to fill the gaps
between the strands and rope so that a complete seal is
provided. The lubrication should be carried out periodi
cally to maintain this seal. The frequency required will
depend upon the particular installation.
COPYRIGHT 2002
LeTourneau, Inc.
21
PUBLICATION OSM5
COMPRESSED AIR
WIRE BRUSHES
AIR BLAST DRYING
BATH OF PENETRATING CLEANER
tag: clean wire rope

FIGURE 15. METHOD OF CLEANING WIRE ROPE
TEMPORARY
WINDING DRUM
PREFERRED
METHOD SINCE
ROPE OPENS UP
OVER SHEAVE
ALLOWING OIL
TO PENETRATE.
AIR BLAST
APPLICATION
AIR OIL
OIL BATH
APPLICATION
BRUSH
APPLICATION
DIP AND SWAB

APPLICATION
OIL BATH APPLICATION
tag: lub wire rope
USING SPLIT WOODEN OR METAL BOXES

ROPE PASSES THROUGH BURLAP OR SIMILAR WIPER AT OUTLET END OF BOX
1CG705, P0151
22
FIGURE 16. METHOD OF LUBRICATING WIRE ROPE

COPYRIGHT 2002
LeTourneau, Inc.
TA7654CG
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
Application of the lubricant may be accomplished by

several methods. These should be considered with due
regard to the viscosity of the compound in its state for
application, length of rope involved and limitation of
facilities.
Light oils may be applied by brushing or running the
rope through an oil bath, by spraying, drip method and
mechanical force feed (Figure 16).
For maximum penetration, the lubricant should be
applied to the rope where it opens up" as it travels
around a sheave or winds on a drum. It is also advisable
to apply the lubricant in a warm area. If the lubricant
must be applied manually in an extremely cold area,
however, rope lubricants are available with pour points
as low as -50 F to -60 F.
blast may also be used provided that dry air is used as

any moisture would promote corrosion.
Where long lengths of rope are involved, brushing or
hand application is tedious. However, a thorough
examination can be carried on at the same time so that
two important jobs can be accomplished in one
operation.
General recommendations regarding the time interval
that should elapse between lubrications are found in the
PREVENTIVE MAINTENANCE SCHEDULES located in
the back of Publication OSM4, in the OPERATING AND
SERVICE MANUAL. The rope should be properly
lubricated at all times, and thorough periodic inspec
tions will indicate when it must be done.
Medium weight lubricant or heavy lubricant applied hot

can be brushed on, applied by hand or by running the
rope through a funnel containing the lubricant. The air
NOTE
If a wire rope is taken out of service for an
appreciable length of time, it should be
cleaned, lubricated and stored in a dry place
where it will be protected from the elements.
NOTES
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
23
PUBLICATION OSM5
WIRE ROPE LUBRICATION

LUBRICATION OF WIRE ROPES IN SERVICE
(1)
(2)
(3)
(4)
(5)
Operating Condi
tions
Ropes working in in
dustrial or marine en
vironments.
Ropes subject to
heavy wear.
Ropes working over

sheaves where (1)
and (2) are not critical.
As (3) but for friction

drive applications.
Standing ropes not

subject to bending.
Predominant cause
of rope deterioration
Corrosion.
Abrasion.
Fatigue.
Fatigue-corrosion.
Corrosion.
Typical applications
Cranes and derricks

working on ships, on
docksides, or in pol
luted atmospheres.
Mine haulage, exca

vator draglines, scrap
ers and slushers.
Cranes and grabs, jib

suspension ropes, pil
ing, percussion and
drilling.
Lift suspension, com

pensating and gover
nor ropes, mine hoist
ropes on friction wind
ers.
Pendant ropes for

cranes and excava
tors. Guys for masts
and chimneys.
Dressing require
ments
Good penetration to
rope interior. Ability to
displace moisture. In
ternal and external
corrosion protection.
Resistance to wash
off". Resistance to
emulsification.
Good antiwear prop

erties. Good adhesion
to rope. Resistance to
removal by mechani
cal forces.
Good penetration to
rope interior. Good lu
brication properties.
Resistance to fling
off".
Nonslip property.
Good penetration to
rope interior. Ability to
displace moisture. In
ternal and external
corrosion protection.
Good corrosion
protection. Resistance
to wash off". Resist
ance to surface crack
ing.
Type of lubricant
Usually a formulation
containing solvent
leaving a thick
(0.1 mm) soft grease
film.
Usually a very viscous

oil or soft grease con
taining M0S2 or
graphite. Tackiness
additives can be of
advantage.
Usually a good gener

al purpose lubricating
oil of about SAE 30
viscosity.
Usually a solventdis
persed temporary cor
rosion preventative
leaving a thin, semi
hard film.
Usually a relatively
thick, bituminous
compound with sol
vent added to assist
application.
Application tech
nique. Refer to Fig
ure 16.
Manual or mechani
cal.
Manual or mechani
cal.
Mechanical.
Normally by hand.
Normally by hand.
Frequency of ap
plications*
Monthly.
Weekly.
10/20 cycles per day.
Monthly.
Six months/2 years.
*The periods indicated are for the general case. The frequency of operation, the environmental conditions and the economics of service dressing will more
correctly dictate the period required.
Opening of rope sections during passage over sheave or drum.

Arrows indicate the access points for lubricant.
1CG1241, P0815
FIGURE 17. WIRE ROPE LUBRICATION
24
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5

WIRE ROPE SPECIFICATIONS
The crane is equipped with wire rope of the specifica
tions listed below. The wire rope on the crane shall be
replaced with rope of the same specifications only.
a.
c.
BRIDLE LINE ASSEMBLY

1. 23/8 inch x 68 ft. wire rope (4121305)
(123.5 ft. boom)
23/8 inch x 93 ft. wire rope (4235450)
(149.5 ft. boom)
MAIN HOOK LINE ASSEMBLY

1. 1 inch wire rope x 2225 ft. (4235088)
2. Rotation resistant
2. 6 x 26 Warrington Seale IWRC EIPS
3. DYFORM 34LR GR2160
3. 274 tons breaking strength
NOTE
4. 70.03 tons breaking strength
NOTE
Must have written certification of 70.03 tons
breaking strength.
b.
Must have written certification of 274 tons

breaking strength.
d.
AUXILIARY HOOK LINE ASSEMBLY
BOOM LINE ASSEMBLY
1. 1 inch wire rope x 550 ft. (P/N 4229660)
2. Rotation resistant.
2. Constructex
3. DYFORM 18 HSLR
NOTE
NOTE

breaking strength.

breaking strength.
NOTES
1OSM5.1, 350SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
25
PUBLICATION OSM5
BOOM POINT SHEAVE WHEELS
1" WIRE ROPE

2225' LONG
70.3 TONS B.S.
HOOK SHEAVE WHEELS
HOOK CABLE DRUM
PCM 350SS CRANE

MAIN HOOK CABLE REEVING SCHEMATIC
1CG1581, P1029
26
TA8664CG
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5
GUIDE SHEAVE WHEEL

AUX. BOOM TIP
SHEAVE WHEEL
1" WIRE ROPE

550' LONG, 57.5 TONS B.S.
10 TON HOOK
AUX. HOOK CABLE DRUM
PCM 350SS CRANE

AUX. HOOK CABLE REEVING SCHEMATIC
1CG1583, P1029
1OSM5.1, 350SS
5/8/00
TA8678CG
COPYRIGHT 2002
LeTourneau, Inc.
27
PUBLICATION OSM5
FLOATING SHEAVE WHEELS
6
8
10
12
3
5
7
GANTRY SHEAVE WHEELS
D.E.
11
1 WIRE ROPE (9 X 40 CONSTRUCTEX)
1075 LONG, 62.5 TONS B.S.
CABLE DRUM
PCM-350SS CRANE
BOOM UP CABLE REEVING SCHEMATIC
1CG1582, P1029
28
TA8925CG
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.1, 350SS
5/8/00
PUBLICATION OSM5

WIRE ROPE SPECIFICATIONS
The crane is equipped with wire rope of the specifica
tions listed below. The wire rope on the crane shall be
replaced with rope of the same specifications only.
a.
c.
BRIDLE PENDANTS
1. 13/4 inch x 50 ft. (P/N 4229572)
MAIN HOOK LINE ASSEMBLY
2. 6 x 26 Warrington Seale - IWRC - EIPS
1. 1inch swaged wire rope x 1375 ft. (4235086)
3. 168 tons breaking strength
NOTE
3. DYFORM 34LR GR2160
Must have written certification of 168 tons

breaking strength.
4. Rotation resistant
NOTE
breaking strength.
b.
d.
AUXILIARY HOOK LINE ASSEMBLY

LUFFING
3. DYFORM 18 HSLR
4. Rotation resistant.
3. CONSTRUCTEX
NOTE
NOTE

breaking strength.

breaking strength.
NOTES
1OSM5.2, 120SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
25
PUBLICATION OSM5
1" WIRE ROPE

1375' LONG
70.3 TONS B.S.
HOOK SHEAVE WHEELS
HOOK CABLE DRUM
PCM 120SS CRANE

TA8926CG
1CG1586, P1030
26
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.2, 120SS
5/8/00
PUBLICATION OSM5
FLOATING SHEAVE HOUSING
DEAD END
3
1 WIRE ROPE
460 LONG
62.5 TONS B.S.
GANTRY SHEAVE HOUSING
BOOM UP CABLE DRUM
TA8928CG
1NGO1588, P1030, 5/3/00
1OSM5.2, 120SS
5/8/00
COPYRIGHT 2002
LeTourneau, Inc.
27
28
PUBLICATION OSM5
COPYRIGHT 2002
LeTourneau, Inc.
1OSM5.2, 120SS
5/8/00
PUBLICATION OSM6
LeTOURNEAU, INC. ELECTRIC DECK CRANE

BRAKES
TABLE OF CONTENTS
TABLE OF CONTENTS
Page
LIST OF ILLUSTRATIONS (Cont'd.)

FIGURE
SCOPE OF THIS PUBLICATION . . . . . . . . . . . . . . . . . 1

GENERAL WARNINGS AND CAUTIONS . . . . . . . . . . 1
SWING MOTOR ELECTROMECHANICAL BRAKE 2
WORKING AIR GAP ADJUSTMENT
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BENCH (MAXIMUM) AIR GAP ADJUSTMENT
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DISASSEMBLY OF SWING MOTOR
ELECTROMECHANICAL BRAKE HEAD . . . . . . . . . 3
BRAKE DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . 3
ASSEMBLY OF THE SWING MOTOR
ELECTROMECHANICAL BRAKE HEAD . . . . . . . . . 3
Page
SWING MOTOR DISC BRAKE STACKING .
480 VAC BACKUP PUMP INSTALLATION .
HYDRAULIC POWER UNIT . . . . . . . . . . . . . .
10
HYDRAULIC BRAKE ASSEMBLY . . . . . . . . .
13
BRAKE CALIPER GROUP . . . . . . . . . . . . . . .
14
MANUALLY RELEASING HYDRAULIC

BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
10
SERVICING BRAKE ACTUATOR . . . . . . . . .
19
11
HYDRAULIC BRAKE SCHEMATIC,

PCM 120SS/350SS . . . . . . . . . . . . . . . . . . . .
21
12
BRAKE CONTROL DIAGRAM . . . . . . . . . . . .
22
HOIST BOOM AND AUXILIARY HOOK

ASSEMBLY DC MOTOR HYDRAULIC BRAKES . . . . 7
GENERAL WARNINGS AND CAUTIONS . . . . . . . . 7
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . 8
DC MOTOR HYDRAULIC BRAKE - SYSTEM
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECT HYDRAULIC OIL RESERVOIR
EVERY 50 HOURS OR WEEKLY . . . . . . . . . . . . . . . 8
SYSTEM PRESSURE CHECKS . . . . . . . . . . . . . . . . 11
OPERATION AND INSPECTION OF DC MOTOR
HYDRAULIC BRAKE CALIPER ASSEMBLIES . . . . 11
DISC PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . 12
MANUALLY RELEASING THE HYDRAULIC
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SERVICING THE HYDRAULIC BRAKE
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSPECTIONS UPON DISASSEMBLY . . . . . . . . . . 17
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BRAKE SYSTEM LEAKAGE CHECK . . . . . . . . . . . . 18

Publication OSM6, BRAKES, is to assist maintenance
personnel with the inspection, adjustment, replacement
of discs, and repair or the electric swing motor brake
and the hydraulic brakes found on the main hook,
boom, and auxiliary hook DC motors. In routine
operation of the crane it is ESSENTIAL to pay close
attention to the stopping action of all of these compo
nents. Brakes are wear items whose service life is
affected by production, scheduling of the machine,
load, speed, and the operator's skill in stopping the
crane's movements properly to minimize wear.
GENERAL WARNINGS AND CAUTIONS

The following general warnings and cautions apply to
both the swing motor electromechanical brake and the
hydraulic brakes or the hoists and boom:
FIGURE
Page
SWING MOTOR ELECTROMECHANICAL

BRAKE SPECIFICATIONS . . . . . . . . . . . . . . .
MOTOR BRAKE ADJUSTMENT . . . . . . . . . .
BRAKE WIRING . . . . . . . . . . . . . . . . . . . . . . .
1OSM6.2a, 120SS & 350SS, Gorilla

6/6/00
When performing service or repair operations

on elevated structures of the crane, NEVER
proceed beyond the safety of hand railed
platforms. Serious injury or loss of life from
falling is possible outside these areas.
COPYRIGHT 2002
LeTourneau, Inc.
BRAKES
PUBLICATION OSM6
the maximum air gap. Maximum air gap for the brake is
0.125 inch (refer to Figure 1).
When the working air gap reaches the Reset gap (refer
to Figure 1), perform the following procedure:
The boom must be in the stowed position and

the drum safety lock pin installed before
inspecting, servicing or repairing any part of
the crane's hydraulic brake system. Also,
place a DO NOT OPERATE sign on the
controls and lock the operators control panel
before performing maintenance or inspecting
the hydraulic brake system. Serious injury or
death is possible if the crane is started or
moved while maintenance or repairs are being
conducted.
a. Back off the three locking capscrews just enough

to free the brake adjusting screws.
b. Turn the adjusting screws to change the air gap.
Turn clockwise to increase air gap; counterclockwise to
decrease air gap.
c. Check gap in at least three equally spaced
locations around brake ring.
d. When desired air gap of 0.080 inch is obtained,
tighten the three locking capscrews to lock the adjust
ing screws and recheck air gap. Tightening the locking
capscrews may cause a slight change in brake
adjustment. Torque capscrew to value listed on torque
tag affixed to brake head.
CAUTION
Swing movement WILL NOT stop immediately

when the SWING joystick potentiometer is
returned to the neutral position. Swing speed,
load, brake adjustment and wind will effect the
distance the boom will travel before regenera
tive braking will bring it to a full stop. The
operator should be aware that there are
variable factors involved and start and stop
swing movements with caution.
BENCH (MAXIMUM) AIR GAP ADJUSTMENT

PROCEDURES
If the brake has been removed from the motor for any
reason, the following procedure should be performed to
adjust the Bench (maximum) air gap (refer to Figure 1):
a. When reassembling the brake, assemble the coil
ring and inner magnet ring and set the maximum air
gap, refer to Figure 1 for the correct bench air gap.
CAUTION
b. This air gap is measured between the bottom of

the maximum air gap adjusting nut and the outer
magnet plate with the brake head completely com
pressed.
DO NOT attempt to stop the crane's rotation by

moving the BRAKE switch to the SET position,
except in an emergency. Doing so may
damage the swing gear and swing motor
pinion.
c. Tighten the jamnut against the adjusting nut, once

the correct air gap has been obtained.
SWING MOTOR ELECTROMECHANICAL

BRAKE
WORKING AIR GAP ADJUSTMENT PROCEDURES
The electromechanical swing motor brake is properly
adjusted when the working air gap between the two
magnet rings is 0.080 of an inch. The inner magnet ring
structure is secured to the outer magnet ring and coil
assembly by three studs, nuts and jamnuts. The setting
of these three nut and jamnut combinations determines
d. Attach the coil and magnet assembly to the

endbell or continuous brake ring.
e. After attaching the coil and magnet assembly to
the endbell, the air gap can be adjusted with the three
adjusting screws. This will not affect maximum air gap
which is limited to the settings prescribed in Figure 1 by
the three hex nut and jamnut combination.
COPYRIGHT 2002
NOTE
If brake air gap is allowed to open to 0.150
inch, the brake will start to slip.
LeTourneau, Inc.

6/6/00
PUBLICATION OSM6
AIR GAP
SETTINGS
BRAKES
Working Air Gap
.080"
Maximum Air Gap
0.125"
Air Gap Gauge
STATIONARY
DISC
ENDBELL
Compressed to 65 lbs., P/N 0782389

(6 ea.) at 2.8125"
COILS
600 VAC, Resistance between phases 8.92

ohms at 20C, P/N 4036237 (6 ea.)
MAGNET RINGS
BRAKE HEAD
ASSEMBLY
BRAKE
ADJUSTING
SCREW
P/N 0955056
SPRINGS
BRAKE DISCS*
ROTATING
DISC
LOCKING
CAPSCREW
MAXIMUM
AIR GAP
ADJUSTING NUT
Rotating P/N 4015420 (3 ea.)

JAMNUT
Stationary P/N 4039598 (4 ea.)

Inner P/N 078-8338
Outer P/N 0814667
MAXIMUM
AIR GAP
P/N 4036240
*Refer to Figure 4 for brake disc stacking procedure.
FIGURE 1. SWING MOTOR ELECTRO

MECHANICAL BRAKE SPECIFICATIONS
WORKING
AIR GAP
DISASSEMBLY OF SWING MOTOR ELEC

TROMECHANICAL BRAKE HEAD
BRAKE
SPRING
The motor brake head consists of two major compo

nents: Inner Magnet Ring and Outer Magnet Ring and
Coil Assembly.
INNER
MAGNET
RING
FIGURE 2. MOTOR BRAKE ADJUSTMENT
NOTE
1CG700, P0602
If a safety or instructional sign is on a part that

is replaced, make sure a new sign is installed
on the replaced part.
TA7661CG
NOTE
a. Separate the inner magnet ring from the outer

magnet ring and coil assembly by removing six (6) nuts
from the studs. Lift the outer magnet ring and coil
assembly off the inner magnet ring.
b. Remove the brake springs from the spring re
cesses of the inner magnet ring. Note the number of and
location of the springs on the inner magnet ring.
c. Check for broken or weak brake springs. Check
brake spring tension in accordance with Figure 1.
d. If the three studs mounted in the inner magnet ring
are worn, they should be replaced.
NOTE
Do not mix coils on the same outer magnet

ring.
f.
Inspect inner magnet ring for physical damage.
g. Inspect outer magnet ring and coil assembly for

physical damage, especially in the area of the brake
adjusting screws. Replace any broken coil anchor bolts.
BRAKE DISC REPLACEMENT

When installing brake discs, care should be made to
assure that discs (both stationary and rotating) be flat.
Warped discs should not be used. Air gaps should be
set up and maintained in accordance with air gap
adjustment procedures as outlined in this publication.
The discs should be stacked as shown in Figure 4.
ASSEMBLY OF THE SWING MOTOR

ELECTROMECHANICAL BRAKE HEAD
The stud threads in the inner magnet ring are

3/ " NPT.
8
e. Check for continuity of the coils in the inner magnet
ring assembly with an ohmmeter. Replace any defective
coil. Refer to Figure 1 for the brake coil resistance.
6/6/00
OUTER
MAGNET
PLATE
a. Place the inner magnet ring on a bench and torque

the three studs to 110-120 ft. lbs. The studs must not
protrude above the flat surface of the inner magnet ring.
COPYRIGHT 2002
LeTourneau, Inc.
BRAKES
PUBLICATION OSM6
L1
L1
1
5
1
L2
10
11
11
3
6
12
5 8
5
12
4
7
L3
6
10
3
4
L3
L2
SWING BRAKE
FIGURE 3. BRAKE WIRING
1CG1577, P1037
If necessary, grind the end of the studs flush with the

surface of the inner magnet ring.
b. Install the brake springs in the spring recesses of
the inner magnet ring with the number of springs
required (by the PARTS CATALOG) to meet the specifi
cations for the particular motor on which the brake head
assembly will be used.
c. If the coils have been removed from the outer
magnet ring, they must be installed with the pigtail
facing inward. Refer to Figure 3 for the wiring diagram of
the coil connections.
d.
f.
With three (3) 1/2" UNF nuts, pull the outer magnet
ring and coil assembly down until the proper air gap is
met (refer to WORKING AIR GAP ADJUSTMENT
PROCEDURES, page 2, to adjust the maximum air
gap). Use the other three (3) 1/2" UNF nuts to lock this
adjustment.
NOTE
There must not be interference or dragging of
the inner magnet ring with the coil boxes. If
necessary, loosen the anchors of the offend
ing coil and readjust.
CAUTION
Tighten the capscrews just enough to prevent

coil movement. Safety lock the capscrews
with 1/4" UNC nuts.
e. Position the outer magnet ring and coil assembly

into the inner magnet ring so that the studs do not line
up with the adjusting screws in the outer magnet ring
and coil assembly.
Lock the coils in position with the coil anchors.
TA8985CG
g. Install the brake adjusting screws in the outer

magnet ring and coil assembly.
COPYRIGHT 2002
LeTourneau, Inc.

6/6/00
PUBLICATION OSM6
BRAKES
ROTATING DISCS
STATIONARY DISCS
FIGURE 4. SWING MOTOR DISC BRAKE STACKING
TA8980S
1CG1564, P1032
NOTES

6/6/00
COPYRIGHT 2002
LeTourneau, Inc.
BRAKES
PUBLICATION OSM6
NOTES
COPYRIGHT 2002
LeTourneau, Inc.

6/6/00
PUBLICATION OSM6
BRAKES
HOIST, BOOM, AND AUXILIARY HOIST ASSEMBLY

DC MOTOR HYDRAULIC BRAKES
The Hoist, Boom, and Auxiliary Hoist Assembly DC
Motors are equipped with a dual caliper, spring applied,
hydraulically released disc brake. Hydraulic power is
provided by a hydraulic power unit. System operation
and maintenance procedures are provided below.
Handling and disposal of used oils may be

subject to federal, state and local laws and
regulations. Use authorized waste disposal
facilities; for example, local collection sites
and garages providing authorized facilities for
receipt of used oil. If in doubt, contact your
state and local environmental authorities or
the Environmental Protection Agency for
direction on proper handling and disposal of
used oil.
GENERAL WARNINGS AND CAUTIONS
The boom must be in the stowed position

before inspecting, servicing or repairing any
part of the crane's hydraulic brake system.
Also, place a DO NOT OPERATE sign on the
controls and lock the operators control panel
conducted.
Hydraulic fluid under pressure can penetrate

the skin and cause serious personal injury,
blindness, or death. If any fluid is injected into
the skin it must be removed within a few hours
by a doctor familiar with treating this type of
injury.
Fluid leaks under pressure may not be visible.
When searching for leaks, NEVER use your
hand, use a piece of cardboard or wood. Wear
work gloves and keep your hand well away
from the possible source of leakage. Do not
tighten or loosen hydraulic lines without first
relieving the pressure. Wear safety goggles
for eye protection.
The hydraulic brake canisters are under

spring pressure. Do not attempt to disas
semble them without the special tools
required. Refer to SERVICING THE HY
DRAULIC BRAKE ACTUATORS, page 17.
6/6/00
CAUTION
CAUTION
To prevent injury, wear hard hat, protective

glasses and other protective equipment as
required by job conditions.
CAUTION
To ensure future safety, if a safety or

instructional sign is on a part that is replaced,
make sure a new sign is installed on the
replaced part. Replace immediately any safety
or instructional sign that is not legible. Refer to
the PARTS CATALOG to order replacement
signs.
SYSTEM DESCRIPTION
NOTE
The hydraulic power unit owner's manual is
provided at the end of this publication. Refer to
Figure 6 for an illustration of the hydraulic
power unit.
a. Hydraulic System: The primary hydraulic power
source is a low pressure gear pump. A secondary
480 VAC pump (see Figure 5) is available as a backup to
the primary pump (see BACKUP AC PUMP MOTOR
section in Publication OSM4 of this manual). In the
event of crane power loss, a Power Loss Lowering
System (PLLS) exists to allow for the constant speed
lowering of a load from the operator's console (see PCM
Crane Power Loss Lowering System, located in Section
5, SOLID STATE CONVERSION SYSTEM, in the REPAIR
AND OVERHAUL manual). This system uses a 24 VDC
motordriven pump mounted on the hydraulic power
unit and powered by four 12 VDC batteries. A manual
release method also exists (see page 15 OF THIS
PUBLICATION) as a backup to the PLLS.
b. Primary Hydraulic Power Source: The primary
hydraulic power source is mounted on a 20gallon
reservoir with the pump inside the reservoir and the
COPYRIGHT 2002
LeTourneau, Inc.
BRAKES
PUBLICATION OSM6
primary motor protruding from the top. This motor is a

IEEE 45 Class in a 3 HP size with 3phase 480volt power
required. The pump produces 5 gpm at the 130 psi
requirement.
c. Power Loss Lowering System Power Source:
The PLLS hydraulic pump and 24 VDC motor are
mounted to the top of the reservoir. At full pressure, the
24 VDC motor will consume 30 to 35 amps from a
battery power pack. The pump produces 3 gpm at 130
psi and has a maximum rating of 3000 psi. This system
is only used for partially releasing the hoist brake and
allowing a load to slip through the brakes to the deck
(POWER LOSS HOIST LOWERING see Section 5,
SOLID STATE CONVERSION SYSTEM, in the REPAIR
AND OVERHAUL MANUAL).
d. Valving: The valving is solenoid operated by 24
VDC and is rated at 4000 psi. It is sized to handle up to
20 gpm. and is being utilized at 5 gpm except during
spring brake apply when the flow will approach 15 gpm.
The solenoids for these valves are equipped with a
manual override feature which allows for manual
operation if control voltage is lost or if a coil should fail.
The coil connector is also equipped with an LED to
indicate it is being energized.
e. Reservoir: The reservoir is of steel construction
and is coated to withstand marine environment. It holds
20 gallons of hydraulic fluid. The suction strainers for
each pump are inside the reservoir and the pressure
filter is mounted on top of the reservoir. A visual level and
temperature gauge is used in conjunction with a low
level switch and a temperature switch. A screw type fill
port is incorporated into the top of the reservoir and a
combination filterdesiccant breather is used to control
atmospheric air ingestion quality.
f.
Hydraulic Fluid: Use only nonflammable hydrau
lic fluid LeTourneau, Inc. P/N 4235122.
bronze, suitable for use in the corrosive marine

environment. A thermocouple mounted in proximity to
the disc monitors temperature during the power loss
hoist lowering function.
Refer to the REPAIR AND OVERHAUL

MANUAL, Section 5, SOLID STATE CONVER
SION SYSTEM, for information on the power
loss lowering card and thermocouple before
any adjustments, disassembly, or assembly of
the thermocouple is attempted.
SYSTEM OPERATION
a. The hydraulic pump becomes operational when
the MASTER switch is turned to the ON position. System
pressure is regulated to 130 psi when the BRAKE switch
is turned to the ENABLE position.
b. The brakes do not release until the appropriate
joystick (hoist or boom) is moved off of the neutral
position. The appropriate electronic controller ener
gizes relay CR2 (hoist) or CR3 (boom) which applies
system pressure through solenoids to the appropriate
springapplied brake canisters and releases the brakes.
Various external conditions, however, can prevent the
controller from releasing the brakes or automatically set
the brakes once they have been released (low hydraulic
fluid pressure, low hydraulic fluid level, high hydraulic
fluid temperature, various limit switches, etc.).
DC MOTOR HYDRAULIC BRAKE - SYS

TEM MAINTENANCE
Routine maintenance is required to keep the Hydraulic
Brake System functioning properly. Refer to Figure 6 for
an illustration of the hydraulic power unit. Also, refer to
the hydraulic power unit owner's manual at the end of
this publication.
g. Hose and Fittings: The hosing and fittings in the

system are rated at 2000 psi minimum which yields an
extremely conservative safety factor at 130 psi working
pressure. the elastomers are rated for usage from 50 F
to +300 F.
h. Brake Caliper Assembly (refer to Figures 7 and
8): The caliper Cclamp and base mount is a steel
casting machined by LeTourneau, Inc. The pads are
metallic filled, organic material containing no asbestos.
The actuating cylinder is a device with the outer
chamber containing a high force spring that applies the
brake when pressure is removed. The cylinder end
closest to the attachment bolts allows a pressure to be
applied to release or modulate the torque of the brake.
Stored externally on the cylinder is a release bolt that
screws into the spring end of the cylinder to allow
release or modulation of the brake using common hand
tools (refer to Figure 9). The disc is made of aluminum
8
CAUTION
NOTE
Refer to SERVICE UPON RECEIPT, located in
Publication OSM1, in the OPERATING AND
SERVICE MANUAL for service and inspec
tions required during startup and the initial 50
and 100 hours of operation. It is essential that
these services be performed to achieve
proper operation and efficient service from the
hydraulic brake system.
INSPECT HYDRAULIC OIL RESERVOIR

EVERY 50 HOURS OR WEEKLY
Inspect the hydraulic oil reservoir weekly for proper level
and condition of the fluid. The hydraulic power unit is
equipped with an Electrical Fluid Level Indicator. This
device provides a sight gauge for quickly checking the
fluid level. If the system is low, the leak should be
COPYRIGHT 2002
LeTourneau, Inc.

6/6/00
PUBLICATION OSM6
BRAKES
1
7
12
10
11
13
13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
FITTING
FITTING
HOSE
FITTING
CHECK VALVE
BUSHING
PUMP MOTOR
FITTING
HOSE
FITTING
PIPE FITTING
POWER UNIT
NIPPLE
DRAIN VALVE
14
FIGURE 5. 480 VAC BACKUP PUMP INSTALLATION

TA9278CG
1CG2077, P1041

6/6/00
COPYRIGHT 2002
LeTourneau, Inc.
BRAKES
1CG1601, P1041
10
A
10
18
11
9
8
19
1
SOL 1
4
C
COPYRIGHT 2002
tag: hyd power unit
13
LeTourneau, Inc.
20
17
16
12
15
7
21
14
7
24
3
25
18
11
10
22
23
11
AB
a
SOL 2
19
AB
b
SOL 3
1
SOL 4
AB
b
SOL 6
SOL 5
AB
a
b
PT
SECTION A-A
23
MOTOR
CHECK VALVE
BREATHER
PRESSURE FILTER
MANIFOLD
OIL FILTER
RESERVOIR
SANDWICH BODY
DIRECT. CONT. VALVE
RELIEF VALVE
3 HP MOTOR
OIL LEVEL GAUGE
GEAR PUMP
14
15
16
17
18
19
20
21
22
23
24
25
SHUTTLE VALVE
SUCTION STRAINER
COUPLING
RELIEF VALVE
PRESSURE GAUGE
GEAR PUMP
ADAPTER
SUCTION STRAINER
PRESSURE SWITCH
DIRECT. CONT. VALVE
OIL LEVEL SWITCH
TEMP. SWITCH
FIGURE 6. HYDRAULIC POWER UNIT
19
SECTION B-B
PUBLICATION OSM6
10
AB
a
TA8982CG

6/6/00
SOL 7
1
2
3
4
5
6
7
8
9
10
11
12
13
PUBLICATION OSM6
BRAKES
repaired and the system filled to the proper level before

operating the crane. Use a filter when filling the
reservoir, with a mesh width of 0.002 in. (0.06 mm) or
better. Fill via the 10 micron system filter. Refer to PCM
CRANE LUBRICATION SPECIFICATIONS, Figure 1 in
Publication OSM4, located in the OPERATING AND
SERVICE MANUAL, for the recommended hydraulic
fluid.
CAUTION
Do not operate the hydraulic system with a low

reservoir fluid level. Cavitation of the hydrau
lic pump can occur which will cause serious
component damage and brake system failure.
SYSTEM PRESSURE CHECKS

Check main system pressure weekly or every 50 hours
of operation. The system should operate at 130 psi.
Note any system pressure corrections in the crane's
permanent file. Frequent readjustment indicates wear
in the pressure relief components. Pressure drops
should be investigated to determine the cause.
OPERATION AND INSPECTION OF DC

MOTOR HYDRAULIC BRAKE CALIPER
ASSEMBLIES
a. DAILY AND MONTHLY FILTER INSPECTION

AND SERVICE
1. High Pressure Filters: The high pressure
filters are equipped with an indicator to
determine when they should be replaced. The
high pressure filters should be checked daily
and replaced if required.
2. Suction Filters: The suction filters require
inspection and cleaning yearly or every 2,500
hours of operation. The filters should be
cleaned with solvent and blown through with
air to remove any buildup of contaminants.
3. Breather Filter: The breather filter is de
signed to eliminate fluid contamination result
ing from wet, dirty air. The breather filter has
an indicator in its side to determine when the
unit needs servicing. The breather should be
inspected daily and serviced when required.
Refer to the PARTS CATALOG for ordering
replacement filters.
b.
SERVICE MANUAL for the recommended hydraulic

fluid.
The DC Motor Hydraulic Brake System has a caliper

assembly and spring/hydraulic actuator. Operation of
the spring/hydraulic actuator is as follows:
a. NORMAL OPERATION The brake in a released position
has hydraulic pressure applied to
the piston opposite the spring
chamber, which keeps the spring
compressed (CAGED). The brake
is in readiness for normal applica
tion by releasing the hydraulic
pressure from the spring chamber.
b. SPRING BRAKE APPLICA
TION - The spring force, acting
against the piston, forces the push
rod against the push rod flange nut
by the piston tube and sets the
brake pads (The spring is now in
an UNCAGED position).
1CG1576, P1037
TA8978CG
HYDRAULIC FLUID REPLACEMENT
The hydraulic fluid should be replaced every five years

under normal conditions. However, fluid contaminated
with water or solid particle contaminants must be
replaced more often. Fluid samples should be taken
every 250 hours as part of a continuing lubricating
analysis program. The type and size or particles should
be analyzed to determine imminent component failure.
Action should be taken before system failure results.
Fluid that is contaminated with a water content of
60 ppm or greater should be replaced immediately. The
system should be drained and refilled when in warm
operating condition. All filters should be cleaned or
replaced as is applicable. Use a filter when filling the
reservoir, with a mesh width of 0.002 in. (0.06 mm) or
better. Fill via the 10 micron system filter. Refer to PCM
CRANE LUBRICATION SPECIFICATIONS, Figure 1 in
Publication OSM4, located in the OPERATING AND
6/6/00
NORMAL OPERATION
c.
SPRING BRAKE
APPLICATION
INSPECTION
The brakes should be checked at regular intervals for

normal wear condition. Inspect the brakes as follows:
COPYRIGHT 2002
1. Land any load on the hook and properly stow

the boom in the boom rest. Install cable drum
lock pin.
2. Inspect brake for loose or missing bolts, nuts,
retaining rings or other attachments. Secure
or replace as required.
3. Inspect carrier and lining (pads) assemblies
for wear, scars or breaks.
NOTE
If adjustment is required, the brakes must be
released.
LeTourneau, Inc.
11
BRAKES
d.
PUBLICATION OSM6
ADJUSTMENT
CAUTION
Install cable drum lock pin before performing

any service work to hydraulic brake system.
Refer to CABLE DRUM LOCK PIN in
Publication OSM4.
Install cable drum lock pin before performing

any service work to hydraulic brake system.
Refer to CABLE DRUM LOCK PIN in
Publication OSM4.
CAUTION
Spring brake chambers are under com

pressed spring force. Releasing the tension
on the brakes must be done with the use of the
jackbolt and nut assembly (P/N 4232980 &
4232981) or shop air minimum 100 psi. If air is
used to release the brake, ensure the supply is
uninterrupted or the brake will set quickly and
unexpectedly possibly causing injury. Refer to
BRAKES, page 15.
CAUTION
Spring brake chambers are under com

pressed spring force. Releasing the tension
on the brakes must be done with the use of the
jackbolt and nut assembly (P/N 4232980 &
4232981) or shop air minimum 100 psi. If air is
used to release the brake, ensure the supply is
uninterrupted or the brake will set quickly,
possibly causing injury. Refer to MANUALLY
RELEASING THE HYDRAULIC BRAKES,
page 15.
1. Use the jackbolt assembly mounted external
ly on the brake cylinder to release tension on
the brake or 100 psi air pressure. Refer to
Figure 9 for an illustration of the use of the
jackbolt.
Numbers in parentheses refer to Figure 8.
2. Loosen the locknut (20) and adjust the stop
bolt (19) to achieve a .060" clearance between
the floating brake pad (15, pad farthest from
actuator) and the rotor (2), measured at the
center of the pad's I.D.
3. Tighten the locknut (20).
4. Loosen the set screw (6) and screw the
adjusting nut (8) to achieve a .060" clearance
between the piston actuated pad (15, pad
closest to actuator) and the rotor (2), again,
measured at the center of the pad's I.D.
5. Tighten the set screw (6) to lock the adjust
ment.
NOTE
Replace the brake pads if lining is less than
1/4" thick.
DISC PAD REPLACEMENT

Numbers in parenthesis refer to Figure 8.
If brake pads or other parts need replacement, remove
the brake assemblies as follows:
12
CAUTION
a. Use the jackbolt assembly mounted externally on

the brake cylinder or shop air of 100 psi minimum to
release tension on the brake. Refer to Figure 9 for an
illustration of the use of the jackbolt.
b. Loosen the jamnut (17) and back the stop bolt (18)
into the brake mount bracket (16) to release the tension
on the springs (32).
c. Unhook the springs (30) from the clamp structure
(29).
d. Remove the mount bolts (33) and caliper mounts
(28) to allow the clamp structure (29) to be maneuvered
clear of the rotor (2).
e. Inspect the rotor. If it is badly grooved or scored,
have it resurfaced or replace it. Minimum thickness is
.68 inch.
f.
Remove the lining bolts (11 and 19) to release the
worn pads (15) from the backing plates (13 and 29).
g. Loosen the setscrew (6). Then back the adjusting
nut (8) toward the actuator (5) to allow for the increased
thickness of the new pads.
h. Position the new pads (15) on the backing plates
(13 and 29) and install the lining bolts (11 and 19).
i.
Position the assembled caliper structure to the
rotor (2). Then position the caliper mount plates (14 and
28) on the brake mount bracket (14) and within the
grooves along each side of the clamp structure (29).
j.
Install the mount bolts (31), and as they are
tightened, continually check that the assembled caliper
structure can move freely toward and away from the
brake rotor. If any binding occurs, reposition the caliper
mount plates (14 and 24) and retighten the mount bolts
(31). Binding of the caliper may cause the pads to
continually drag against the rotor, resulting in excessive
wear.
COPYRIGHT 2002
LeTourneau, Inc.

6/6/00
PUBLICATION OSM6
BRAKES
k. Connect the springs (30) to the clamp structure

(29).
l.
Screw the stop bolt (18) out until the clearance
between the floating pad (15, pad farthest from
actuator) and the rotor is .060 " measured at the center
of the pad. Tighten the locknut (17).
m. Turn the adjusting nut (8) until the piston actuated
pad (15, pad closest to actuator) has clearance of .060"
between it and the rotor (2). Then tighten the set
screw (6).
To check the run out tolerance while the brake

head assembly is removed, place a dial
indicator on the rotor assembly and rotate the
rotor by hand one revolution. If run out should
exceed .005 of an inch, it will be necessary to
check rotor installation.
n. Activate the brakes and check for proper move
ment of the caliper and actuator rod.
NOTE
If excessive wear is observed on the brake
head carrier linings, the brake rotor run out
should be checked. This should be done at the
time new carrier linings are installed.
12
15
14
13
16
9
17
66
2
11
55
10
10
14
12
tag: air brake assy
LOCKNUT
STOP BOLT
FLOATING PAD
ROTOR
SETSCREW
ADJUSTING NUT
PISTON ACTUATED PAD
ACTUATOR
SPRING
LINING BOLT
LINING BOLT
MOUNT BOLTS
CALIPER
CALIPER MOUNT
BRAKE MOUNT BRACKET
BACKING PLATE
BACKING PLATE
FIGURE 7. HYDRAULIC BRAKE ASSEMBLY

TA8973CG
1NGO1602, P1041

6/6/00
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
COPYRIGHT 2002
LeTourneau, Inc.
13
BRAKES
PUBLICATION OSM6
3
4
5
6
7
16
10
8
13
15
14
12
20
19
18
17
11
21
30
22
34
29
33
32
24
25
23
26
31
28
27
1
2
3
4
5
6
7
BRAKE HUB
DISC
LOCKWASHER
BOLT
BRAKE ACTUATOR
SETSCREW
INSERT
8
9
10
11
12
13
14
SLEEVE NUT
RING
BOSS
CAPSCREW
LOCKWASHER
CLAMP PLATE STR.
PLATE
15
16
17
18
19
20
21
PAD
MOUNT STR.
JAMNUT
BOLT
CAPSCREW
LOCKWASHER
NUT
22
23
24
25
26
27
28
LOCKWASHER
BAR
LOCKWASHER
BOLT
FLATWASHER
SPACER
PLATE
29
30
31
32
33
34
CLAMP STR.
SPRING
BOLT
WASHER
BOLT
LOCKWASHER
FIGURE 8. BRAKE CALIPER GROUP

TA9275CG
1CG2078, P1041
14
COPYRIGHT 2002
LeTourneau, Inc.

6/6/00
PUBLICATION OSM6
BRAKES
MANUALLY RELEASING THE HYDRAULIC BRAKES

For emergency situations requiring the release of the
brakes, adjustment, replacement of the brake pads, or
other repair requiring removal of the brake caliper
assembly, the tension on the brakes can safely be
released using a jackbolt and primary hand tools. A
jackbolt and nut assembly (P/N 4232980 & 4232981) is
mounted externally on the brake cylinder to allow
release or modulation of the brake (refer to Figure 9).
Refer to Figure 9 for an illustration of the jackbolt
assembly installed on the brake actuator.

the cable drum lock pin installed before
inspecting, servicing, or repairing any part of
controls and lock the operator's control panel
conducted.
Jackbolt must be bottomed into threaded

recess in cylinder rod. Use flat on jack bolt to
tighten and keep it from screwing out of
cylinder rod when jacknut is turned CCW.
1 1
1 SPECIAL TOOL
P/N 4232980 & 4232981
2 ACTUATOR TOP PLATE
3 CYLINDER ROD
4 JAMNUT
5 PISTON
1CG1593, P1037

6/6/00
FIGURE 9. MANUALLY RELEASING HYDRAULIC BRAKES
COPYRIGHT 2002
LeTourneau, Inc.
TA8932CG
15
BRAKES
PUBLICATION OSM6
NOTES
16
COPYRIGHT 2002
LeTourneau, Inc.

6/6/00
PUBLICATION OSM6
BRAKES
SERVICING THE HYDRAULIC BRAKE ACTUATORS

The following instructions are provided to help techni
cians with the replacement of the hydraulic brake
actuator seal kit.
e. Remove the mount bolts (33) and caliper mounts

(16 & 30) to allow the clamp structure (31) to be
maneuvered clear of the rotor (2).
f.
Unbolt the brake actuator (5) and take it to a
suitable workbench.
DISASSEMBLY
a. Do not remove pipe plug (24). Plug will act as guide
for press stud.
b. Position the brake actuator into brake actuator
press (P/N 4235028) with the 5/818 UNF studs
protruding through the bottom of the press' base plate.
Secure with mounting nuts. Refer to Figure 10.
NEVER attempt to disassemble the brake

actuators while mounted on the motor. The
brake actuators are under spring pressure
and can cause serious injury if not disas
sembled and assembled in the proper manner.
Disassemble and assemble the brake actua
tors only with the proper tools and per the
instructions in this document.
c. Power the press' ram down until it seats firmly

against the top of the brake actuator.
d. Remove the four 3/8" acorn nuts and washers (1)
from the bolts (23) securing the top plate (3) of the
actuator.
e. Slowly release hydraulic pressure. The spring
force against the inside of the cover will allow the cover
and internal components of the actuator to be safely
removed after the ram is backed off sufficiently.
REMOVAL
Numbers in parenthesis refer to Figure 8.
f.
Remove the springs (4 & 5) and piston (7) from the
actuator.
CAUTION
g. Remove the seals and wear rings (6, 8, 9, 10 & 11)

from the piston (7) and actuator housing (12 & 21).
Brake actuators are under compressed spring

force. Releasing the tension on the brakes
must be done with the use of the jackbolt and
nut assembly (P/N 4232980 & 4232981) or
shop air minimum 100 psi. If air is used to
release the brake, ensure the supply is
uninterrupted or the brake will set quickly and
unexpectedly possibly causing injury. Refer to
BRAKES, page 15.
h. Remove cylinder rod (15) and Oring (16), bushing

(17), Oring (18), and seals (19 & 20).
INSPECTIONS UPON DISASSEMBLY

a. Check actuator cylinder bore (12) for scoring and
dents.
a. Use the jackbolt assembly mounted externally on

the brake cylinder or shop air of 100 psi minimum to
release tension on the brake. Refer to Figure 9 for an
illustration of the use of the jackbolt. Attach shop air to
the inlet port of the actuator if that is your chosen
method.
6/6/00
c. Loosen the jamnut (19) and back the stop bolt (20)
into the brake mount bracket (18) to release the tension
on the springs (32).
d. Unhook the springs (32) from the clamp structure
(31).

the drum safety lock pins installed before
inspecting, servicing, or repairing any part of
controls and lock out the operator's control
panel before performing maintenance or
inspecting the hydraulic brake system.
Serious injury or loss of life is possible if the
crane is started or moved while maintenance
or repairs are being conducted.
b. Disconnect hydraulic lines from the actuator (if not

done to connect shop air for releasing spring tension).
b. Inspect the cylinder rod (15), bushing (17) and

piston (7). Remove any nicks and scratches. If it is
determined that the cylinder rod and piston are
corroded, scored, or notched, they should be replaced.
c. Thoroughly clean the springs (4 & 5) and coat with
a light rust preventative lubricant.
COPYRIGHT 2002
LeTourneau, Inc.
17
BRAKES
PUBLICATION OSM6
NOTE
f.
Install the actuator onto the caliper. Tighten mount
nuts to 200 ft. lbs.
If mounting studs are removed from housing,

use Loctite threadlocking compound to
reassemble. If piston is removed from
cylinder rod, use Loctite threadlocking
compound on retaining nut.
g.
Install assembly onto motor.
h.
Reconnect hydraulic lines.
BRAKE SYSTEM LEAKAGE CHECK

a. Adjust brakes so push rod travel is as short as
possible without brake shoes dragging.
ASSEMBLY
a. Install seal kit (P/N 4232978) and lubricate with

lubricant (P/N 1510360). Refer to Figure 10.
b. Install piston (7), bushing (17), and springs (4 & 5)
into actuator housing (12 & 21).
CAUTION
Do not operate main hook, boom, or auxiliary

hook motors until you are sure there are no
leaks and the brakes are functioning properly.
c. Install actuator housing into press. Secure with

nuts.
b. Turn MASTER switch to the ON position to activate

hydraulic power unit.
d. Use pipe plug as centering guide. Use the

hydraulic ram to press the cover structure (3) until it
meets the case (12).
c.
d. Check pressure gauge. A drop is pressure indi

cates a leak in the plumbing.
e. Install the four 3/8" acorn nuts (1) and washers (2)
onto the bolts (23) which the secure the cover structure.
Torque to 25 ft. lbs.
e. Turn BRAKE switch to the ENABLE position

(released). Check pressure gauge. A drop in pressure
indicates a leak in the actuator.
Turn BRAKE switch to the SET position.
NOTES
18
COPYRIGHT 2002
LeTourneau, Inc.

6/6/00
WARNING
NEVER attempt to disassemble the brake actuators while mounted on the motor:
The brake actuators are under spring pressure and can cause serious injury if not
disassembled and assembled in the proper manner. Disassemble and assemble
the brake actuators only with the proper tools and per the instructions in
SERVICING THE HYDRAULIC BRAKE ACTUATORS, page 17.
IF PIPE PLUG REMOVED FOR USE OF MANUAL

RELEASE TOOL, REINSTALL PRIOR TO USING
PRESS FOR DISASSEMBLY
2
12
24
A
3
13
B
4
CYLINDER SHOWN IN RETRACTED POSITION

HAS 2 STROKE
14
25
15
PRESS P/N 423-5028

16
PIPE PLUG USED FOR CENTERING TOP WITH RAM
AFTER ACTUATOR IS SECURED

IN PRESS WITH RAM SEATED
AGAINST ACTUATOR, REMOVE
3/8 ACORN NUTS, BACK OFF
STUD SLOWLY TO DISASSEMBLE ACTUATOR. REVERSE
PROCEDURE FOR ASSEMBLY.
SECURE WITH
MOUNTING NUTS
1NGO1594, Ldgr220, 2/12/98
1OSM6.2b, Gorilla
6/6/00
CYLINDER SHOWN IN
RELEASED POSITION
FIGURE 10. SERVICING BRAKE ACTUATOR
COPYRIGHT 2002
LeTourneau, Inc.
SEAL KIT 4232978 INSTALLATION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
3/8" ACORN NUTS

LOCKWASHER
TOP PLATE
BOOST SPRING
HEAVY SPRING
ORING
PISTON
ORING
WEAR RING
ORING
WEAR RING
ACTUATOR HOUSING
ORING
JAMNUT
CYLINDER ROD
ORING
BUSHING
ORING
SEAL
SEAL
BOTTOM PLATE
WASHER
3/8" UNS X 71/2" BOLT
3/8" NPT PIPE PLUG
WARNING DECAL
MOUNT STUDS
6
17
18
7
19
20
8
21
26
10
22
11
23
TA8931CG
19
H
T
P
6A
6B
P T
SOL. 8
7A
1A 1B
7B
P T
SOL. 3
B
H
A
P T
BOOM HOIST BRAKE
H
SOL. 5
SOL. 9
A
3A 3B
SOL. 2
P T
PUBLICATION OSM6
1CG1567, P1032, 11/6/98

6/6/00
AUXILIARY HOIST BRAKE
HOIST BRAKE
5A 5B
SOL. 4
P T
SOL. 7
COPYRIGHT 2002
LeTourneau, Inc.
130 PSI
SOL. 1
100 PSI
AC
5 GPM
DC
RESERVOIR
3 GPM
FUNCTIONAL DESCRIPTION:
SOLENOID 1
- ENERGIZE REQUIRED FOR ALL FUNCTIONS.
SOLENOID 2
- ENERGIZE FOR RELEASE OF HOIST BRAKE.
SOLENOID 2, 3 & 8 - ENERGIZE FOR POWER LOSS LOWER AND EMERGENCY RELEASE TENSION ON HOIST BRAKE.
SOLENOID 4
- ENERGIZE FOR RELEASE OF AUXILLIARY HOIST BRAKE.
SOLENOID 4, 5 & 9 - ENERGIZE FOR POWER LOSS LOWER AND EMERGENCY RELEASE TENSION ON AUXILIARY HOIST BRAKE.
SOLENOID 4, 5 & 9 - ENERGIZE FOR CONSTANT TENSION ON AUXILIARY HOIST BRAKE.
SOLENOID 7
- ENERGIZE FOR RELEASE OF BOOM HOIST BRAKE.
NOTE:
1. THERE ARE 2 BRAKE CALIPERS ON EACH MOTOR.
2. HOLD IS SHOWN AS H, TENSION IS SHOWN AS T.
21
BRAKES
TA8943CG
FIGURE 11. HYDRAULIC BRAKE SCHEMATIC, PCM 120SS/350SS
22
1NGO2757, P0327
LeTourneau, Inc.
COPYRIGHT 2002
E5
T3
E5
T3
UPPER
CYLINDER
20
M1
20
LOWER
CYLINDER
E1
HOIST BRAKE
UPPER
CYLINDER
E1
LOWER
CYLINDER
E1
AUXILIARY HOIST BRAKE
M1
E1
10
10
10
14
A3
14
A2
SOL 3
A3
10
A2
SOL 5
E4
T1
24
25
22
28
25
22
E4
23
T1
24
23
29
28
29
A2
E4
18
A2
E4
3
SOL 9
E3
SEE NOTE
P1
P1
19
SEE NOTE
E3
SOL 8
12
12
AB
AB
21
21
SOL 1
VALVE DETAIL
SOL 7
SOL 4
SOL 2
AB
SEE NOTE
15
A4
26
E6
A4
11
UPPER
CYLINDER
A1
T2
16
A4
17
M1
LOWER
CYLINDER
BOOM HOIST BRAKE

E1
20
T4
E5
T3
13
M2
E7
P2
5A
5B
E2
21
P2
4A
4B
P2
P2
3A
3B
E2
P2
2A
2B
P2
21
P2
1A
1B
E2
BRAKES
PUBLICATION OSM6
FIGURE 12. BRAKE CONTROL DIAGRAM
TA102434

6/6/00
PUBLICATION OSM6
BRAKES
BRAKE CONTROL DIAGRAM

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

6/6/00
BRAKE CONTROL UNIT

HYDRAULIC POWER UNIT
SOLENOID VALVE
LOCKWASHER
ANGLE MOUNT
ANGLE MOUNT
HOSE
HOSE
HOSE
HOSE
HOSE
HOSE
HOSE
BOLT
MANIFOLD
HOSE
HOSE
HOSE
HOSE
HOSE
KIT COVER
VALVE
SUBPLATE
BOLT KIT
SEAL KIT
HOSE
PLATE MOUNT
SUBPLATE
BOLT KIT
COPYRIGHT 2002
ADAPTERS:
A1 HYDRAULIC
A2 HYDRAULIC
A3 HYDRAULIC
A4 HYDRAULIC
FITTING
FITTING
FITTING
FITTING
ELBOWS:
E1 HYDRAULIC
E2 HYDRAULIC
E3 HYDRAULIC
E4 HYDRAULIC
E5 HYDRAULIC
E6 HYDRAULIC
E7 HYDRAULIC
FITTING
FITTING
FITTING
FITTING
FITTING
FITTING
FITTING
PLUGS:
P1 JIG PLUG
P2 PLUG W/#12 ORING
TEES:
T1 HYDRAULIC
T2 HYDRAULIC
T3 HYDRAULIC
T4 HYDRAULIC
FITTING
FITTING
FITTING
FITTING
MISCELLANEOUS FITTINGS:
M1 PIPE REDUCER
M2 CAP NUT
LeTourneau, Inc.
23
BRAKES
PUBLICATION OSM6
NOTES
24
COPYRIGHT 2002
LeTourneau, Inc.

6/6/00
PUBLICATION OSM4
LUBRICATING OIL ANALYSIS

An effective preventive maintenance program will give
the owner or equipment manager the ability to predict
and control downtime. An ongoing oil analysis program
is very important in identifying components that are in
need of replacement, overhaul or a change in their
maintenance to prevent an unscheduled breakdown or
premature failure.
THE ROLE OF LUBRICATING OIL ANALY

SIS IN A PREVENTIVE MAINTENANCE
PROGRAM
Service intervals for the drivers and gearboxes on the
crane are included in PREVENTIVE MAINTENANCE
SCHEDULES located in the back of this publication.
These recommendations are based on normal
conditions and a lubricating oil analysis program
should be used to supplement these recommenda
tions. If the crane is used in extremes of temperatures,
prolonged operation, sandy or dusty conditions or
exposure to moisture, the lubrication intervals may have
to be modified. An ongoing lubricating oil analysis
program can help to identify problems resulting from the
above mentioned conditions and others that may cause
accelerated component failure which are unique to your
operation. A preventive maintenance program custom
tailored for a specific application is the most effective
manner in which to maintain heavy equipment.
NOTE
Lubricating oil analysis is designed to detect
only that type of failure which characteristical
ly begins with an increase in metal wear; that
is, worn bearings, worn gears and slowly
progressing fatigue failures. Component
failures which are catastrophic and instanta
neous in nature are not caught by lubricating
oil analysis.
oil (copper, iron, aluminum, silica, or chromium) indi

cates what part is wearing.
Lubricating oil analysis is not effective unless it is
done on a continual basis in order to establish a
wear trend. At least two or three samples must be taken
and recorded to establish this trend which reflects the
conditions in which the crane is working. After the trend
is established, records will readily show any accelerated
increase in this pattern. Comparisons to other cranes
with like components and working in similar conditions
can also be made and used in forecasting downtime
and production scheduling.
ANALYSIS OF LUBRICATING OIL IN

LeTOURNEAU, INC. DRIVERS AND GEAR
BOXES
LeTourneau, Inc. has done extensive research on driver
and gearbox life/maintenance programs. This research
has confirmed the value of an ongoing lubricating oil
analysis program for obtaining maximum life from the
drivers and gearboxes on the crane.
a.
SAMPLE COLLECTION
Oil samples should be drawn and analyzed every

250 hours of operation, again prior to an oil change
and more often if suspicious of component opera
tion. The crane should be operated for at least one hour
with continual operation of the component prior to
taking a sample from a driver or gearbox. The oil
samples should then be taken within 10 minutes of
stopping the machine. Approximately 35 oz. is normally
required for analysis. Be sure receptacle is clean.
NOTE
A suction pump should be used to draw the oil
sample, as this will result in the most accurate
analysis reports. BE SURE to thoroughly clean
the suction pump between taking samples in
several components.
PROGRAM OPERATION
With lubricating oil analysis, the wear of internal
components can be determined without taking the
machine apart. At the recommended oil change
interval or as otherwise recommended; a sample of the
oil should be collected and sent to a testing facility who
analyzes its microscopic metal content with special
emission or atomic absorption spectrophotometry
equipment. When this is done regularly, a record or
wear trend is established for that component or group
on components from several machines. If the amount of
certain metal or other foreign matter rises suddenly
above the normal wear trend, it can indicate failure is
imminent. The type of metal or material detected in the
4OSM 4.3a, Gorilla
8/30/01
NOTE
Samples must be sent promptly to the testing
facility. Analysis and reporting must be
likewise equally prompt. Any delay could
negate the application of the analysis report.
All samples must be analyzed under identical
conditions or the results will not be usable.
Newly changed oil or oil recently added to a system will
not give a true picture when it is analyzed. Also,
deviation from accepted procedures in taking the
sample can invalidate the analysis results. Any of these
conditions could have dangerous or misleading conse
quences because the sample analysis would be
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION OSM4
incorrect and not indicate the true condition of the

component.
2. Viscosity test: If viscosity shows a large

increase or decrease, then change the oil.
The magnetic plug should also be inspected and

cleaned regularly. Record the appearance and weight
of metal accumulated. In the event of the appearance of
a large increase in the amount of metallic particles or
chips, the gearbox or driver should be inspected
internally. If no damage is readily evident, the compo
nent should be removed from service and disas
sembled and the source(s) of the contamination
identified and repaired.
3. Insoluble material test: If the amount of

insoluble material test shows a large increase,
the oil should be changed. This could indicate
the failure of a seal and the seals should be
closely examined.
b.
PROPER DOCUMENTATION
Proper documentation is critical to the success of an

ongoing lubricating oil analysis program. It is
especially important to maintain accurate and detailed
records when analyzing several components on one
crane or a group of cranes. This documentation should
include:
WEAR TREND ANALYSIS

Of particular concern are the levels of silicate (contami
nation) and iron (wear). The results of each sample
taken should be compared to at least two or three
previous samples (from the same component) in order
to conduct wear trend analysis. A sudden increase in
the amount of these contaminants in the oil would signal
the need for corrective action such as flushing or
disassembly of the component.
NOTE
Flushing the driver or gearbox is strongly
recommended if iron content reaches 100
ppm. If these high levels of iron content
continue after flushing, disassembly and
inspection should be considered. In order to
maximize component life, the amount of iron
contained in the oil must be kept as low as
possible.
1. Date of sample
2. Serial or identification numbers of the compo
nent
3. Total hours of component life
4. Hours of operation since last oil change
5. Complete results of all tests conducted
NOTE
6. Serial number of the crane and position of the

gearbox or driver (main hoist, aux. hoist,
boom luffing, swing)
Refer to DRIVER MAINTENANCE, Page 13, for

additional information on servicing drivers.
Service requirements for gearboxes are found
in the PREVENTIVE MAINTENANCE SCHED
ULES located in the back of this section. Also,
refer to PCM CRANE LUBRICATION SPECIFI
CATIONS, Figure 1, for lubricants recom
mended for use in drivers and gearboxes.
7. Appearance and weight of magnetic plug

accumulation
8. Any other applicable comments about the
component's operation
c.
RECOMMENDED TESTS
1. Spectrographic analysis: This test checks
for the metal content in the oil. The amounts in
parts per million should be compared to the
previous sample. If a significant increase in
any of the elements appears, perform a
gearcase inspection. A sudden increase in
iron content will indicate excessive wear of
one or more of the drive train components. A
sudden increase in chromium should indicate
unusual wear of a bearing. If silicon content
only shows a large step change, the oil should
be changed.
a.
Synthetic and speciality lubricants have become popu

lar with many equipment owners and may be beneficial
where temperature extremes (hot and cold) are encoun
tered. Contact LeTourneau, Inc. through your distributor
to determine acceptable lubricants for your operation.
NOTE
It is important to emphasize that a large
increase in iron or chromium content between
two consecutive tests indicates component
failure.
10
SYNTHETIC AND SPECIALITY LUBRICANTS
COPYRIGHT 2002
CAUTION
If the service intervals recommended in the

PREVENTIVE MAINTENANCE SCHEDULES
are exceeded due to the use of synthetic or
speciality lubricants, it is essential to monitor
the component with lubricating oil analysis.
The guideline of 100 ppm. of iron content will
apply and the component should be flushed if
this amount is reached. Disassembly and
inspection should be undertaken if wear trend
analysis indicates a reoccurrence after
flushing.
LeTourneau, Inc.
4OSM 4.3a, Gorilla

8/30/01
PUBLICATION OSM4
HYDRAULIC BRAKE OIL

The hydraulic brake system is equipped with a power
unit which has a 20 gallon reservoir. This unit is factory
equipped with fire resistant brake fluid (P/N 4235122).
It is recommended that oil samples be taken for analysis
every 250 hours of operation or monthly. The reservoir
should be drained and thoroughly cleaned every five
years or when lubricating oil analysis indicates a
water or solid particle contamination of 60 ppm or
greater. Refer to Publication OSM6, BRAKES, in the
OPERATING AND SERVICE MANUAL for additional

information on servicing the hydraulic brake system.
NOTE
The ultimate success of a lubricating oil
analysis program rests with the owner or
equipment manager. If good samples are
taken, forwarded promptly, and the feedback
used wisely, a lubricating oil analysis program
will be very effective.
NOTES
4OSM 4.3a, Gorilla

8/30/01
COPYRIGHT 2002
LeTourneau, Inc.
11
PUBLICATION OSM4
NOTES
12
COPYRIGHT 2002
LeTourneau, Inc.
4OSM 4.3a, Gorilla

8/30/01
PUBLICATION OSM4
POWER LOSS LOWERING SYSTEM INSPECTION

AND TEST PROCEDURES
The following procedures are recommended as a
minimum periodic inspection and checkout of the
Power Loss Lowering System. These procedures
should be conducted every 250 hours or monthly as
outlined in the PREVENTIVE MAINTENANCE
SCHEDULES, located in the back of this publication.
b. Inspect the auxiliary and hoist brake rotor thermo

couple for proper thermocouple to brake rotor clear
ance (.050 .002 inches, rotor cold).
NOTE
d. Ensure that the EMERGENCY HOIST RELEASE

switch is in the OFF position.
Refer to PCM CRANE POWER LOSS LOWER

ING SYSTEM, located in Publication ROM6 in
the REPAIR AND OVERHAUL MANUAL, for a
detailed explanation of the Power Loss
Lowering System.
e. Ensure that the CONSTANT TENSION switch is in

the OFF position.
c. Inspect the auxiliary hoist temperature transmitter

for proper electrical connections and connection tight
ness.
f.
With the MASTER switch in the ON position and
the HOIST SELECT switch in the AUX position, lift any
convenient load to approximately 25% of full up travel.
g. Position the HOIST joystick to NEUTRAL and the
BRAKE switch to the SET position.
24 VDC BATTERY BANK AND CHARGER

The crane has 24 VDC battery backup power available
for power loss lowering functions in the event of a power
loss situation. A bank of four 12 VDC, maintenance free
lead batteries is mounted on top of the machinery
house. The system contains a regulated battery char
ger, which operates from 120 VAC, to restore the battery
bank to full charge after the unit has supplied backup
power to the crane. After the full charge has been
reached, the charger continues to tricklecharge the
batteries to maintain a full charge without overcharging.
The battery charger is operational when the 600A
Feeder Breaker to the crane is closed (ON).
The charger has a 5amp fuse on the 120 VAC input. An
internal ganged 15A circuit breaker protects the system
in the event that loading exceeds ratings. The battery
charger is calibrated to float the battery bank at
27.5 VDC (the optimum voltage for the battery type).
The GREEN pilot light is ON when the battery charger is
properly ON and the battery is floating at proper DC
voltage. The RED pilot light comes ON when the battery
is connected to the charger in reverse polarity. If you see
this RED light ON, immediately disconnect the charger
from the battery bank.
The batteries are maintenance free other than it is
recommended that the connections be checked
every two months for tightness.
POWER LOSS HOIST LOWER TEST

PROCEDURE (AUXILIARY AND MAIN
HOIST)
a. Inspect the Power Loss Lowering Card and the
auxiliary and main hoist Speed Sensor Filter Cards for
proper electrical connections and connection tightness.
4OSM 4.3a, Gorilla
8/30/01
COPYRIGHT 2002
Uncontrolled load descent during test can

cause serious injury or death! BE ALERT OBSERVE HOOK LOWERING SPEED. If at any
time during this procedure it appears that the
load is descending when it shouldn't be or is
descending uncontrollably, it is imperative
that the operator immediately move the HOIST
joystick to the NEUTRAL position and release
the POWER LOSS HOIST LOWER pushbutton.
The following switch settings should also be
made:
D BRAKE switch in the SET position
D EMERGENCY HOIST RELEASE switch in the
OFF position
D CONSTANT TENSION
position
switch in the OFF
D MASTER switch in the OFF position.
CAUTION
The Power Loss Hoist Lower function has the

potential to generate extreme brake rotor and
pad temperatures (the heavier the load, the
faster the temperature will rise). Always
station an observer in a location where the
brakes can be visually monitored when doing
a power loss hoist lower. Because of the brake
dust that can be generated by dragging
through the brakes it is advised that the
observer wear a respirator and view the
procedure from the catwalk looking through
the door into the crane machinery house. This
observer must be able to contact the operator
LeTourneau, Inc.
17
PUBLICATION OSM4

and signal a procedure shutdown should the

temperature sensing system obviously fail (as
evidenced by a glowing red brake rotor,
excessive sparking, smoke, flame, etc.).
e. With the MASTER switch in the ON position and

the HOIST SELECT switch in the AUX position, lift an
approximately 5,000 lb load to approximately 25% of full
up travel.
NOTE
The SPEED/TEMP WARNING light should be
out and stay out throughout this procedure
(unless brake rotor temperature exceeds
approximately 700F).
f.
Position the HOIST joystick to NEUTRAL and the
h. To activate power loss hoist lower mode, perform

the following steps:
If at any time during this procedure it appears

that the load is descending when it shouldn't
be or is descending uncontrollably, it is
imperative that the operator move the
CONSTANT TENSION switch to the OFF
position. The following switch settings should
also be made: BRAKE switch in the SET
position, EMERGENCY HOIST RELEASE
switch in the OFF position, and MASTER
switch in the OFF position.
1. MASTER switch in the BAT position (POWER

ON light flashing).
2. BRAKE switch in the ENABLE position.
3. POWER LOSS HOIST LOWER pushbutton
depressed and held.
4. HOIST joystick moved in the LOWER direction
(HOIST joystick contact must close).
The load should accelerate to and descend at a

constant rate (300 rpm of motor speed) as the load pulls
through the partially released hoist brake. When
satisfied that the power loss lowering system is lowering
the load as expected, release the POWER LOSS HOIST
LOWER pushbutton and return the HOIST joystick to
NEUTRAL, at which point the brake will set and the load
will stop. Take the BRAKE switch to SET and the
MASTER switch to OFF. The crane is now ready for
normal operations.
This procedure has the potential to generate

extreme brake rotor and pad temperatures
(the heavier the load, the faster the tempera
ture will rise and the faster the load will
accelerate). Always station an observer in a
location where the brakes can be visually
monitored when doing a constant tension
mode test lower operation. Because of the
brake dust that can be generated by dragging
through the brakes, it is advised that the
observer wear a respirator and view the
procedure from the catwalk, looking through
the door into the crane machinery house. This
observer must be able to contact the operator
and signal a shutdown should the temperature
sensing system obviously fail (as evidenced
by a glowing red brake rotor, excessive
sparking, smoke, flame, etc.).
Should the crane not perform as expected, refer to the

POWER LOSS HOIST LOWER section of PCM CRANE
POWER LOSS LOWERING SYSTEM, located in Publica
tion ROM6 in the REPAIR AND OVERHAUL MANUAL,
for a detailed explanation of how this system works.
i.
Repeat Steps f" through h" above with a load on
the main hoist and the HOIST SELECT switch in the
MAIN position.
NOTE
CONSTANT TENSION TEST PROCEDURE

(POWER LOSS OPERATIONS, AUXILIARY
HOIST ONLY)
CAUTION
The SPEED/TEMP WARNING light should be

out and stay out throughout this procedure
(unless brake rotor temperature exceeds
approximately 700F).
g. To activate constant tension mode under power
loss conditions, perform the following steps:
b. Inspect the auxiliary hoist brake rotor thermocou

ple for proper thermocouple to brake rotor clearance
(.050 .002 inches, rotor cold).
1. MASTER switch in the BAT position (POWER

ON light flashing).

ness.
3. CONSTANT TENSION switch in the BAT

position and held there (CONSTANT TEN
SION and AUX RUN lights should come on).
18
COPYRIGHT 2002
LeTourneau, Inc.
4OSM 4.3a, Gorilla

8/30/01
PUBLICATION OSM4
This will cause the brakes to partially release and

maintain a line tension of approximately 3,300 lbs. The
suspended 5,000 lb load will begin to descend and
accelerate. Once movement is seen, turn the
CONSTANT TENSION switch to OFF, which should set
the brake and stop the load. Take the BRAKE switch to
SET and the MASTER switch to OFF. The crane is now
ready for normal operations.
CONSTANT TENSION section of PCM CRANE POWER
LOSS LOWERING SYSTEM, located in Publication
ROM6 in the REPAIR AND OVERHAUL MANUAL, for a
detailed explanation of how this system works.
CONSTANT TENSION TEST PROCEDURE

(NORMAL OPERATIONS, AUXILIARY
HOIST ONLY)

3. CONSTANT TENSION switch in the ON posi
tion (CONSTANT TENSION and AUX RUN
lights should come on).
This will cause the aux hoist motor to power up and
maintain approximately 3,300 lbs of up tension on the
line. This will result in all of the slack being taken out of
the line but no movement of the load (3,300 lbs of
tension will not be enough to lift 5,000 lbs of load). Verify
aux hoist motor torque by reading the following values
on the hoist motor controller tester (located in the crane
control room at the top on the column):
4. IA = +0.62 to +0.68 (hoist motor armature
current)
5. IF = +1.23 to +1.37 (hoist motor field current)
Verify that each of the following three actions will disable
constant tension mode:
6. CONSTANT TENSION switch in the OFF
position. This will set the brake and make
tester signal IA equal zero. Put the aux hoist
back into constant tension mode by taking the
CONSTANT TENSION switch back to ON
before performing the next step.
b. Inspect the auxiliary hoist brake rotor thermocou

ple for proper thermocouple to brake rotor clearance
(.050 .002 inches, rotor cold).
ness.
7. BRAKE switch in the SET position. This will set

the brake and make tester signal IA equal
zero. Put the aux hoist back into constant
tension mode by first taking the BRAKE switch
to the ENABLE position and then taking the
CONSTANT TENSION switch to OFF and
back to ON before performing the next step.

e. With the MASTER switch in the ON position and
the HOIST SELECT switch in the AUX position, attach
the aux hook to an approximately 5,000 lb load resting
on the deck of the rig, leaving a little bit of cable slack.
8. HOIST joystick out of neutral (move it in the UP

torque direction). This disables constant ten
sion mode and automatically returns load
control in either direction to the HOIST
joystick.
f.
Position the HOIST joystick to NEUTRAL and the
NOTE
Once disabled by any of the three means
above, constant tension mode will stay
disabled until the CONSTANT TENSION
switch is cycled from ON to OFF and back to
ON again.

that the load is descending when it shouldn't
be or is descending uncontrollably, it is
imperative that the operator move the
CONSTANT TENSION switch to the OFF
position. The following switch settings should
also be made: BRAKE switch in the SET
position, EMERGENCY HOIST RELEASE
switch in the OFF position, and MASTER
switch in the OFF position.
Should the crane not perform as expected, refer to

CONSTANT TENSION MODE OPERATION AND TROU
BLESHOOTING, located in Publication ROM6 in the
REPAIR AND OVERHAUL MANUAL.
g. To activate constant tension mode when not under

power loss conditions, perform the following steps:
1. MASTER switch in the ON position (POWER
ON light ON).
4OSM 4.3a, Gorilla
8/30/01
EMERGENCY HOIST RELEASE TEST

PROCEDURE (NORMAL OPERATIONS,
MAIN AND AUXILIARY HOIST)
a. Position the hooks in a safe area. Position the
HOIST SELECT switch to the AUX position.
COPYRIGHT 2002
LeTourneau, Inc.
19
b. Position the HOIST joystick to NEUTRAL, BRAKE

switch to the SET position.

that the load is descending, it is imperative
that the operator move the EMERGENCY
HOIST RELEASE switch to the OFF position.
The following switch settings should also be
made: BRAKE switch in the SET position,
CONSTANT TENSION switch in the OFF
position, and MASTER switch in the OFF
position.
c. To activate emergency release mode , perform the
following steps:
1. MASTER switch in the ON position (POWER
ON light ON).
2. BRAKE switch in the SET position.
3. OVERLOAD PROTECTION switch in the ON
position (OVERLOAD PROTECTION ACTIVE
light should come on).
4. EMERGENCY HOIST RELEASE switch in the
ON position (GROSS OVERLOAD, EMER
GENCY HOIST RELEASE, and AUX RUN
PUBLICATION OSM4
The Emergency Release system uses the same circuitry

and generates the same results as does an Automatic
Overload Protection System (AOPS) activation. Visually
check that the top canister of the aux hoist motor brake
remains set, that the bottom brake canister releases
fully, and that LED3 on the hoist controller (GOL Veac
Disable, visible through the window in the hoist
controller front cover) illuminates. The external cab
mounted alarm and the machinery house mounted
alarm will sound with a pulsating tone. Clear the alarms
with the ACKNOWLEDGE HORN BUTTON, take the
EMERGENCY HOIST RELEASE switch to OFF, and take
the OVERLOAD PROTECTION SWITCH to RESET and
then back to ON.
EMERGENCY HOIST RELEASE (NORMAL OPERA
TIONS) section of PCM CRANE POWER LOSS LOWER
ING SYSTEM, located in Publication ROM6 in the
REPAIR AND OVERHAUL MANUAL, for a detailed
explanation of how this system works.
d. Repeat steps b" and c" above with the HOIST
SELECT switch in the MAIN position.
e. Position the OVERLOAD PROTECTION switch to
RESET unless directed otherwise by a supervisor.
NOTES
20
COPYRIGHT 2002
LeTourneau, Inc.
4OSM 4.3a, Gorilla

8/30/01
PUBLICATION ROM6
SOLID STATE CONVERSION SYSTEM
PCM CRANE POWER LOSS LOWERING SYSTEM

The primary purpose of the PCM crane power loss
lowering system is to enable the operator to lower a load
(main or auxiliary hoist) while suffering power loss
conditions to the crane's hoist system (loss of main AC
power and/or 24 VDC power supply). This system can
also be used to lower a load during scenarios other than
power loss (such as failure or malfunction of the normal
hoisting system). When the Master Switch is turned to
BAT, backup batteries supply 24 VDC to the power loss
lowering card (PLLC, see Figure 24) and to various other
necessary backup components. The PLLC, which
monitors operator commands, motor speed, and motor
brake rotor temperature, manipulates a proportional
hydraulic relief valve to partially release the motor park
brake. This allows the load to slip through the brake and
descend at a constant speed (approximately 300 rpm at
the motor) via gravity. The system hydraulic pressure to
the motor brake is varied in proportion to the current
supplied to the proportional valve's solenoid by the
PLLC. This current varies based on speed feedback to
the PLLC from the motor's two speed sensors. A
thermocouple monitors brake rotor temperature and
halts the lowering process when the temperature
exceeds approximately 700F (371C). Lowering is
allowed to resume once the rotor has cooled to
approximately 450F (232C). Besides the mode of
operation described above (Power Loss Hoist Lower),
the PLLC is also responsible for backup battery
Constant Tension operation, and for monitoring the
status of the normal (nonpower loss) Emergency Hoist
Release operation (descriptions of each to follow).
Before initiating this procedure, inspect the

main and auxiliary hoist brake rotor thermo
couples for proper thermocouple to brake
rotor clearance (.050 .002 inches, rotor
cold). Inspect the PLLC, the main and auxiliary
speed sensor filter cards, and the main and
auxiliary hoist temperature transmitters for
proper electrical connections and tightness.
CAUTION
This procedure has the potential to generate

extreme brake rotor and pad temperatures
(the heavier the load, the faster the tempera
ture will rise). Always station an observer in a
location where the brakes can be visually
monitored when doing a power loss hoist
lower. Because of the brake dust that can be
generated by dragging through the brakes, it
is advised that the observer wear a respirator
and view the procedure from the catwalk,
looking through the door into the crane
control room. This observer must be able to
contact the operator and signal a procedure
shutdown should the temperature sensing
system obviously fail (as evidenced by a
glowing red brake rotor, excessive sparking,
smoke, flame, etc.)
1. EMERGENCY HOIST RELEASE switch must
be in the OFF position.
NOTE
2. CONSTANT TENSION switch must be in the

OFF position.
The Power Loss Lowering System should be

inspected and tested monthly in accordance
with the PREVENTIVE MAINTENANCE
SCHEDULES, located in Publication OSM4 in
3. MASTER switch must be in the BAT position

(POWER ON light flashing).
4. AUX or MAIN hoist position selected with the
HOIST SELECT switch.
5. BRAKE switch must be in the ENABLE
position.
NOTE
6. POWER LOSS HOIST LOWER button pressed

and held.
These instructions reference general electri

cal schematic 4221678, located in the back of
Section 4, Electrical System Troubleshooting
(in this manual), and general hydraulic
schematic 4223396, located in the back of
Publication OSM6 in the OPERATING AND
SERVICE MANUAL.
7. HOIST joystick moved in the LOWER direction

(HOIST joystick contact must close and the
AUX or MAIN RUN light should come on).
a. POWER LOSS HOIST LOWER: Power Loss Hoist

Lower is the normal means of lowering a suspended
load when operating under power loss conditions. To
activate power loss hoist lower mode, the following
conditions must be met:
1ROM 6.2d, Gorilla
5/12/99 (Rev 8/30/01)
CAUTION
For the discussion that follows, assume that the Hoist

Select switch is in MAIN. When BAT is selected with the
Master Switch, relay BTB becomes energized, which
makes wire 11D hot through a set of normally closed
CR15 contacts (see electrical schematic referenced
above). 11D becoming hot energizes SOL8 and also
indicates to the PLLC that the main hoist is selected.
SOL8 causes its associated hydraulic valve to shift,
COPYRIGHT 2002
LeTourneau, Inc.
73
PUBLICATION ROM6
FIGURE 24. POWER LOSS POWERING CARD (1 of 2)

9NGO18761, P1064
74
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 6.2d, Gorilla

5/12/99 (Rev8/30/01)
PUBLICATION ROM6
FIGURE 24. POWER LOSS LOWERING CARD (2 of 2)

9CG24711, P0225
1ROM 6.2d, Gorilla

5/12/99 (Rev 8/30/01)
COPYRIGHT 2002
LeTourneau, Inc.
75
PUBLICATION ROM6
resulting in the proportional hydraulic relief valve SOL3

being placed in series with the upper brake canister
(see hydraulic schematic referenced above). When the
Power Loss Hoist Lower push button is depressed and
the hoist joystick is moved in the lower direction, wire
EL4 to the PLLC will become hot causing CR39 and
SOL3 to be energized by the PLLC. This results in a set
of CR39 contacts closing, which energizes CR41 and
SOL2. A set of CR41 contacts will then close energizing
CR28, which energizes CTR15, which applies 24V
battery power to the backup hydraulic DC pump motor.
SOL2 energizing applies full system pressure (approxi
mately 130 psi) to the springapplied lower brake
canister (causing it to fully release) and a variable
pressure (via the PLLCcontrolled proportional relief
valve SOL3) to the springapplied upper brake canister.
The PLLC, which supplies approximately 14 VDC to
each main hoist motor speed sensor filter card through
wires 12MH1 and 12MH2, monitors main hoist motor
speed on wires 92MH1 and 92MH2 from the motor
speed sensors (these signals are pulse trains gener
ated by magnetic pickups with 1 Hz corresponding to
1 rpm of motor speed). If the speed is less than
300 rpm, more current (in the form of a pulse width
modulated signal) is sent to SOL3 by the PLLC, causing
the relief valve to bypass less fluid to tank, resulting in
more pressure to the upper brake canister (and
therefore less braking effort and more motor speed for a
given load). If the speed is more than 300 rpm, less
current is sent to SOL3, causing the relief valve to
bypass more fluid to tank, resulting in less pressure to
the upper brake canister (and therefore more braking
effort and less motor speed for a given load). This
dynamic feedback system results in a relatively
constant lowering speed for a full range of loads (up to
and including rated load). Auxiliary hoist operation is
similar except that CR15 will be energized resulting in
wire 11G being hot and SOL9, CR40, SOL5, SOL4 and
CR42 being energized as opposed to their main hoist
counterparts listed above.
Should motor speed exceed approximately 750 rpm in
power loss hoist lower mode, the PLLC will set the brake
fully (overspeed condition). Wire EL4 will have to be
deenergized (Power Loss Hoist Lower button released,
hoist joystick neutral) and then reenergized in order to
initiate another lowering attempt.
Temperature sensing circuitry and logic are discussed
in the Temperature Sensing section following.
NOTE
Power Loss Hoist Lower mode will be
overridden by constant tension mode (wire
CT3 hot) and emergency hoist release mode
(wires ER1 or ER2 hot).
76
b. CONSTANT TENSION (AUXILIARY HOIST

ONLY): Constant tension mode is used when the load is
on the deck of a vessel that is pitching up and down due
to wave motion. To activate constant tension mode
under power loss conditions, the following conditions
must be met:
be in the OFF position.
2. MASTER switch must be in the BAT position
(POWER ON light flashing).
3. HOIST SELECT switch must be in the AUX
position.
4. BRAKE switch must be in the ENABLE
position.
5. CONSTANT TENSION switch must be turned
to the BAT position and held there
(CONSTANT TENSION and AUX RUN lights
should come on).
When BAT is selected with the Master Switch, relay BTB
becomes energized, which makes wire 11G hot through
a set of normally open CR15 contacts (see electrical
schematic referenced above). 11G becoming hot
energizes SOL9 and also indicates to the PLLC that the
aux hoist is selected. SOL9 causes its associated
hydraulic valve to shift, resulting in the proportional
hydraulic relief valve SOL5 being placed in series with
the upper brake canister (see hydraulic schematic
referenced above). When the Constant Tension switch
is held in the BAT position, wire CT4 to the PLLC will
become hot, causing CR40 and SOL5 to be energized
by the PLLC. This results in a set of CR40 contacts
closing, which energizes CR42 and SOL4. A set of CR42
contacts will then close energizing CR28, which ener
gizes CTR15, which applies 24V battery power to the
backup hydraulic DC pump motor. SOL4 energizing
applies full system pressure (approximately 130 psi) to
the springapplied lower brake canister (causing it to
fully release) and a reduced pressure (via the PLLCcon
trolled proportional relief valve SOL5) to the springap
plied upper brake canister. (This reduced pressure is
constant and is set during initial calibration of the
system by lifting a 3300lb. load with the aux hook, going
into power loss" constant tension mode as described
above, and then adjusting the mid" pot on component
U9 (proportional valve drive card) on the PLLC until the
load just starts slipping. This effectively applies a
constant current to SOL5 to maintain approximately
3300 lbs. of line tension on the hoist cable. This
preadjusted pressure is dependent upon CR11 being
energized when the Constant Tension switch is turned
to BAT. This opens a set of CR11 contacts and removes
24V from wire 43SA to the PLLC, which makes the mid
pot setting on U9 effective. During this constant tension
operation under power loss conditions, should the deck
drop from under the load due to wave motion, the load
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 6.2d, Gorilla

5/12/99 (Rev8/30/01)
PUBLICATION ROM6
will also drop if it weighs more than 3300 lbs. There will
be no motor power, of course, to take up the slack when
the deck rises again.
Top motor speed allowed by the PLLC in constant
tension mode is 2665 rpm. Should motor speed exceed
this maximum, the park brake will be fully set and the
constant tension switch will have to be cycled from OFF
back to BAT in order to resume constant tension
operation.
Temperature sensing circuitry and logic are discussed
in the Temperature Sensing section following.
NOTE
The end result is that during an Emergency Release

operation, the top brake canister of the selected hoist
motor will be fully set, and the bottom brake canister will
be fully released, resulting in a holding force of
approximately 150% of maximum rated load. If a true
gross overload exists, the load will pull through the one
brake canister without causing structural damage to the
crane.
To reset the Emegency Release sytem, place the
Emergency Hoist Release switch to OFF and then cycle
the Overload Protection switch to RESET and then back
to ON. The Gross Overload light should go out and the
Overload Protection Active light should illuminate.
Constant tension mode will be overridden by

emergency hoist release mode (wires ER1 or
ER2 hot) and overrides power loss hoist lower
mode (wire EL4 hot).
c. EMERGENCY HOIST RELEASE (NORMAL
OPERATIONS): The emergency hoist release mode is
designed to be used if the hook becomes entangled in a
vessel that is moving away from the crane. To activate
emergency hoist release mode when not under power
loss conditions, the following conditions must be met:
1. MASTER switch must be in the ON position.
2. OVERLOAD PROTECTION switch must be in
the ON position (OVERLOAD PROTECTION
ACTIVE light on).
3. AUX or MAIN hoist position selected with the
HOIST SELECT switch.
be put in the ON position (EMERGENCY
HOIST RELEASE and AUX or MAIN RUN
Placing the Emergency Hoist Release Switch in ON
position causes CR9 to energize. A set of CR9 contacts
connects wire 3F to wire GOL, which initiates the same
chain of events that results from an Automatic Overload
Protection System (AOPS) activation (refer to Publica
tion ROM6 in the REPAIR AND OVERHAUL MANUAL for
more information on the AOPS). Wire GOL applies 24V
to the hoist controller, which in turn energizes CR44,
which energizes SOL1 (Brake Master Solenoid) and
SOL8. The hoist controller also energizes CR44A, which
energizes SOL9. SOL8 and SOL9 route hydraulic
pressure away from the top brake canisters of the main
and aux hoist motors respectively and to the proportion
al relief valve solenoids SOL3 and SOL5 (see Hydraulic
Schematic referenced above). No current is sent to
SOL3 or SOL5 from the PLLC during an Emergency
Release operation, so all hydraulic pressure to the top
canisters is bypassed to tank through SOL3 and SOL5,
and the top canisters remain fully set.
1ROM 6.2d, Gorilla
5/12/99 (Rev 8/30/01)
At the same time, the hoist controller also energize

CR43, which energizes either SOL2 if the main hoist is
selected, or SOL4 if the aux hoist is selected. This
applies full hydraulic pressure to the selected motor's
bottom brake canister, releasing it fully.
NOTE
Emergency hoist release mode overrides
constant tension (wire CT4 hot) and power
loss hoist lower (wire EL4 hot) modes.
d. TEMPERATURE SENSING: A descending load
opposed by friction drag torque on the motor brake
rotor will generate heat. Brake rotor temperature is
sensed by a thermocouple mounted .050 inches from
the radial edge of the rotor (cold). As the rotor heats up it
expands and its heat is transmitted through the air gap
to the thermocouple. The thermocouple's millivolt
signal is routed to a 420mA temperature transmitter
which sends a proportional current signal to the PLLC
on wire TX1 (main hoist) or TX2 (auxiliary hoist). If the
rotor temperature is sensed to be greater than approxi
mately 700F, the PLLC will set the park brake until rotor
temperature drops to less than approximately 450F, at
which point lowering will be reenabled.
COPYRIGHT 2002
NOTE
Rotor temperature has no effect on emer
gency release mode.
CAUTION
The thermocouple/temperature transmitter

combination is calibrated to measure rotor
temperature across an air gap which
decreases as the rotor heats up and expands.
Should the thermocouple ever physically
contact the rotating brake rotor, its sensed
temperature will go up rapidly causing a
premature temperature shutdown of the
lowering process (refer to LED1 and LED3 in
PLLC LED's, below). This will also result in
rapid wear and failure of the thermocouple
element, likewise causing a temperature
LeTourneau, Inc.
77
PUBLICATION ROM6
shutdown (see LED1 and LED3). For these

reasons it is important to maintain proper
thermocouple to rotor clearance (.050 .002
inch, rotor cold).
The dual speed sensor arrangement is

designed for redundancy; only one speed
sensor and its associated processing circuit
are normally necessary for power loss
lowering. The PLLC allows lowering with the
SPEED/TEMPERATURE warning light flashing
but the cause of the flashing light should be
investigated and rectified as soon as possible.
Should both speed sensors or PLLC speed
sensor signal processing circuits fail, the
PLLC will have no speed feedback and will
sense" that the load is not moving. Should
this be the case, when a lower mode is
initiated, the park brake will be released and
the load will descend unabated. Also, since
both speed feedback systems are disabled,
the SPEED/TEMPERATURE light will not
illuminate. It is important that the operator
always maintain extreme caution when using
the power loss lowering system (as with any
lowering operation) and always be prepared
to come out of a lowering mode (joystick
neutral, POWER LOSS HOIST LOWER push
button released, CONSTANT TENSION switch
off, EMERGENCY HOIST RELEASE switch off)
should a problem be suspected. Coming out
of a lowering mode will set the park brake and
stop the load. Note that having both speed
sensors and/or speed sensor signal process
ing circuits fail at the same time is an
extremely unlikely situation. Speed sensor
condition and PLLC speed sensor signal
processing circuitry condition are constantly
monitored during normal crane operations
(with malfunctions indicated by a flashing
SPEED/TEMPERATURE light), so any power
loss lowering situation should begin with two
known good speed sensors and circuitry. A
possible failure scenario to be aware of,
however, would be to have both of the speed
sensors not wired or improperly wired to the
PLLC resulting in no speed feedback to the
card. It is therefore important that the power
loss lowering system be regularly checked for
proper installation and functioning in accor
dance with the crane's preventive mainte
nance schedule.
NOTE
Refer to Figure 25 for an illustration of the
thermocouple and installation procedures.
Refer to Figure 26 for an illustration of the
temperature transmitters.
e. SPEED/TEMPERATURE Warning Light: The
SPEED/TEMPERATURE warning light (located on the
operator's console) comes on in the following modes
and for the following reasons (for further information on
troubleshooting what is specifically causing a flashing
or a steady light, refer to PLLC LED'S, below):
1. Steady Mode: The light will come on and
glow steadily and the park brake will be set
(exception: in emergency release mode, the
park brake will remain released regardless of
the status of this light) in the event of:
(a) The motor brake rotor reaching its maxi
mum allowed temperature of approxi
mately 700F. The light will go out and
lowering will be allowed once the rotor
temperature has cooled to less than
approximately 450F.
(b) A failure of the brake rotor temperature
sensing thermocouple.
(c) A failure of the brake rotor 420mA
temperature transmitter.
NOTE
A failure of one hoist motor's thermocouple
and/or temperature transmitter will cause the
SPEED/TEMPERATURE warning light to come
on steady but will not disable the lowering
capability of the other hoist motor. For further
information on troubleshooting what is
specifically causing a flashing or a steady
light, refer to PLLC LED's, below.
2. Flashing Mode: This light will flash in the
event of:
78
(a) Motor speed greater than 250 rpm and a

failure of one of the two motor speed
sensors.
f.
PLLC LED'S: Mounted on the PLLC are eight
LED's (light emitting diodes) (refer to Figure 24). These
LED's have the following labels and meanings:
(b) Motor speed greater than 250 rpm and a

failure of one of the two speed sensor
signal processing circuits on the PLLC.
1. LED1 (AH Temp Hi). If this LED comes on, the

SPEED/TEMPERATURE warning light on the
operator's console will also come on and glow
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 6.2d, Gorilla

5/12/99 (Rev8/30/01)
PUBLICATION ROM6
steadily. While the LED is on, the auxiliary park

brake will be set and lowering will be disabled
(exception: emergency release mode). This
LED comes on if:
(a) The auxiliary hoist motor brake rotor
temperature is sensed to be greater than
approximately 700F (greater than
4 VDC on wire TX2). The LED goes out
when the rotor temperature is sensed to
be less than approximately 450F (less
than 2 VDC on wire TX2).
(b) The auxiliary hoist temperature transmit
ter senses that the thermocouple ele
ment is open (approximately 5.25 VDC
on wire TX2).
(c) The auxiliary hoist temperature transmit
ter itself malfunctions (approximately
5.25 VDC on wire TX2).
2. LED2 (AH XM Open). If this LED comes on,
the SPEED/TEMPERATURE warning light on
the operator's console will also come on and
glow steadily. This LED comes on if the
auxiliary hoist temperature transmitter is
sending less than .5 VDC on wire TX2 to the
PLLC (normally it should always read a
minimum of 1 VDC). This would indicate a
probable miswired or malfunctioning trans
mitter. While the LED is on, the auxiliary hoist
park brake will be set and lowering will be
disabled (exception: emergency release
mode).
3. LED3 (MH Temp Hi). If this LED comes on,
glow steadily. While the LED is on, the main
park brake will be set and lowering will be
disabled (exception: emergency release
mode). This LED comes on if:
(a) The main hoist motor brake rotor temper
ature is sensed to be greater than
approximately 700F (greater than
4 VDC on wire TX1). The LED goes out
when the rotor temperature is sensed to
be less than approximately 450F (less
than 2 VDC on wire TX1).
(b) The main hoist temperature transmitter
senses that the thermocouple element is
open (approximately 5.25 VDC on wire
TX1).
(c) The main hoist temperature transmitter
itself
malfunctions
(approximately
5.25 VDC on wire TX1).
1ROM 6.2d, Gorilla
5/12/99 (Rev 8/30/01)
COPYRIGHT 2002
4. LED4 (MH XM Open). If this LED comes on,

glow steadily. This LED comes on if the main
hoist temperature transmitter is sending less
than .5 VDC on wire TX1 to the PLLC (normally
it should always read a minimum of 1 VDC).
This would indicate a probable miswired or
malfunctioning transmitter. While the LED is
on, the main park brake will be set and
lowering will be disabled (exception: emer
gency release mode).
5. LED5 (AH SS1 Fail). If the auxiliary hoist
motor speed is greater than 250 rpm and this
LED comes on, the SPEED/TEMPERATURE
warning light on the operator's console will
come on and flash. This LED comes on if:
(a) The auxiliary host speed sensor 1 is not
sending a signal to the PLLC (see NOTE
below).
(b) The auxiliary hoist speed sensor 1 signal
processing circuitry on the PLLC is
malfunctioning (see NOTE below).
NOTE
Circuitry on the PLLC essentially compares
the signals received from the auxiliary hoist
speed sensor 1 and auxiliary hoist speed
sensor 2 and turns on LED5 if a signal is
sensed from speed sensor 2 but not from
speed sensor 1. Consequently if both speed
sensors or both speed sensor signal process
ing circuits are malfunctioning, no difference
between the two will be detected and LED5 will
not come on.
6. LED6 (AH SS2 Fail). If auxiliary hoist motor
speed is greater than 250 rpm and this LED
comes on, the SPEED/TEMPERATURE warn
ing light on the operator's console will come
on and flash. This LED comes on if:
(a) Auxiliary hoist speed sensor 2 is not
sending a signal to the PLLC (see NOTE
below).
(b) The auxiliary hoist speed sensor 2 signal
NOTE
the signals received from auxiliary hoist
speed sensor 1 and auxiliary hoist speed
sensor 2 and turns on LED6 if a signal is
sensed from speed sensor 1 but not from
speed sensor 2. Consequently if both speed
LeTourneau, Inc.
79
PUBLICATION ROM6
sensors or both speed sensor signal process

ing circuits are malfunctioning, no difference
between the two will be detected and LED6 will
not come on.
malfunctioning, no difference between the two

will be detected and LED7 will not come on.
7. LED7 (MH SS1 Fail). If main hoist motor

(a) Main hoist speed sensor 1 is not sending
a signal to the PLLC (see NOTE below).
(b) The main hoist speed sensor 1 signal
8. LED8 (MH SS2 Fail). If main hoist motor

(a) Main hoist speed sensor 2 is not sending
a signal to the PLLC (see NOTE below).
(b) The main hoist speed sensor 2 signal
NOTE
the signals received from main hoist speed
sensor 1 and main hoist speed sensor 2 and
turns on LED8 if a signal is sensed from speed
sensor 1 but not from speed sensor 2.
Consequently, if both speed sensors or both
speed sensor signal processing circuits are
malfunctioning, no difference between the two
will be detected and LED8 will not come on.
NOTE
the signals received from main hoist speed
sensor 1 and main hoist speed sensor 2 and
turns on LED7 if a signal is sensed from speed
sensor 2 but not from speed sensor 1.
Consequently, if both speed sensors or both
speed sensor signal processing circuits are
NOTES
80
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 6.2d, Gorilla

5/12/99 (Rev8/30/01)
PUBLICATION ROM6
3
3
2
1
4
1
BRACKET INSTALLATION
BRAKE CALIPER
ASSEMBLY
THERMOCOUPLE
BRACKET ASSEMBLY
THERMOCOUPLE
ASSEMBLY
OUTSIDE EDGE
OF BRAKE DISC
OUTSIDE EDGE
OF BRAKE DISC
.002"
.050" CLEAR
(REF)
1.
2.
3.
4.
MOUNTING BRACKET
COMPRESSION FITTING
THERMOCOUPLE ASSEMBLY
THREAD LOADING COMPOUND - LOCTITE RC271
1. Insert compression fitting (Item 2) into bracket (Item 1) using Loctite (Item 4).
2. Install bracket onto brake caliper using caliper mount bolt as shown. Adjust bracket as necessary so
that compression fitting is perpendicular to radial edge of brake disk. Tighten caliper mount bolt.
3. Loosen compression fitting nut and insert thermocouple (Item 3) through fitting bushing and teflon
ferrule (internal to fitting) until thermocouple tip measures .050" above brake disk edge. Tighten fitting
nut using Loctite (Item 4) and recheck for .050 .002" clearance. Loosen nut and readjust if
necessary.
4. Route thermocouple wire as shown on machine wire layout; terminate thermocouple wire as shown
on machine schematic.
1CG1875, P1064
1ROM 6.2d, Gorilla

5/12/99 (Rev 8/30/01)
FIGURE 25. HYDRAULIC BRAKE THERMOCOUPLE INSTALLATION

COPYRIGHT 2002
LeTourneau, Inc.
TA8987CG
81
TX2
CASE
GRND
ACT2
(YEL)
ACT1
(RED)
AUX HOIST
5 6
7 8
SET 2
SET 1
3B
PUBLICATION ROM6
T/C , MV
8 9
OUT+
3B
TX1
CASE
GRND
MTC 1 MTC 2
(RED) (YEL)
9
SET 2
MAIN HOIST
5 6
7 8
SET 1
T/C , MV
8 9
OUT+
TEMP XMIT PANEL

4228556
TEMP XMIT
AUX HOOK
4180161
TEMP XMIT
MAIN HOOK
4180161
FIGURE 26. HYDRAULIC BRAKE THERMOCOUPLE TEMPERATURE TRANSMITTERS

1CG1877, P1064
TA8988CG
NOTES
82
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 6.2d, Gorilla

5/12/99 (Rev8/30/01)
PUBLICATION ROM1
LeTOURNEAU, INC., PCM 120SS ELECTRIC DECK CRANE

REPAIR AND OVERHAUL MANUAL
STRUCTURAL COMPONENTS
Page
Page
TABLE OF CONTENTS
TABLE OF CONTENTS
PCM120SS FLOATING SHEAVE HOUSING

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . 2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CRANE TESTING, EXAMINATION, AND

CERTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 31

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SURVEY AND APPROVAL . . . . . . . . . . . . . . . . . . . . 3

ANNUAL EXAMINATIONS . . . . . . . . . . . . . . . . . . . . 3
PCM120SS HOOK AND BLOCK ASSEMBLY . . . . . . 33
CONTROL BOOK AND CERTIFICATE . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CRITICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 5
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CRITICAL MECHANICAL COMPONENTS . . . . . . . 5

CRITICAL STRUCTURAL COMPONENTS . . . . . . . 5
CABLE DRUM LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . 35
CRITICAL RIGGING COMPONENTS . . . . . . . . . . . 5
PCM120SS STRUCTURAL REPAIRS . . . . . . . . . . . . 37
PCM120SS MACHINERY HOUSE AND WINCH

INSTALLATION - BOOM, MAIN HOOK AND
AUXILIARY HOOK ASSEMBLIES . . . . . . . . . . . . . . . . 7
WELDING REQUIREMENTS . . . . . . . . . . . . . . . . . . 37
STRUCTURAL MATERIALS . . . . . . . . . . . . . . . . . . . 37
STRUCTURAL REPAIR PROCEDURES . . . . . . . . . 37
MACHINERY HOUSE DESCRIPTION . . . . . . . . . . . 7
PCM350SS/120SS ELECTRIC DECK CRANE

PAINT RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 39
PCM120SS COLUMN AND SWING TABLE . . . . . . . 9

DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 9
MATERIALS AND EQUIPMENT

RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . 39
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . 39
PCM120SS TURNTABLE ROLLER ASSEMBLY . . 13
PAINT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 40
POST PAINT INSPECTION AND SERVICES . . . . . 40

REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13
FIGURE
PCM120SS SWING GEAR UNIT ASSEMBLY . . . . . . 15
Page
MACHINERY HOUSE AND WINCH

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .
INNER COLUMN AND SWING TABLE . . . . .
10
PCM120SS GANTRY ASSEMBLY . . . . . . . . . . . . . . . 19
SWING TABLE ROLLER ADJUSTMENT . . .
14
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SWING GEAR UNIT ASSEMBLY . . . . . . . . . .
16
GANTRY GROUP - PCM 120 . . . . . . . . . . .
20
BOOM AND AUXILIARY HOIST - PCM 120
27
PCM120 BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . 25
BOOM TIP INSTALLATION WITH

AUXILIARY HOIST - PCM 120 . . . . . . . . . . .
29
BOOM GROUP WITH AUXILIARY HOIST

PCM 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
10
FLOATING SHEAVE HOUSING ASSEMBLY
32
11
MAIN HOOK AND BLOCK ASSEMBLY PCM 120 (50TON) . . . . . . . . . . . . . . . . . . . . .
34
12
LOCK PIN MOUNT STRUCTURE

INSTALLATION - PCM120SS . . . . . . . . . . .
36
SWING GEAR UNIT DC MOTOR . . . . . . . . . . . . . . . 15

SWING GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BOOM DISASSEMBLY AND REMOVAL . . . . . . . . . 25

BOOM INSPECTIONS AND SERVICES . . . . . . . . . 25
BOOM REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 25
PCM120SS GANTRY SHEAVE HOUSING
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1ROM 1.2a, 120SS (Gorilla)

4/20/99
COPYRIGHT 2002
LeTourneau, Inc.
PCM 120SS ELECTRIC DECK CRANE STRUCTURAL COMPONENTS
PUBLICATION ROM1

Publication ROS1, STRUCTURAL COMPONENTS, is to
assist maintenance personnel and operators in the
location, inspection, adjustment and repair or replace
ment of the various structural components of the crane.
NOTE
work.
NEVER remove the DC drive motors access

covers unless the electrical system is turned
off, locked out, and grounded. Contact with
high voltage terminals inside the motors will
result is serious injury or loss of life.
NOTE
BEFORE attempting to disassemble any of the

major components of the machine BE SURE to
provide hoists or cranes and lifting devices of
adequate capacity and height.

nature, it is indicated by the word
SHOULD" and is recommended to be consid
ered, the advisability of which depends on the
facts in each situation.
NEVER stand under or place any body part

under components while hoisted. Serious
injury, loss of life could result in the event of an
accident.
WARNINGS AND CAUTIONS

Before any inspections or repairs are performed to the
structural components of the crane it is critically
important to read and comply with the following
warnings and cautions. These warnings and cautions
will not be reiterated in the following text:
When inspecting or performing maintenance

or repair operations on elevated structures of
the crane, NEVER proceed beyond the safety
of handrailed platforms. Serious injury or loss
of life from falling is possible outside these
areas.
CAUTION

required by job conditions. ALWAYS wear
gloves when handling wire rope.
CAUTION

signs.
CAUTION
BEFORE welding on any structural members

of the machine refer to Publication LET1,
FIELD WELDING PROCEDURES, located in
the back of Section 1, of the REPAIR AND
OVERHAUL MANUAL. Serious damage to
electrical and electronic controls is possible
unless precautions described in this publica
tion are adhered to.
Ladders and catwalks attached to the crane

are designed for servicing of the crane only
while the crane is stopped. No personnel are
allowed on any structure of the crane during
operation. Serious injury or loss of life could
result from falling or crushing.
2
Place a DO NOT OPERATE sign on the

controls of the machine and secure the
controls before performing any maintenance
or repair operations. Serious injury or death is
possible if the machine is started or moved
while maintenance or repair operations are
being conducted.
COPYRIGHT 2002
LeTourneau, Inc.

4/20/99
PUBLICATION ROM1
CRANE TESTING, EXAMINATION, AND CERTIFICATION

The following general guidelines for the testing, ex
amination and certification of the crane are included to
alert the deck supervisor, operator and maintenance
personnel of these requirements and the CRITICAL
IMPORTANCE of these procedures for the continued
safe operation of the crane.
NOTE
ANNUAL EXAMINATIONS
Cranes shall undergo a thorough examination at least
every twelve (12) months by a competent person, or
more frequently if required by the certifying authority.
a.
It is the responsibility of the deck supervisor,

crane operator, and maintenance personnel to
make sure the applicable tests and certifica
tions required by the certifying authority under
which the crane is being operated are met. It is
also the responsibility of the above personnel
to have the required documentation of these
tests, examinations, and certification on hand
and in the format required by the certifying
authority. There are many different certifying
authorities worldwide and these guidelines
should not be considered all inclusive.
Certifying authorities may have the power to
impose fines and harsher penalties for willful
or neglect violations of crane testing,
examination, and certification.
STRUCTURAL INSPECTION
The annual thorough inspection shall comprise control

and function testing of the crane as well as visual control
of elongation, wear and tear, corrosion, cracking and
formation of fractures, etc. The examination shall be
carried out in such a way that it, as far as possible, will
give a reliable knowledge of the safety of the examined
components.
b.
INSPECTIONS FOR OVERLOADED CRANE
A crane which has been exposed to a load moment

exceeding 110% of the permitted load moment (includ
ing maximum calculated for dynamic load) shall be
thoroughly examined by a competent person before it is
again taken into use.
CONTROL BOOK AND CERTIFICATE
SURVEY AND APPROVAL

Before a crane is, or crane components are, first taken
into use, and later every four (4) years, a competent
person shall have controlled constructions and calcula
tions, carried out testing and examination of strength,
quality of materials, workmanship and structural design
as well as certification in connection with this in
compliance with the requirements of the certifying
authority.
After the crane has been tested and thoroughly
examined with a satisfactory result by a qualified
person, a certificate will be issued. The original test
certificate shall be filed on board with the Cargo Gear

4/20/99
Register (Control Book ILO Form No. 1). A copy of this

certificate may be requested by the certifying authority.
The results of initial testing, tests and examinations

every four (4) years as well as the annual examinations
and all kinds of tests and examinations after repairs or
alterations of the crane or hoisting gear, shall be entered
in the Control Book (ILO Form No. 1). All controls, crane
functions and safety devices shall be inspected and
tested annually and when found to function properly the
results shall be entered into the Control Book. The entry
shall be written by the competent person who carried
out the inspection and the examination. Control Book
and Certificate shall both be kept on board. The Control
Book and certificate shall be available for the surveyor of
the certifying authority.
COPYRIGHT 2002
LeTourneau, Inc.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1

4/20/99
PUBLICATION ROM1
CRITICAL COMPONENTS
The following is a list of components of the crane which
should be considered as critical components." These
components are ones which affect the safety of the
crane from a structural and load hoisting standpoint.
These components should be of prime concern to the
deck supervisor, operator and maintenance personnel
with regards to certification, inspection, maintenance
and prompt repair per the appropriate guidelines.
CRITICAL MECHANICAL COMPONENTS

a. All lines and linkage between the brake control
element and the component to be controlled.
b.
Hoist, boom, and swing brake systems
c. Drums, shafts, and gears of hoisting and swing

systems
CRITICAL STRUCTURAL COMPONENTS

a.
Boom chord members
b.
Boom section connection components
c.
Boom foot pins
d. Primary load members of gantries, masts and

Aframes
e. Load transfer members of the rotating upper
structure
f.
Pedestal and swing circle transition pieces
CRITICAL RIGGING COMPONENTS

a.
All running wire ropes in hoist system
b. All standing wire rope in load restraint and support

system
d.
Swing bearing and gear
c.
Hook block assembly
e.
Wire rope sheaves and sheave shafts
d.
Wire rope deadend connection devices
f.
Electric drive motors for hoists, boom, and swing
e.
Floating harness or bridle assemblies

4/20/99
COPYRIGHT 2002
LeTourneau, Inc.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1

4/20/99
PUBLICATION ROM1
PCM120SS MACHINERY HOUSE AND WINCH INSTALLATION

BOOM, MAIN HOOK AND AUXILIARY HOOK ASSEMBLIES
NOTE
The PCM120SS Electric Deck Crane is equipped with a

Winch Housing Assembly positioned on the side of the
Machinery House. The Winch Housing Assembly
consists of three major parts; the Boom Gear Drive
Assembly, the Hook Gear Drive Assembly, and the
Auxiliary Gear Drive Assembly.
Refer to WARNINGS AND CAUTIONS,

page 2, before performing any inspection or
repair to the structural members of the crane.
Refer to
Section 4
location
electrical,
nents.
REMOVAL OF WINCH HOUSING

ASSEMBLY DC DRIVE MOTORS AND
DRIVERS
MACHINERY HOUSE DESCRIPTION

Access to the Machinery House and the electrical
control components, swing and hoisting machinery can
be gained through the access door. A ventilation and
service hatch is provided for cooling and maintenance
servicing. This compartment contains the Solid State
control components, relay switches, transformers, fuse
boxes and other switch gear of the crane. Refer to the
PARTS CATALOG for location of specific control de
vices.
It is necessary to remove the driver and DC motor for

any of the Winch Housing Drive Assemblies to work on
either the driver unit or motor except for minor repair or
adjustments.
Instructions are provided in Section 2, DC MOTORS, for
an inplace inspection of the DC drive motors. Instruc
tions are provided in Section 7, DRIVERS, for an inplace
inspection of the drivers' internal components and the
subsequent removal of a DC drive motor and driver as a
unit if the inspections warrant removal.
Due to the presence of potentially injurious

conditions, only qualified personnel should
enter the Machinery House. Before attempting
to work on a component, make sure all
electrical power is turned off and locked out
and a DO NOT OPERATE sign is attached to
the controls. Also, station an operator at the
remote control operator's console or in the
cab if energized tests of the components are
made.

4/20/99
the Troubleshooting guide in

for information concerning the
of malfunctioning or damaged
electronic or mechanical compo
CAUTION
Under no circumstances should the owner

attempt to disassemble the driver past the
removal of the cover during the inplace
inspection. This is especially important if the
driver is in warranty. Unauthorized disassem
bly will void the warranty.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1
2
4
5
3
4
5
1.
2.
3.
4.
5.
6.
7.
8.
CABLE DRUM STR.

BOLT
N3 DRIVER
ORING
N9 MOTOR
MACHINERY HOUSE
SWING TABLE
CAPSCREW
FIGURE 1. MACHINERY HOUSE AND WINCH INSTALLATION

TA8995CG
1CG1857, P1058
COPYRIGHT 2002
LeTourneau, Inc.

4/20/99
PUBLICATION ROM1
PCM120SS INNER COLUMN AND SWING TABLE ASSEMBLY

NOTE
The Column and Swing Table Assembly is the turn table

and outer column structure which allows the crane to
rotate around the inner column and gear structure.
Refer to Figure 2.
DISASSEMBLY PROCEDURES
Use care to prevent damage to grease seals,

bearings and spacer.
INSPECTIONS AND SERVICES

a. Thoroughly clean all bearings, bearing spacers,
grease seals and capscrews.
b.

Examine for burrs, nicks and dress out.
NOTE
Small burrs and nicks can be dressed out, but
damaged or worn bearings and bushings
must be replaced.
NOTE
A suitable hoisting device such as an auxiliary
crane will be required for disassembly and
reassembly procedures.
c. Examine bearings, spacers and grease seals.

Replace if damaged or worn.
a. Tighten (8) bolts, 4 in the Outer Column Structure

and 4 in the Swing Table. These bolts are used to
support and keep the Swing Table Assembly centered.
d. Use proper lubricant on bearings, spacers and

grease seals as prescribed PCM CRANE LUBRICATION
SPECIFICATIONS, Publication OSM4, Figure 1,
located in the OPERATING AND SERVICE MANUAL.
CAUTION
REASSEMBLY
It is essential to install eight 11/4" UNF bolts,

as shown on Figure 3, Item (1), to support and
keep the swing table centered. The bolts
should be installed four in the swing table and
four in the column structure. Failure to install
the bolts could result in damage to the crane
and a potentially hazardous situation.
a. Install bearings, spacer and grease seals in

bearing hub.
NOTE
Use care to prevent damage to grease seals
during reassembly and installation.
b. Remove (6) bolts holding seal cap to spindle on

top of inner column and gear structure.
b. With a suitable hoisting device, position upper

bearing assembly over spindle.
c. Remove (24) bolts that retain the upper bearing

assembly to the Swing Table. DO NOT reuse these
bolts.
c.
Remove the three jacking screws from the bearing
hub.
d. Using (3) of the bearing hub bolts, jack entire

upper structure assembly from spindle, using tapped
holes in the bearing hub.
e. With a suitable hoisting device, lift the upper
bearing assembly from spindle.
NOTE
e.
Relieve tension on lineup bolts.
f.
Recheck torque on bearing hub and seal cap
bolts.
NOTE
BE SURE the hoisting device is adequate and

that the Swing Table Assembly is secured to
the inner column structure with the lineup
bolts.
Check to be sure lineup bolts have been

backed off enough to prevent any interference
in the cranes rotation.
f.
Remove the two grease seals from the bearing
hub.
g. With a suitable tool, drive the thrust bearing,
bearing spacer and roller bearing out of bearing hub.
4/20/99
d. Bolt seal cap to spindle. Refer to the CAPSCREW

TORQUE CHART, located in the appendix of this manual
for the proper torque.
g. Refill upper bearing assembly with proper lubri

cant through pipe on side of bearing hub. Refer to the
PCM CRANE LUBRICATION SPECIFICATIONS, Figure
1 in Publication OSM4, located in the OPERATING AND
SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
3
4
12
5
6
11
8
13
9
10
18
17
16
17
16
14
19
15
20
21
22
27
23
28
29
24
30
21
31
25
26
32
1NGO2265, P1234
10
FIGURE 2. INNER COLUMN AND SWING TABLE

COPYRIGHT 2002
LeTourneau, Inc.
TA8992CG

4/20/99
PUBLICATION ROM1
INNER COLUMN AND SWING TABLE

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

4/20/99
OIL LEVEL GAUGE

PIPE CAP
PIPE NIPPLE
ELBOW
BOLT
TUBE STR.
BOLT
SEAL CAP
BOLT
BEARING HUB
NIPPLE
ELBOW
MACHINERY HOUSE
OUTER COLUMN STR.
BOLT
LOCKWASHER
BOLT
GREASE FITTING
RETAINER PLATE
ROLLER PIN
OIL SEAL
ROLLER
BEARING ASSY.
RETAINER
SPACER & SEAL RETAINER
RETAINER
BOLT
THRUST BEARING
BEARING SPACER
ROLLER BEARING
GREASE SEAL
INNER COLUMN STR.
COPYRIGHT 2002
LeTourneau, Inc.
11
PUBLICATION ROM1
5
6
7
4
2
1.
2.
3.
4.
BOLT, 11/4" UNF

SWING TABLE
INNER COLUMN STR.
BOLT, 1" UNF
5. ELBOW STR.
6. WIRE TUBE STR.
7. UPPER BEARING ASSY.
FIGURE 3. PCM120SS SWING BEARING REPLACEMENT - UPPER COLUMN ASSEMBLY

1NGO2264, P1060
12
TA9488S8
COPYRIGHT 2002
LeTourneau, Inc.

4/20/99
PCM120SS SWING TABLE ROLLER ASSEMBLY

NOTE
The Swing Table Roller Assembly, located on the bottom

of the outer column allows the crane to rotate. Refer to
Figure 2.

must be replaced.
c. Examine oil seals, rings and retainers. Replace if

damaged or worn.
REASSEMBLY PROCEDURES
Refer to WARNINGS AND CAUTIONS, page 2,

before performing any inspection or repair to
the structural members of the crane.
a. Install bearings, bushings and oil seals. Lubricate

bearings.
NOTE
NOTE

Use care to prevent damage to oil seals during

reassembly and installation.
a. Reduce load on the rollers by removing the boom

or raising the boom to its maximum UP position.
b. Remove the capscrews and bolt retainer pads on
top of the roller assembly.
c. With proper hoisting device lift out the entire Swing
Table Roller Assembly.
b. With Swing Table Roller Assembly completely

together, use a suitable hoisting device to position roller
assembly into the roller housing structure.
c. Install all rollers with the dimple on the roller flange
closest to the column.
NOTE
NOTE
The dimple indicates the high side of the roller

pin.
Be sure that a suitable such as an auxiliary

crane is used and that the Swing Table Roller
Assembly is well secured to it.
d. Remove the oil seal and oil seal ring from under the
bearing and remove the bearing roller from the bearing
pin.
e.
d. Adjust all rollers out until they touch the swing gear.
Position of the rollers can be seen through the viewing
access hole next to the roller flange.
NOTE
Large adjustment is made by rotating the
roller flange independently of the retainer
pad. Smaller adjustment can be made using
the slotted holes of the retainer pad.
Remove the bearing and roller off the bearing pin.
f.
Remove oil seal holder, oil seal and oil seal ring
from bearing pin.
e. Using a feeler gauge between the rollers and the

swing gear, adjust the three nonloaded rollers in,
leaving a .020 inch gap between the roller and the gear.
NOTE
Use care to prevent damage to oil seal, rings,
holder, bearing and rollers.
f.
Secure the bolt retainer pads to roller flanges and
roller table.

a. Thoroughly clean all bearings, rollers, oil seals,
rings, pins, capscrews, magnetic particle test all pins
and rollers.
b.
Examine for nicks, burrs and dress out.
1ROM 1.2b, 120SS (Gorilla)

4/20/99
g. Place grease fitting on top on the pin roller and

lubricate the bearing thoroughly in accordance with
Figure 1, PCM LUBRICATION SPECIFICATIONS, Publi
cation OSM4, located in the OPERATING AND SER
VICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc.
13
PUBLICATION ROM1
THREADED LIFTING EYES
PRYBAR
ROLLER
ACCESS
HOLE
SWING GEAR
FEELER GAUGE
.020
FIGURE 4. SWING TABLE ROLLER ADJUSTMENT

1CG1845, P1052
14
TA8981P
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 1.2b, 120SS (Gorilla)

4/20/99
PUBLICATION ROM1
PCM120SS SWING GEAR UNIT ASSEMBLY

The Swing Gear Unit Assembly controls the rotation of
the crane and is powered by a S1A, DC motor driving
through a #5 gearbox assembly mounted out from the
Swing Table and King Pin Structure. The Swing Gear
Unit output shaft operates on the round gear rack of the
Swing Table to obtain crane rotation. Refer to Figure 5
for an illustration of the components of the Swing Gear
Unit Assembly.
SWING GEAR UNIT DC MOTOR

The Swing Gear Unit DC motor when used in conjunc
tion with the LeTourneau, Inc. power and control system
provides the operator with a wide range of control of
motor speed and output power. These motors are
1ROM 1.2c, 120SS (Gorilla)

4/20/99
especially wound to provide maximum output through

out the full range of motor speed. A multiple disc friction
type spring applied electromechanically released SCR
powered motor brake is an integral part of the motor.
Refer to Section 2 for disassembly, inspection, repair
and reassembly procedures for the DC swing motor.
Also, refer to the LeTourneau, Inc. Publication TAKING
CARE OF YOUR DC MOTOR, located in the back of
Section 2 for additional information on maintenance,
troubleshooting and repair of DC motors.
SWING GEARBOX
Refer to Section 6, Gearboxes, for information concern
ing the disassembly, repair and replacement and
reassembly procedures for the # 5 gearbox assembly.
COPYRIGHT 2002
LeTourneau, Inc.
15
PUBLICATION ROM1
18
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4
5
19
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7
15
8
14
10
13
12
11
1CG1858, P1058
16
FIGURE 5. SWING GEAR UNIT ASSEMBLY

COPYRIGHT 2002
LeTourneau, Inc.
TA8994CG

4/20/99
PUBLICATION ROM1
SWING GEAR UNIT AS SEMBLY

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
LID STRUCTURE
TOGGLE LATCH
ORING
BOLT
LOCKWASHER
ORING
S1A DC MOTOR
BOLT
BOLT
WASHER BAR
LOCKNUT
#5 SWING GEARBOX
LOCKWASHER
BOLT
TERMINAL TUBE
TERMINAL TUBE
COVER STRUCTURE
MACHINERY HOUSE
& WINCH GROUP
19. SWING TABLE GROUP

4/20/99
COPYRIGHT 2002
LeTourneau, Inc.
17
18
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1

4/20/99
PUBLICATION ROM1
PCM120SS GANTRY ASSEMBLY

rigid steel pipe assembly that is pinned to the Swing
Table Structure. The Gantry Sheave Housing Assembly
is pinned to the top of the Gantry Structure to give
proper fleet angle. The Boom Positive Stop is pinned to
the Gantry Structure to stop the boom at a minimum
radius. Refer to Figure 6 for an illustration of the
components of the Gantry Assembly.
Refer to WARNINGS AND CAUTIONS, page 2

a. Remove bolts, keeper plates and pins from the top

of the boom stop support. Remove bolts, keepers and
pins from back of boom stop assembly. Hoist Boom
Stop Structure away.
b. Remove bolts, keeper plates and pins from base of
boom stop support and hoist it away.
c. With a suitable hoisting device secured to the top
of the front Gantry Structure, remove bolts, keeper
plates and pins from the top and bottom of the Rear
Gantry and pins from the top and bottom of the Rear
Gantry Structure and hoist away.
d. Remove bolts, keeper plates and pins from base of
Front Gantry Structure and hoist away.
NOTE

Thoroughly clean all pins, nuts and bolts with a suitable
solvent and allow to air dry. Any worn parts should be
replaced.

NOTE
DISASSEMBLY
All shafts and gears must be magnetic particle

tested.
Place boom in boom rest, and with a suitable hoisting

device, remove the Gantry Sheave Housing Assembly.
NOTE
Refer to GANTRY SHEAVE HOUSING AS

SEMBLY, page 23.

4/20/99
To reassemble the Gantry Assembly, reverse the

procedures in DISASSEMBLY, above.
COPYRIGHT 2002
LeTourneau, Inc.
19
PUBLICATION ROM1
25
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7
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24
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5
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1
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20
7
17
16
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15
7
1
19
9
14
10
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12
11
FIGURE 6. GANTRY GROUP - PCM 120

1CG1859, P1059
20
TA8998CG
COPYRIGHT 2002
LeTourneau, Inc.

4/20/99
PUBLICATION ROM1
GANTRY GROUP - PCM 120

1.
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6.
7.
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18.
19.
20.
21.
22.
23.
24.
25.

4/20/99
BOLT
LOCKING BAR
PIN
R.H. VERTICAL GANTRY STR.
L.H. VERTICAL GANTRY STR.
PIN
PIN
CENTER PIPE STR.
FRONT GANTRY STR.
BOLT
GREASE FITTING
BOLT
BEARING RETAINING
SHEAVE PIN
SPACER
SHEAVE
SEAL
BEARING
SPACER
SUPPORT STR. - SHOCK
PIN
PUSHER STR.
SPRING
BOLT
BOOM STOP SUPPORT STR.
COPYRIGHT 2002
LeTourneau, Inc.
21
22
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1

4/20/99
PUBLICATION ROM1
PCM120SS GANTRY SHEAVE HOUSING ASSEMBLY

NOTE
The Gantry Sheave Housing Assembly is made up of

three (3) sheave wheels and four (4) divider plates. Its
function is to assist in the raising and lowering of the
boom. Refer to Figure 6 for an illustration of the Gantry
Sheave Housing Assembly.

must be replaced.
NOTE
Sheaves and sheave wheel pins are to be
magnetic particle tested.

REASSEMBLY
a. Reassemble and lubricate wheel bearing assem
blies.
NOTE
b. Insert bearing assembly and spacer into first

wheel. Put wheel into position between spacers and
slide sheave wheel pin through spacers, wheel bearing
and wheel.

DISASSEMBLY
a. With a suitable hoisting device attached, remove
the pin retainers and pin from the Gantry Sheave
Housing Assembly. This will allow the whole Gantry
Sheave Housing Assembly to drop down.
b.
Remove the square nuts, pins and pipe spacers.
NOTE
c. Repeat procedure in Step b" until all wheels,

bearing assemblies and spacers are in place and the
sheave wheel pin is all the way through the sheave
divider plates.
d. Replace retainer plates with three (3) 1/2inch bolts
each side of sheave wheel pin. Refer to the CAPSCREW
TORQUE CHART in the appendix of this manual for the
proper torque.
e. Replace sheave housing pin and at the same time
replace the three (3) spacer pipes, one between each
sheave housing plate. Replace square nuts on sheave
housing pins. Refer to the CAPSCREW TORQUE
CHART in the appendix of this manual for the proper
torque.
Only one sheave housing pin needs to be

removed and if the back pin is removed a
complete inspection of all wire ropes can be
made.
NOTE
c. Remove bolts and retainer plates on sheave wheel

pin. Remove pin with caution.
CAUTION
f.
With a suitable hoisting device, raise Gantry
Sheave Housing Assembly up and connect back to top
of gantry with the gantry hinge pin. Replace keeper
plates with two (2) 5/8inch bolts in the end of each pin.
Tighten bolts. Refer to the CAPSCREW TORQUE
CHART, in the appendix of this manual for the proper
torque.
In removing the sheave wheel pin, care should

be taken not to drop or damage the sheave
wheels, wheel bearings and spacers.

a. Thoroughly clean all parts to the Gantry Sheave
Housing Assembly.
b. Inspect all pins, wheels, bearings and spacers.

4/20/99
Make sure all wire ropes are in proper order.
g. Lubricate bearing assemblies through the grease

fitting on the end of the sheave wheel pin as specified in
Figure 1, PCM CRANE LUBRICATION SPECIFI
CATIONS, in Publication OSM4, located in the OPER
ATING AND SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc.
23
24
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1

4/20/99
PUBLICATION ROM1
PCM120SS BOOM ASSEMBLY

rigid steel boom made up of four sections. The lower
structure is 20 feet in length. There are two middle
sections; one of 40 feet and one of 20 feet in length. The
upper boom section is 20 feet in length. Sections are
connected using bolt plates, bolts and nuts. Each joint
of the boom has a male and a female fit for additional
safety. Refer to Figures 7, 8 and 9 for illustrations of the
Boom Assembly.
g.
Spool boom wire rope onto the cable drum.
h. Attach suitable hoisting device to boom structure

and lower to a prepared work surface. Remove locking
bars, base pins, and self aligning bushings.
i.
In succession, remove the capscrews and nuts
that hold the upper, middle and lower boom sections
together and remove each with a suitable hoisting
device.
j.
Remove pin retainers, sheave pins, bearings and
30inch sheave wheels from boom tip and boom tip
extension structure.

k. Remove cotter pin and sheave pin from guide

sheave housing assembly.
l.
Remove bolts, lockwashers and lock plate from
guide sheave housing assembly and drive out sheave
housing pin. Remove the 22inch sheave wheel.
Remove bearing seal and bearing assembly.
NOTE
BOOM INSPECTIONS AND SERVICES
BOOM DISASSEMBLY AND REMOVAL

a. Hoist the Main Hoist and Auxiliary Hoist Hook
(optional) and block assemblies close enough to the tip
to prevent the wire ropes from fouling when the boom is
lowered.
a. Thoroughly clean all bearings, bushings, spacers,

nuts, pins and grease fittings in a solvent and allow to air
dry.
b. Inspect all components for excessive wear and/or
damage. Replace or repair when necessary.
b. Above a flat working surface, lower the boom until

the tip almost touches.
CAUTION
Replace ALL nuts and bolts for boom

connections every four years of operation,
also bolts and nuts are to be replaced if any
boom sections must be replaced. Failure to
comply with this instruction could result in
serious injury or death and damage to the
crane.
DO NOT lower the boom below a parallel with

the base of the boom. Do not let the tip touch
the deck surface because it might bend or
damage the boom structure.
c. Remove the Main Hoist Hook and Block Assembly
and the Auxiliary Hoist Hook and Block Assembly
(optional).
NOTE
d. Spool Main Hook and Auxiliary Hook (optional)

lines on to the drums.
ALL pins and critical welds are to be magnetic

particle tested.
e. With a suitable lifting device, lower the Floating

Sheave Assembly on top of boom and secure.
BOOM REASSEMBLY
f.
Remove boom wire rope dead end for gantry
sheave assembly.
To reassemble the Boom Assembly, reverse the proce

dures in Boom Dissassembly and Removal, above.

4/20/99
COPYRIGHT 2002
LeTourneau, Inc.
25
26
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1

4/20/99
12
19
13
20
20
14
11
22
21
18
10
16 15
21
18
17
VIEW - D
VIEW A
VIEW B
VIEW C
SECTION A-A
C
B
5
6
1.
2.
3.
4.
5.
6.
BOOM BASE STR.

BOOM MID SECTION, 40 FT.
BOOM MID SECTION, 20 FT.
BOOM TOP STR.
CABLE SHEAVE INSTALLATION
BOOM TIP EXTENSION STR.
7.
8.
9.
10.
11.
PLATE
BOLT
CAP PLATE
GREASE FITTING
LUFFING CABLE
12.
13.
14.
15.
16.
BOLT
NUT
IDLER
WASHER
NUT
17.
18.
19.
20.
21.
22.
IDLER MOUNT STR.

BASE PIN
BUSHING
LOCK BAR
BOLT
SLEEVE
FIGURE 7. BOOM AND AUXILIARY HOIST - PCM 120

1CG1860, Ldgr22
1ROM 1.2, FO1, 120SS (Gorilla)

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28
COPYRIGHT 2002
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11
12
14
1
3
7
16
13
12
11
12
5
14
13
12
11
17
4
8
16
9
6
5
4
10
5
6
15
11
6
12
13
14
12
5
11
12
13
14
11
12
14
13
12
11
12
11
1.
2.
3.
4.
5.
BOLT
LOCKWASHER
TOP PLATE
PIN RETAINER
BOLT
1CG1861, P1059
6.
7.
8.
9.
GREASE FITTING
BOLT
PLATE
PLATE
10.
11.
12.
13.
GREASE FITTING
BOLT
PLATE
PLATE
14.
15.
16.
17.
SHEAVE
SHEAVE PIN
SHEAVE PIN
BOOM TIP EXT. STR.
FIGURE 8. BOOM TIP INSTALLATION WITH AUXILIARY HOIST - PCM 120

4/20/99
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LeTourneau, Inc.
TA9001CG
29
PUBLICATION ROM1
2
1
10
7
4
5
5
6
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
BRIDLE LINE ASSY.

WIRE ROPE ASSY.
SINGLE SHEAVE DYNAMETER
MAIN HOOK LINE ASSY.
ANTI TWOBLOCK SENSOR
CLAMP
OPEN WEDGE SOCKET
OVERHAUL BALL ASSY.
HOOK & BLOCK ASSY.
LINE LOAD CELL
FIGURE 9. BOOM GROUP WITH AUXILIARY HOIST - PCM 120

1CG1854, P1057
30
TA9002CG
COPYRIGHT 2002
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4/20/99
PUBLICATION ROM1
PCM120SS FLOATING SHEAVE HOUSING ASSEMBLY

NOTE
The Floating Sheave Housing Assembly is a pulley

made up of three (3) 30inch sheave wheels. Its function
is the raising and lowering of the crane's boom. Refer to
Figure 10 for an illustration of the components of the
Floating Sheave Housing Assembly.
Magnetic particle tests should be conducted

on all critical welds and pins during
disassembly or every four (4) years.

a. Thoroughly clean all parts of the Floating Sheave
Housing Assembly.


NOTE
NOTE

must be replaced.

REASSEMBLY
DISASSEMBLY
a. Lower the Floating Sheave Housing Assembly into
the cradle provided on the top of the boom. Remove the
two (2) 1/2inch bolts and retainer plate that holds the
bridal connector pin in place. With proper hoisting
device remove pin.
b. Lower Floating Sheave Housing Assembly to a
prepared working surface.
c. Remove the square nuts, bolts and pipe spacers
that hold the 4 side and inner plates together.
NOTE

4/20/99
c. Replace the retainer plates and 5/8inch bolts.

Refer to the CAPSCREW TORQUE CHART in the
appendix of this manual for the proper torque.
d. Replace spacers and sheave housing pins, one
spacer between each sheave housing plate. Replace 2
inch square nuts.
d. Remove 5/8inch bolts and retainer plates that

hold the sheave wheel pin. Remove pin with caution.
In removing the sheave wheel pin care should

b. Insert bearing assemblies and spacers into

sheave wheels. Put into position and slide sheave wheel
pin through spacers, wheel bearings and sheave
wheels.
NOTE

made.
NOTE

blies.
e. Replace bridle connector and secure into place

with bridal connector pin and spacers. Replace retainer
plates with 5/8inch bolts. Refer to the CAPSCREW
proper torque.
f.
Lubricate bearing assemblies through the grease
fitting on the end of sheave housing wheel pin as
specified in Figure 1, PCM CRANE LUBRICATION
SPECIFICATIONS, in Publication OSM4, located in the
COPYRIGHT 2002
LeTourneau, Inc.
31
PUBLICATION ROM1
3
4
5
22
8
8
23
11
10
15
12
21
7
8
13
20
11
14
15
19
15
19
14
17
18
16
17
1.
2.
3.
4.
5.
6.
7.
8.
1CG1862, P1059
32
UPPER BRIDLE STR.

LOWER BRIDLE STR.
PIN
RETAINER
BOLT
SPACER
RETAINER PLATE
BOLT
9.
10.
11.
12.
13.
14.
15.
16.
NUT
RETAINER
GREASE FITTING
BOLT
SHEAVE
BEARING SPACER
SPACER
SEAL
17.
18.
19.
20.
21.
22.
23.
BEARING SPACER
BEARING
BOLT
CENTER PIN
PIN
SIDE PLATE
INNER PLATE
FIGURE 10. FLOATING SHEAVE HOUSING ASSEMBLY

COPYRIGHT 2002
LeTourneau, Inc.
TA8977CG

4/20/99
PUBLICATION ROM1
PCM120SS HOOK AND BLOCK ASSEMBLY

The Hook and Block Assembly is in two parts. The Hook
Assembly itself and the Sheave Housing Assembly. The
Hook and Block Assembly is used for hoisting materials.
Refer to Figure 11 for an illustration of the components of
the Hook and Block Assembly.
DISASSEMBLY
a. Lower the Hook and Block Assembly to a prepared
working surface.
b. The Hook Assembly itself is disassembled by first
removing the keeper plates that retain the swivel block.
measure the same as original, if not, discard

the hook.
REASSEMBLY
a. In reassembling the Sheave Housing Assembly,
first reassemble an lubricate all bearing assemblies.
b. Insert bearing assemblies and spacers into the
first wheel. Put wheel into position between spacers,
bearing seals, wheel bearings and sheave wheel.
NOTE
c. With a suitable hoisting device attached to the

Hook Assembly, remove the tie bolts and tie pins that
hold the Sheave Housing Assembly together.
d. Remove the bolts that hold the retainer plates on
the sheave wheel pin. Remove the pin with caution.
NOTE
c. Place Hook Assembly between sheave housing

plates.
d. Repeat procedure b" in this section until all
wheels, bearing assemblies, spacers and seals are in
place and the sheave wheel pin is all the way through
sheave and divider plates.

wheels, wheel bearings, spacers, seals and
Hook Assembly.
e. Remove Hook Assembly to a prepared working
surface.
f.
Remove the cotter pin and 4inch hook nut and
carefully remove the hook itself so as not to damage the
bearing assembly.
g.
Outside sheave plates are wider than the two

divided plates, so the two wider bearings
spacers must go to the outside.
Remove the bearing assembly.
e. Replace sheave wheel pin retainer plates and

bolts. Refer to the CAPSCREW TORQUE CHART in the
f.
Replace sheave housing tie bolts and tie pins and
at the same time replace the 3inch spacer pipes. Refer
to the CAPSCREW TORQUE CHART in the appendix of
this manual for the proper torque.
NOTE

a. Thoroughly clean all parts of the Hook and Block
Assembly.
b. Inspect all pins, wheels, bearing assemblies,
spacers and seals. Replace if damaged or worn.
NOTE
Hook wheels and pins are to be Magnetic
Particle Tested every four (4) years or if
disassembled, to A.P.I. 2C 1983.
NOTE
Check crane hooks for deformation or cracks.
Hooks will be discarded where cracks exist or
throat opening is 15 percent more than the
original throat opening. Hooks will also be
discarded where they are bent or twisted more
than 10 from the plane of the original hook
configuration. The shank of the hook shall
1ROM 1.2d, 120SS (Gorilla)

4/20/99

fitting on the end of the sheave housing wheel pin as
h. Lubricate the hook thrust bearing located on the
side of the swivel bearing block as specified in Figure 1,
PCM CRANE LUBRICATION SPECIFICATIONS, in Pub
lication OSM4, located in the OPERATING AND SER
VICE MANUAL.
i.
Perform a No Load Test" prior to putting back in
service.
NOTE
The Auxiliary Hook Assembly is a vendor
supplied item. Refer to the Parts Catalog for
ordering information.
COPYRIGHT 2002
LeTourneau, Inc.
33
PUBLICATION ROM1
1
2
3
28
29
5
6
8
27
9
10
11
14
1
26
15
25
3
16
11
24
10
17
13
23
18
12
22
19
20
21
1.
2.
3.
4.
5.
6.
7.
SPACER
KEEPER PLATE
BOLT
BEARING RETAINER
GREASE FITTING
BOLT
NUT
8.
9.
10.
11.
12.
13.
14.
RETAINER ROD
SHEAVE
BEARING SPACER
BEARING SPACER
SEAL
BEARING
BOLT
15.
16.
17.
18.
19.
20.
21.
LOCKWASHER
COVER STR.
COTTER PIN
THRUST BEARING
BEARING BLOCK
HOOK
LATCH KIT
22.
23.
24.
25.
26.
27.
28.
29.
FELT SEAL
NUT
ORING
TIE PIN
MOUNT PLATE
SHEAVE PIN
SIDE PLATE
DIVIDER PLATE
FIGURE 11. MAIN HOOK AND BLOCK - PCM 120 (50TON)

1CG1863, P1060
34
TA8971CG
COPYRIGHT 2002
LeTourneau, Inc.

4/20/99
PUBLICATION ROM1
CABLE DRUM LOCK PIN

The cable drums for the main and auxiliary hooks and
boom luffing are equipped with a safety lock pin mount
structure to prevent the cable drum from turning if the
brake is released for service or repair or if the DC drive
motor must be removed. The pin for the applicable drum
should be installed anytime these operations or any

other operation which requires the drum to remain
stationary are being conducted. Refer to Figures 12 for
illustrations of the lock pin mount structure for the PCM
120SS.
NOTES

4/20/99
COPYRIGHT 2002
LeTourneau, Inc.
35
PUBLICATION ROM1
B
2
B
A
5
4
6
7
5
7
8
8
VIEW A-A
1.
2.
3.
4.
5.
6.
7.
8.
MACHINERY HOUSE
KING PIN & SWING TABLE STR.
CABLE DRUM STR.
LOCK PIN STR.
BOLT
LOCK PIN MOUNT STR.
BOLT
PLATE
VIEW B-B
FIGURE 12. LOCK PIN MOUNT STRUCTURE INSTALLATION - PC 120

TA8950CG
1NGO1591, P1031, 6/1/98
36
COPYRIGHT 2002
LeTourneau, Inc.

4/20/99
PUBLICATION ROM1
PCM120SS STRUCTURAL REPAIRS

The following instructions pertain to structural repairs of
the crane and welding procedures which relate to safety
and integrity of the load bearing members.
WELDING REQUIREMENTS
Certain materials are manufactured exclusively by
LeTourneau, Inc. Substitution of these materials is not to
be attempted without prior approval by LeTourneau,
Inc. due to the possible incompatibility of alternate
materials. Should the owner desire, LeTourneau, Inc.
will provide personnel and materials for repairs and/or
replacements if requested.
BOOM DIAGONAL PIPES: 3" XHVY. X .300 wall

thickness and are made from A53 Gr.B or equal.
STRUCTURAL REPAIR PROCEDURES

Before any structural repairs are made magnetic
particle and dye penetrant tests shall be conducted.
CAUTION
BEFORE proceeding with any structural

repairs and/or replacements, BE SURE that
there is no load on the crane and power has
been disconnected from the crane.
Instructions for welding of LeTourneau, Inc. structural

steel are included in LeTourneau, Inc. Publication LeT1,
FIELD WELDING PROCEDURES, located in the back of
Section 1, in the REPAIR AND OVERHAUL MANUAL. It is
ESSENTIAL to review these procedures and contact
both your distributor and LeTourneau, Inc. prior to
attempting ANY structural repairs to this crane. Anyone
performing structural repairs to the crane shall meet the
following qualifications:
The boom should be supported in either the boom rest

or temporary supports.
NOTE
NOTE
Anyone performing structural repairs to the

crane shall meet the following qualifications:
American Welding Society Specifications for
Welding Machinery and Equipment Classifica
tion and Application of Welded Joints for AWS
D14.4 77.
No repairs and/or replacements shall be

undertaken without prior approval from
LeTourneau, Inc. and the certifying authority
under which the crane is operating. Any
repairs shall be witnessed by an attending
surveyor of the certifying authority.
STRUCTURAL MATERIALS
COLUMN PLATES: 1" thick and made from N20 BHT
MAIN BOOM PIPES: 65/8" O.D. LET. X .375 wall
thickness and are made from high strength steel
(70,000 minimum yield, 100,000 minimum tensile
charpy of 20 lb. at -40).
CAUTION
It is essential to isolate the Load Moment

Indicator system from the crane's electrical
system prior to welding repairs or damage will
result.
If emergency repairs and/or replacements are neces

sary, the certifying authority shall be provided with a
detailed description of the extent of the repair and/or
replacement, materials and procedures used, plus any
other pertinent data, at the earliest possible time.
Arrangements shall also be made for an inspection by
the certifying authority's representative.
NOTES

4/20/99
COPYRIGHT 2002
LeTourneau, Inc.
37
PUBLICATION ROM1
NOTES
38
COPYRIGHT 2002
LeTourneau, Inc.

4/20/99
PUBLICATION ROM1

PAINTING RECOMMENDATIONS
These instructions cover surface preparation, coating
system and inspection requirements to be used in the
painting of LeTourneau, Inc. Electric Deck Cranes. The
recommended two coat system with two part inorganic
zinc silicate primer combats corrosion by the elimination
of rust creep" or undercutting of all blasted steel
surfaces including the crane's Machinery House, Col
umn, Gantry, Boom and other structural components.
These instructions are minimal requirements for normal
conditions. Local conditions and overall condition of the
crane's painted surfaces may require additional mea
sures to ensure quality paint work.
NOTE
Sandblast Equipment: Pangborn Blast System or

equivalent
Paint Equipment: Devilbiss Air Spray Gun - Model MBC
510 with air cap AU1239704; 10 gallon Pressure Feed
Tank with Air Motor Agitator Q.S.A. 503 or equivalent
NOTE
Materials and equipment listed above are
used successfully by LeTourneau, Inc. in the
manufacturing process. Substitute items that
meet specifications listed are acceptable.
a. Securely seal the ventilator fan, access door and

any other place blasting sand or paint overspray might
enter the Machinery House or Operator's Cab (option
al). Cover the glass and weatherstripping on the
Operator's Cab (optional). Use masking tape or other
suitable material to seal these areas.
b. Cover or remove the wire rope as necessary to
prevent contamination from blasting sand and paint.
CAUTION
c. Cover and seal the swing gear and swing pinion to

be sure no contamination from sand or paint occurs.
Surface preparation and painting requires

working in close proximity with chemicals and
vapors which can cause skin and respiratory
injury. Read and follow all safety precautions
mentioned in paint manufacturers specifica
tions.
d. Protect any exposed electrical wiring or terminals

from damage by sandblasting.
e. Sandblast to a commercial blast clean finish
(almost near white) per Steel Structures Paint Council,
Surface Preparation Specification SSPCSP1063T.
The grit size should be Mesh/U.S. Sieve Series and be
clean, washed silica such as Lone Star #1 or equal.
Nozzle velocity of the abrasive should not be less than
100 psi.
Also, follow these additional safety precau

tions:
1. Wear the appropriate respirators, eye
protection and protective clothing to prevent
injury. Do not use solvents or thinners to clean
skin.
NOTE
Do not reuse blasting sand. Oil and grease
should be removed by hosing or by wiping
with a suitable solvent.

RECOMMENDATIONS
NOTE
MATERIALS RECOMMENDED
Sandblast Media: Lone Star #1 Bulk Blast Media or

equivalent
Paint and Primer: Refer to manufacturer's product
information following this article.
4/20/99
CAUTION
Use caution to not damage seals when

sandblasting in close proximity to swing
gearbox and drivers.
2. Do not smoke, eat or drink in the surface

preparation and painting area. Also, keep
sparks, heat and open flames away from the
these areas.
a.
EQUIPMENT RECOMMENDED
SURFACE PREPARATION
Refer to paint manufacturer's specification

sheets for physical properties, performance
limitations, additional instructions for surface
preparation, application and safety precau
tions specific to the application of their
products. Specification sheets for the original
equipment paint are provided at the end of this
article.
b.
COPYRIGHT 2002
After sandblasting, ALL welds should be

inspected by a qualified person and any that
are suspected of being cracked are to be dye
penetrant and magnetic particle tested. Refer
to STRUCTURAL REPAIRS, and publication
LeTourneau, Inc.
39
PUBLICATION ROM1
LeT1, FIELD WELDING PROCEDURES, loca

ted in Section 1 in the REPAIR AND
OVERHAUL MANUAL before attempting ANY
welding repairs to the structural components
of the crane.
Care must be taken to minimize surface

contamination from atmospheric pollution
such as dust, industrial fallout etc.
f.
All rough welds, burrs, weld splatter and other
sharp surface projections should be ground smooth.
Any grinding done after sandblasting should be re
blasted to obtain a surface like the remainder of the area
to be painted.
g. Sandblasting and painting operations should be
scheduled so that they will not be in progress at the
same time or so that blasting is not in progress while
there is wet paint within the range of sandblasting
contamination. The blast cleaned surface should be
coated with one coat of primer as specified during the
same day as blasted and also before any visible rust
occurs. Sandblasted steel wet by rain or moisture prior
to priming should be reblasted.
NOTE
Surfaces which do not require painting should
be masked or otherwise protected during the
painting of adjacent work. Also, be aware of
possible damage to surrounding rig compo
nents from overspray and take appropriate
measures to protect them.
NOTE
A color contrast has been purposely estab
lished between the primer and the finish coat.
The color contrast is designed to act as an
indicator to insure complete coverage with
both primer and finish coat. The contrast is not
to be so great as to markedly influence the
appearance of the top coat.
POST PAINTING INSPECTION AND

SERVICES
Post painting inspection and servicing should be
conducted by a qualified person to be sure the
requirements listed the paint manufacturer's specifica
tions are met and that no damage to crane components
by contamination from sandblasting and painting will
occur. The following inspections and services should be
performed:
a. Inspect the paint to be sure that a film thickness as
listed in Figure 13 is met. Measurement should be made
by Dry FilmMikrotest or equivalent gauge.
PAINT APPLICATION
a. Primer and paint used should be the original used
in the manufacturing process or equivalent, conform to
the paint manufacturers specifications and be applied
listed in Figure 13.
b. Painting should be done in a neat and workman
like manner and all joints and crevices should be filled
where necessary and thoroughly painted. Paint should
be applied only on surfaces that are completely dry.
c. Painting should only be permitted within a range of
temperature and humidity recommended by the paint
manufacturer as published in specifications for the
particular product.
40
CAUTION
b. Inspect Machinery House, control panels, motors,

wiring, and terminals for contamination from sandblast
ing and painting. Vacuum out any contamination.
c. Inspect the slewing bearing, gear, gearbox pinion
and lubricant to be sure no contamination from
sandblasting and painting is present. Clean and
lubricate as required.
d. Inspect the wire rope to be sure no contamination
from sandblasting and painting is present. Clean and
e. Inspect pins and bushings for contamination from
sandblasting and painting and clean as required.
COPYRIGHT 2002
LeTourneau, Inc.

4/20/99
PUBLICATION ROM1
Component
Metal Prep
Outer Column and Gear Str.

(PC 350); Inner Column and
Gear Str. (PC 120)
Swing Table, Gantry Boom
(except tip), Machine House
Exterior, Other crane structures
Near white
shot or
sand blast
SSPC10
Primer
Tie Coat
One coat inorganic One coat red

zinc primer 21/2
expoxy 1 MIL DFT
to 3 MLS DFT
One Coat Grey

HiSol expoxy
4-6 MILS DFT
One Coat Yellow
HiSolids epoxy
4-6 MILS DFT
One Coat Orange
HiSolids epoxy
4-6 MILS DFT
Boom Tip
Machine House
Interior
Wire brush to
remove rust
and loose
scale. Wash
to remove oil,
grease and
foreign matter.
Welded Hand
Railjoints
YELLOW
One coat epoxy

primer 4 MILS DFT
None
One Coat Whle

Polyurethane
1.5 to 2 MILS DFT
None
None
Two coats cold

galv. compound,
2-3 MILS
total DFT
ORANGE
FIGURE 13. PCM CRANE PAINT REQUIREMENTS

1CG1565, P1033

4/20/99
Top Coat
COPYRIGHT 2002
LeTourneau, Inc.
TA8941CG
41
PUBLICATION ROM1
LeTOURNEAU, INC., PCM 350SS ELECTRIC DECK CRANE

REPAIR AND OVERHAUL MANUAL
STRUCTURAL COMPONENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
Page
Page
PCM350SS BOOM ASSEMBLY . . . . . . . . . . . . . . . . . 23
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . 2
BOOM DISASSEMBLY AND REMOVAL . . . . . . . . . 23
CRANE TESTING, EXAMINATION, AND

CERTIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BOOM INSPECTIONS UPON DISASSEMBLY . . . . 23

BOOM REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 23
SURVEY AND APPROVAL . . . . . . . . . . . . . . . . . . . . 3
PCM350SS FLOATING SHEAVE HOUSING

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ANNUAL EXAMINATIONS . . . . . . . . . . . . . . . . . . . . 3
CONTROL BOOK AND CERTIFICATE . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CRITICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 5
CRITICAL MECHANICAL COMPONENTS . . . . . . . 5
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CRITICAL STRUCTURAL COMPONENTS . . . . . . . 5
PCM350SS HOOK AND BLOCK ASSEMBLY . . . . . . 31
CRITICAL RIGGING COMPONENTS . . . . . . . . . . . 5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PCM350SS MACHINERY HOUSE AND WINCH

INSTALLATON BOOM, MAIN HOOK, AND
AUXILIARY HOOK ASSEMBLIES . . . . . . . . . . . . . . . . 7

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
MACHINERY HOUSE DESCRIPTION . . . . . . . . . . . 7
CABLE DRUM LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL OF WINCH HOUSING ASSEMBLY

DC DRIVE MOTORS AND DRIVERS . . . . . . . . . . . . 7
PCM350SS STRUCTURAL REPAIRS . . . . . . . . . . . . 35
PCM350SS SWING TABLE AND KING PIN

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STRUCTURAL MATERIALS . . . . . . . . . . . . . . . . . . . 35
WELDING REQUIREMENTS . . . . . . . . . . . . . . . . . . 35
STRUCTURAL REPAIR PROCEDURES . . . . . . . . . 35

PAINTING RECOMMENDATIONS . . . . . . . . . . . . . . . . 37


RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . 37
PCM350SS LOWER BEARING AND SOCKET

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . 37
PAINT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 38
POST PAINTING INSPECTION AND SERVICES . . 38
PCM350SS SWING GEAR UNIT ASSEMBLY . . . . . . 15
FIGURE
SWING GEAR UNIT DC MOTOR . . . . . . . . . . . . . . . 15
SWING GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . 15

PCM350SS GANTRY ASSEMBLY . . . . . . . . . . . . . . . 17
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSPECTIONS UPON DISASSEMBLY . . . . . . . . . . 17
Page
WINCH INSTALLATION . . . . . . . . . . . . . . . . 8
SWING TABLE ROLLER ASSEMBLY . . . . 10
SWING TABLE ROLLER ADJUSTMENT . 11
SWING GEAR UNIT INSTALLATION
GANTRY ASSEMBLY
BOOM AND AUXILIARY HOIST . . . . . . . . 25
PCM350SS GANTRY SHEAVE HOUSING

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 30
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MAIN HOOK AND BLOCK PCM 350SS (75TON) . . . . . . . . . . . . . . . . 32
LOCK PIN MOUNT STRUCTURE

INSTALLATION - PCM 350SS . . . . . . . . . 34
10
PCM CRANE PAINT REQUIREMENTS . . 39

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1

Publication ROM1, STRUCTURAL COMPONENTS, is
to assist maintenance personnel and operators in the
location, inspection, adjustment and repair or replace
ment of the various structural components of the crane.
NOTE
work.
NEVER remove the DC drive motors access

covers unless the electrical system is turned
off, locked out, and grounded. Contact with
high voltage terminals inside the motors will
result is serious injury or loss of life.
Do not perform welding on hooks.
BEFORE attempting to disassemble any of the

major components of the machine BE SURE to
provide hoists or cranes and lifting devices of
adequate capacity and height.
NEVER stand under or place any body part
under components while hoisted. Serious
injury, loss of life could result in the event of an
accident.
NOTE
nature, it is indicated by the word
SHOULD" and is recommended to be consid
ered, the advisability of which depends on the
facts in each situation.
Ladders and catwalks attached to the crane

are designed for servicing of the crane only
while the crane is stopped. No personnel are
allowed on any structure of the crane during
operation. Serious injury or loss of life could
result from falling or crushing.

Before any inspections or repairs are performed to the
structural components of the crane it is critically
important to read and comply with the following
warnings and cautions. These warnings and cautions
will not be reiterated in the following text:

required by job conditions. ALWAYS wear
gloves when handling wire rope.
CAUTION

signs.
When inspecting or performing maintenance

or repair operations on elevated structures of
the crane, NEVER proceed beyond the safety
of handrailed platforms. Serious injury or loss
of life from falling is possible outside these
areas.
CAUTION
BEFORE welding on any structural members

of the machine refer to Publication LET1,
FIELD WELDING PROCEDURES, located in
the back of Section 1, of the REPAIR AND
OVERHAUL MANUAL. Serious damage to
electrical and electronic controls is possible
unless precautions described in this publica
tion are adhered to.

controls of the machine and secure the
controls before performing any maintenance
or repair operations. Serious injury or death is
possible if the machine is started or moved
while maintenance or repair operations are
being conducted.
2
CAUTION
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
CRANE TESTING, EXAMINATION, AND CERTIFICATION

The following general guidelines for the testing, ex
amination and certification of the crane are included to
alert the deck supervisor, operator and maintenance
personnel of these requirements and the CRITICAL
IMPORTANCE of these procedures for the continued
safe operation of the crane.
NOTE
ANNUAL EXAMINATIONS
Cranes shall undergo a thorough examination at least
every twelve (12) months by a competent person, or
more frequently if required by the certifying authority.
a.
It is the responsibility of the deck supervisor,

crane operator, and maintenance personnel to
make sure the applicable tests and certifica
tions required by the certifying authority under
which the crane is being operated are met. It is
also the responsibility of the above personnel
to have the required documentation of these
tests, examinations, and certification on hand
and in the format required by the certifying
authority. There are many different certifying
authorities worldwide and these guidelines
should not be considered all inclusive.
Certifying authorities may have the power to
impose fines and harsher penalties for willful
or neglect violations of crane testing,
examination, and certification.
STRUCTURAL INSPECTION
The annual thorough inspection shall comprise control

and function testing of the crane as well as visual control
of elongation, wear and tear, corrosion, cracking and
formation of fractures, etc. The examination shall be
carried out in such a way that it, as far as possible, will
give a reliable knowledge of the safety of the examined
components.
b.
INSPECTIONS FOR OVERLOADED CRANE
A crane which has been exposed to a load moment

exceeding 110% of the permitted load moment (includ
ing maximum calculated for dynamic load) shall be
thoroughly examined by a competent person before it is
again taken into use.
CONTROL BOOK AND CERTIFICATE
SURVEY AND APPROVAL

Before a crane is, or crane components are, first taken
into use, and later every four (4) years, a competent
person shall have controlled constructions and calcula
tions, carried out testing and examination of strength,
quality of materials, workmanship and structural design
as well as certification in connection with this in
compliance with the requirements of the certifying
authority.
After the crane has been tested and thoroughly
examined with a satisfactory result by a qualified
person, a certificate will be issued. The original test
certificate shall be filed on board with the Cargo Gear
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
Register (Control Book ILO Form No.1). A copy of this

certificate may be requested by the certifying authority.
The results of initial testing, tests and examinations

every four (4) years as well as the annual examinations
and all kinds of tests and examinations after repairs or
alterations of the crane or hoisting gear, shall be entered
in the Control Book (ILO Form No.1). All controls, crane
functions and safety devices shall be inspected and
tested annually and when found to function properly the
results shall be entered into the Control Book. The entry
shall be written by the competent person who carried
out the inspection and the examination. Control Book
and Certificate shall both be kept on board. The Control
Book and certificate shall be available for the surveyor of
the certifying authority.
COPYRIGHT 2002
LeTourneau, Inc.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
CRITICAL COMPONENTS
deck supervisor, operator and maintenance personnel
with regards to certification, inspection, maintenance
and prompt repair per the appropriate guidelines.

a. All lines and linkage between the brake control
element and the component to be controlled.
b.
Hoist, boom, and swing brake systems
c. Drums, shafts, and gears of hoisting and swing

systems

a.
Boom chord members
b.
Boom section connection components
c.
Boom foot pins
d. Primary load members of gantries, masts and

Aframes
e. Load transfer members of the rotating upper
structure
f.
Pedestal and swing circle transition pieces

a.
All running wire ropes in hoist system
b. All standing wire rope in load restraint and support

system
d.
Swing bearings and gear
c.
Hook block assembly
e.
Wire rope sheaves and sheave shafts
d.
Wire rope deadend connection devices
f.
Electric drive motors for hoists, boom, and swing
e.
Floating harness or bridle assemblies
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
LeTourneau, Inc.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS MACHINERY HOUSE AND WINCH INSTALLATION

BOOM, MAIN HOOK, AND AUXILIARY HOOK ASSEMBLIES

Winch Housing structure positioned on the side of the
Machinery House. The Winch Housing structure con
sists of three major parts; the Boom Gear Drive
Assembly, the Hook Gear Drive Assembly, and the
Auxiliary Gear Drive Assembly.
be gained through the access door. A ventilation and

service hatch is provided for cooling and maintenance
servicing. This compartment contains the Solid State
control components, relay switches, transformers, fuse
boxes and other switch gear of the crane. Refer to the
PARTS CATALOG for location of specific control de
vices.
REMOVAL OF WINCH HOUSING

ASSEMBLY DC DRIVE MOTORS AND
DRIVERS
Refer to WARNINGS AND CAUTIONS, page

2, before performing any inspection or repair
to the structural members of the crane.
It is necessary to remove the driver and DC motor for

any of the Winch Housing Drive Assemblies to work on
either the driver unit or motor except for minor repair or
adjustments.
Due to the presence of potentially injurious

conditions, only qualified personnel should
enter the Machinery House. Before attempting
to work on a component, make sure all
electrical power is turned off and locked out
and a DO NOT OPERATE sign is attached to
the controls. Also, station an operator at the
remote control operator's console or in the
cab if energized tests of the components are
made.
Instructions are provided in Section 2, DC MOTORS, for

an inplace inspection of the DC drive motors. Instruc
tions are provided in Section 7, DRIVERS, for an inplace
inspection of the drivers' internal components and the
subsequent removal of a DC drive motor and driver as a
unit if the inspections warrant removal.
MACHINERY HOUSE DESCRIPTION

Access to the Machinery House and the electrical
control components, swing and hoisting machinery can
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
CAUTION
Under no circumstances should the owner

attempt to disassemble the driver past the
removal of the cover during the inplace
inspection. This is especially important if the
driver is in warranty. Unauthorized disassem
bly will void the warranty.
LeTourneau, Inc.
PUBLICATION ROM1
2
4
5
1
3
4
5
3
4
6
7
1.
2.
3.
4.
5.
6.
7.
8.
CABLE DRUM STR.

BOLT
N3 DRIVER
ORING
N9 MOTOR
MACHINERY HOUSE
SWING TABLE & KING PIN STR.
CAPSCREW
FIGURE 1. WINCH INSTALLATION - PCM 350SS

1CG1843, P1052
TA8919CG
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS SWING TABLE AND KING PIN ASSEMBLY

NOTE
The Swing Table King Pin Assembly, located on top of

the pyramid, is the upper portion of the whole Swing
Table Assembly which allows the crane to rotate.

must be replaced.
c. Examine oil seals, rings and retainers. Replace if
damaged or worn.

a. Install bearings, bushings and oil seals. Lubricate

bearings.
NOTE
NOTE


a. Reduce load on the rollers by removing the boom
or raising the boom to its maximum UP position.
b. Remove the capscrews and bolt retainer pads on
top of the roller assembly.
b. With Swing Table Roller Assembly completely

together, use a suitable hoisting device to position roller
assembly into the Roller Housing Structure.
c. Install all rollers with the dimple on the roller flange
closest to the column.
NOTE
c. With proper hoisting device lift out the entire Swing

Table Roller Assembly.
NOTE
d. Install two threaded lifting eyes into two of the

holes on the roller. Leave an empty hole between the
two lifting eyes. Insert a long pry bar through the lifting
eyes to turn the rollers. Refer to Figure 3.
Be sure that a suitable such as an auxiliary

crane is used and that the Swing table Roller
Assembly is well secured to it.
d. Remove the oil seal and oil seal ring from under the
bearing and remove the bearing roller from the bearing
pin.
e.
The dimple indicates the high side of the roller

pin.
e. Adjust all rollers out until they touch the swing gear.
Position of the rollers can be seen through the viewing
access hole next to the roller flange.
NOTE
Remove the bearing and roller off the bearing pin.
Large adjustment is made by rotating the

roller flange independently of the retainer
pad. Smaller adjustment can be made using
the slotted holes of the retainer pad.
f.
Remove oil seal holder, oil seal and oil seal ring
from bearing pin.
NOTE
f.
Using a feeler gauge between the rollers and the
swing gear, adjust the three nonloaded rollers (oppo
site the boom) in, leaving a .020 inch gap between the
roller and the gear (refer to Figure 3).
Use care to prevent damage to oil seal, rings,

holder, bearing and rollers.

a. Thoroughly clean all bearings, rollers, oil seals,
rings, pins, capscrews, and magnetic particle test all
pins and rollers.
b. Examine for nicks, burrs and if any are noted, use a
hand grinder to remove them.
1ROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
g. Secure the bolt retainer pads to roller flanges and

roller table.
h. Place grease fitting on top on the pin roller and
lubricate the bearing thoroughly in accordance with
CATIONS, Publication OSM4, located in the OPERAT
ING AND SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
23
22
21
4
20
7
19
8
10
11
12
18
13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
14
GREASE FITTING
BOLT
PAD
ROLLER PIN
OIL SEAL
ROLLER
BEARING
OIL SEAL RING
OIL SEAL HOLDER
RETAINER RING
OIL SEAL
BUSHING
BEARING
SOCKET STR.
OIL SEAL
HEX NUT
BOLT
COLUMN & GEAR STR.
SWING TABLE &
KING PIN STR.
BOLT
ORING
MANHOLE COVER
BOLT
15
17
16
1CG1844, P1052
10
FIGURE 2. SWING TABLE ROLLER ASSEMBLY

COPYRIGHT 2002
LeTourneau, Inc.
TA8904CG
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
THREADED LIFTING EYES
PRYBAR
ROLLER
ACCESS
HOLE
SWING GEAR
FEELER GAUGE
.020
FIGURE 3. SWING TABLE ROLLER ADJUSTMENT

1CG1845, P1052
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
TA8981P
COPYRIGHT 2002
LeTourneau, Inc.
11
12
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS LOWER BEARING AND SOCKET ASSEMBLY

NOTE
The Lower Bearing And Socket Assembly, located at the

bottom of the pyramid, is the lower portion of the whole
Swing Table Assembly which allows the crane to rotate.
Refer to Figure 2.

must be replaced.
c.
d. Use proper lubricant on bearings, bushing and oil

seals as specified in PCM CRANE LUBRICATION
SPECIFICATIONS, Figure 1, Publication OSM4, lo
cated in the OPERATING AND SERVICE MANUAL.

NOTE
on all gears and shafts every four (4) years or
when disassembled for repairs.
NOTE
A jack and a hoisting device such as an
auxiliary crane of sufficient size and capacity
will be required for disassembly and reas
sembly procedures.
a.
a.
Remove capscrews from bearing socket structure.

b. With a suitable hoisting device, lift the Lower
Bearing and Socket Assembly up the pyramid structure.
NOTE
d. With a suitable hoisting device, attach a sling to

bearing socket structure.
e. Rotate bearing socket structure to 45. This will
allow bearing socket to pass column base plate.
NOTE
Replace capscrews into bearing socket structure.
f.
Replace the nut on the bottom of the swing turn
table.
a. Thoroughly clean bearings, bushing, oil seals and

capscrews.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
c. Rotate bearing socket structure 45 to allow it to

pass up through the column base plate and into place.
e. Relieve tension on jacking device to put load back
on the thrust bearing.
Examine for burrs and nicks.
BE SURE the Lower Bearing and Socket

Assembly is well secured before hoisting.
d.
BE SURE that a suitable hoisting device is

used and the Lower Bearing socket Assembly
is well secured before removal.
b.
Install bearings, bushing and oil seals.
NOTE
Remove nut on the bottom of the swing table tube.
b. With a suitable jacking device placed between the

swing gear and bottom of the swing table, jack upward
to relieve the load on the thrust bearing.
c.
Examine oil seals and replace if damaged or worn.
g. Lubricate the bearing through the fitting on the

side of the assembly as specified in Figure 1, PCM
CRANE LUBRICATION SPECIFICATIONS in Publication
OSM4, located in the OPERATING AND SERVICE
MANUAL.
COPYRIGHT 2002
LeTourneau, Inc.
13
14
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS SWING GEAR UNIT ASSEMBLY

The Swing Gear Unit Assembly controls the rotation of
the crane and is powered by a S1A, DC motor driving
through a #5 gearbox assembly mounted out from the
swing table and king pin structure. The Swing Gear Unit
output shaft operates on the round gear rack of the
swing table to obtain crane rotation. Refer to Figure 4 for
an illustration of the components of the Swing Gear Unit
Assembly.
type spring applied electromechanically released mo

tor brake is an integral part of the motor. Refer to
Section 2 for disassembly, inspection, repair, and
reassembly procedures for the DC swing motor. Also,
refer to the LeTourneau, Inc. Publication TAKING CARE
OF YOUR DC MOTOR, located in the back of Section 2
for additional information on maintenance, trouble
shooting, and repair of DC motors.
SWING GEAR UNIT DC MOTOR

The Swing Gear Unit DC motor when used in conjunc
tion with the LeTourneau, Inc. power and control system
provides the operator with a wide range of control of
motor speed and output power. These motors are
especially wound to provide maximum output through
out the full range of motor speed. A multiple disc friction
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
SWING GEAR BOX

Refer to Section 7, SWING GEARBOX, for information
concerning the disassembly, repair and replacement
and reassembly procedures for the #5 swing gearbox
assembly.
COPYRIGHT 2002
LeTourneau, Inc.
15
PUBLICATION ROM1
3
4
5
17
6
16
7
15
14
13
9
10
12
11
1.
2.
3.
4.
5.
6.
7.
8.
9.
LID STR.
TOGGLE LATCH
ORING
BOLT
LOCKWASHER
ORING
S1A DC MOTOR
BOLT
BOLT
1CG1846, P1053
16
10.
11.
12.
13.
14.
15.
16.
17.
WASHER BAR
LOCKNUT
#5 SWING GEARBOX
LOCKWASHER
BOLT
TERMINAL TUBE
TERMINAL TUBE
COVER STR.
FIGURE 4. SWING GEAR UNIT INSTALLATION

COPYRIGHT 2002
LeTourneau, Inc.
TA8962CG
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS GANTRY ASSEMBLY

rigid steel pipe assembly that is pinned to the swing
table structure. The Gantry Sheave Housing Assembly
is pinned to the top of the Gantry Structure to give
proper fleet angle. The Boom Positive Stop is pinned to
the Gantry Structure to stop the boom at a minimum
radius. Refer to Figure 5 for an illustration of the
components of the Gantry Assembly.
Refer to WARNINGS AND CAUTIONS, page

2, before performing any inspection or repair
to the structural members of the crane.
b. Remove bolts, keeper plates and pins from the top

of the Boom Stop Support. Remove bolts, keepers and
pins from back of Boom Stop Assembly. Hoist Boom
Stop Structure away.
c. Remove bolts, keeper plates and pins for base of
Boom Stop Support and hoist it away.
d. With a suitable hoisting device secured to the top
of the Front Gantry Structure, remove bolts, keeper
plates and pins form the top and bottom of the Rear
Gantry and pins from the top and bottom of the Rear
Gantry Structure and hoist away.
e. Remove bolts, keeper plates and pins from base of
Front Gantry Structure and hoist away.
NOTE
INSPECTIONS UPON DISASSEMBLY

a. Thoroughly clean all pins, nuts and bolts with a
suitable solvent and allow to air dry. Any worn parts
should be replaced.

NOTE
DISASSEMBLY
All shafts and gears must be magnetic particle

tested.
a. With a suitable hoisting device, remove the Gantry

NOTE
Refer to GANTRY SHEAVE HOUSING AS

SEMBLY, page 18.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
To reassemble the Gantry Assembly, reverse the

procedures in DISASSEMBLY, above.
COPYRIGHT 2002
LeTourneau, Inc.
17
PUBLICATION ROM1
1
2
3
22
21
20
3
19
23
18
4
2
17
1
15
16
15
14
8
4
1
5
6
14
2
13
4
3
11
12
10
1
3
9
2
8
FIGURE 5. GANTRY ASSEMBLY

1CG1847, P1053
18
TA8970CG
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
GANTRY ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
BOLT
KEEPER PLATE
PIN
PIN
LOWER GANTRY STR.
REAR GANTRY STR.
LOWER GANTRY STR.
FRONT GANTRY STR.
GREASE FITTING
BOLT
RETAINER PLATE
SHEAVE PIN
BEARING SPACER
BEARING SPACER
SEAL
BEARING
SHEAVE
SLEEVE
PUSHER STRUCTURE
BOOM STOP SPRING
BOLT
BOOM STOP STR.
BOOM STOP SUPPORT STR.
COPYRIGHT 2002
LeTourneau, Inc.
19
20
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS GANTRY SHEAVE HOUSING ASSEMBLY

NOTE
The Gantry Sheave Housing Assembly is made up of six

(6) sheave wheels and seven (7) divider plates. Its
function is to assist in the raising and lowering of the
boom. Refer to Figure 5 for an illustration of the Gantry
Examine for burrs and nicks. With a hand

grinder, remove any that are noted.
NOTE
Sheaves and sheave wheel pins are to be
magnetic particle tested.

REASSEMBLY
blies.
NOTE
b. Insert bearing assembly and spacer into first

wheel. Put wheel into position between spacers and
slide sheave wheel pin through spacers, wheel bearing
and wheel.

DISASSEMBLY
a. With a suitable hoisting device attached, remove
the three (3) capscrews from the end of the gantry hinge
pins. Remove the two gantry hinge pins. This will allow
the whole Gantry Sheave Housing Assembly to drop
down.
b. Remove the two 1/2inch bolts that hold the sheave
housing pin keeper plates. Remove sheave housing pin
and six (6) spacers.
NOTE
made.
CAUTION


a. Thoroughly clean all parts to the Gantry Sheave
Housing Assembly.
replace if damaged.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
d. Replace retainer plates with three (3) 1/2inch bolts

each side of sheave wheel pin. Refer to the CAPSCREW
proper torque.
e. Replace sheave housing pin and at the same time
replace the six (6) spacer pipes, one between each
sheave housing plate. replace keeper plates with
1/2inch bolts, each side of sheave housing pins. Refer
to the CAPSCREW TORQUE CHART in the appendix of
this manual for the proper torque.
NOTE
c. Remove retainer plates on sheave wheel pin.

Remove pin with caution.
c. Repeat procedure b" until all wheels, bearing

assemblies and spacers are in place and the sheave
wheel pin is all the way through the sheave divider
plates.

f.
With a suitable hoisting device, raise gantry
sheave housing unit up and connect back to top of
gantry with the two gantry hinge pins. Replace keeper
plates with three (3) 1/2inch bolts in the end of each pin.
Tighten capscrews. Refer to the CAPSCREW TORQUE
CHART in the appendix of this manual for the proper
torque.
fitting on the end of the sheave wheel pin as specified in
CATIONS, in Publication OSM4, located in the OPER
ATING AND SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc.
21
22
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS BOOM ASSEMBLY

rigid steel boom made up of four sections. The lower
structure is 43 feet 6 inches in length. There are two
middle sections; one of 20 feet and one of 40 feet in
length. With the Auxiliary Hoist System (optional), the
top boom section has a length of 25 feet. Sections are
connected using bolt plates, bolts and nuts. Each joint
of the boom has a male and a female fit for additional
safety. Refer to Figure 6 for an illustration of the Boom
Assembly.
i.
In succession, remove the capscrews and nuts
that hold the upper, middle and lower boom sections
together and remove each with a suitable hoisting
device.
j.
Remove pin retainers, idler sheave pin, bearing
and 30 inch sheave wheel from auxiliary hoist boom tip
weldment.
k. Remove cotter pin and sheave pin form guide
sheave housing assembly.
l.
Remove bolts, lockwashers and lock plate from
guide sheave housing assembly and drive out sheave
housing pin. Remove the 22 inch sheave wheel.
Remove bearing seal and bearing assembly.

NOTE
m. Remove bolts, retainer plates and sheave wheel

pins from boom housings. Secure sheave in place and
drive out sheave pins. Roll out the sheaves onto a
prepared surface. remove all bearing seals, spacers
and bearings.

BOOM DISASSEMBLY AND REMOVAL

a. Hoist the Main Hoist and Auxiliary Hoist Hook
(optional) and block assemblies close enough to the tip
to prevent the wire ropes from fouling when the boom is
lowered.
b. Above a flat working surface, lower the boom until
the tip almost touches.
h. Attach suitable hoisting device to boom structure

and lower to a prepared work surface.
BOOM INSPECTIONS UPON

DISASSEMBLY
a. Thoroughly clean all bearings, bushings, spacers,
nuts, pins and grease fittings in a solvent and allow to air
dry.
b. Inspect all components for excessive wear and/or
damage. Replace or repair when necessary.
CAUTION
DO NOT lower the boom below a parallel with

the base of the boom. Do not let the tip touch
the deck surface because it might bend or
damage the boom structure.
Replace ALL nuts and bolts for boom

connections every 4 years of operation, also
bolts and nuts are to be replaced if any boom
sections must be replaced. Failure to comply
with this instruction could result in serious
injury or death and damage to the crane.
c. Remove the Main Hoist Hook and Block Assembly

and the Auxiliary Hoist Hook and Block Assembly
(optional).
NOTE
d. Spool Main Hook and Auxiliary Hook (optional)

lines on to the drums.
ALL pins and critical welds are to be magnetic

particle tested.
e. With a suitable lifting device, lower the floating

sheave assembly on top of boom and secure.
f.
Remove boom wire rope dead end for gantry
sheave assembly.
g.
Spool boom wire rope onto the cable drum.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
BOOM REASSEMBLY
To reassemble the Boom Assembly, reverse the proce
dures in BOOM DISASSEMBLY AND REMOVAL, above.
COPYRIGHT 2002
LeTourneau, Inc.
23
24
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
14
15
8
12
13
16
10
19
17
VIEW A
VIEW B
11
VIEW C
20 21
14
SECTION EE
18
A
C
B
1.
2.
3.
4.
5.
6.
7.
LOWER BOOM SECTION

MID BOOM SECTION - 40'
MID BOOM SECTION - 20'
TOP BOOM SECTION
BOOM TIP W/AUXILIARY HOIST
BOOM TIP EXTENSION
BRIDLE CABLE ASSEMBLY
8.
9.
10.
11.
12.
13.
14.
BOLT
CAP PLATE
GREASE FITTING
LUFFING ATTACHMENT STR.
BOLT
NUT
BOLT
15.
16.
17.
18.
19.
20.
21.
PIN RETAINER
BUSHING, SELFALIGNING
BUSHING, PIN
GREASE FITTING
HINGE PIN
IDLER
NUT
NOTE: REFER TO FIGURE 6, PARTS 2 AND 3, FOR ILLUSTRATIONS OF THE BOOM TIP ASSEMBLY.
FIGURE 6. BOOM AND AUXILIARY HOIST (1 of 3)
1CG1848, Ldgr221
1-ROM 1.1, 350SS, FO1

6/25/98
TA8991CG
COPYRIGHT 2002
LeTourneau, Inc.
25
26
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
1CG1849, P1054
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
LeTourneau, Inc.
COPYRIGHT 2002
11
12
14
13
16
12
11

11
15
12
12
14
13
17
12
14
13
11
12
18
11
19
11
12
10
13
13
14
12
14
12
11
12
11
12
13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
14
12
11
BOLT
TOP PLATE
PIN RETAINER
BOLT
GREASE FITTING
BOLT
CUFFING ATTACHMENT
CAP PLATE
BOLT
GREASE FITTING
BEARING SPACER
BEARING SEAL
BEARING ASSY.
SHEAVE
BOOM TIP EXTENSION STR.
IDLER SHEAVE PIN
SHEAVE PIN
BOOM TIP STR.
SHEAVE PIN
PUBLICATION ROM1
BOOM TIP INSTALLATION WITH AUXILIARY HOIST - PCM 350SS
TA8993CG
27
PUBLICATION ROM1
2
1
3
10
7
6
4
5
5
6
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
BRIDLE LINE CABLE ASSY.

WIRE ROPE ASSY., 550'
SINGLE SHEAVE DYNAMOMETER
MAIN HOOK LINE ASSY., 1" X 2225'
ANTITWO BLOCK SENSOR
CLAMP, WIRE ROPE - 1"
OPEN WEDGE SOCKET, 1"
OVERHAUL BALL ASSY., 10T
HOOK AND BLOCK ASSY.
LINK LOADCELL
BOOM GROUP WITH AUXILIARY HOIST
1CG1850, P1055
28
TA8989CG
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS FLOATING SHEAVE HOUSING ASSEMBLY

NOTE
The Floating Sheave Housing Assembly is a pulley

made up of six (6) 30 inch sheave wheels. Its function is
the raising and lowering of the crane's boom. Refer to
Figure 7 for an illustration of the components of the
Floating Sheave Housing Assembly.

on all critical welds and pins during
disassembly or every four (4) years.

a. Thoroughly clean all parts of the Floating Sheave
Housing Assembly.


NOTE
NOTE
Examine for burrs and nicks. With a hand

grinder, remove any that are noted.

REASSEMBLY
blies.
DISASSEMBLY
a. Lower the Floating Sheave Housing Assembly into
the cradle provided on the top of the boom. Remove the
three (3) 1/2inch bolts on the end of the pin that holds
the bridal connector structure in place. With proper
hoisting device remove pin.
b. Remove the two (2) 1/2inch bolts and keeper
plates on the end of sheave housing pins that holds the
five (5) sheave divider plates together. remove pin and
six (6) spacer pipes.
NOTE
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
d. Replace sheave housing pins and spacers, one

between each sheave housing plate. replace keeper
plates and 1/2inch bolts and tighten to proper torque.
c. Remove 1/2inch bolts and retainer plates that

hold the sheave wheel pin. Remove pin with caution.
In removing the sheave wheel pin care should

c. Replace the retainer plates and 1/2inch bolts.

NOTE

made.
NOTE
b. Insert bearing assemblies and spacers into

sheave wheels. Put into position and slide sheave wheel
pin through spacers, wheel bearings and sheave
wheels.
e. Replace bridle connector and secure into place

with bridal pin structure and cap plate with 1/2inch
f.
Lubricate bearing assemblies through the grease
fitting on the end of sheave housing wheel pin as
COPYRIGHT 2002
LeTourneau, Inc.
29
PUBLICATION ROM1
3
18
2
17
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
16
15
3" PIPE SPACER

30" SHEAVE WHEEL
11/8" BEARING SPACER
KEEPER PLATE
1/2" NC X 1" BOLT
5/8" O/S PLATE
RETAINER PLATE
1/8" GREASE FITTING
1/2" NC X 11/4" BOLT
SHEAVE HOUSING PIN
SHEAVE WHEEL PIN
CAP PLATE
FLOATING HOUSING STR.
BRIDLE CONN. STR.
BRIDLE PIN STR.
BEARING SEAL
BEARING ASSY.
3/4" BEARING SPACER
4
5
6
7
8
9
14
13
12
5
11
10
FIGURE 7. FLOATING SHEAVE HOUSING ASSEMBLY
1CG1851, P1055
30
TA8934CG
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS MAIN HOOK AND BLOCK ASSEMBLY

The Hook and Block Assembly is in two parts. The Hook
Assembly itself and the Sheave Housing Assembly. The
Hook and Block Assembly is used for hoisting materials.
Refer to Figure 8 for an illustration of the components of
the Hook and Block Assembly.
DISASSEMBLY
a. Lower the Hook and Block Assembly to a prepared
working surface.
b. The hook Assembly itself is disassembled by first
removing the keeper plates that retain the swivel block.
measure the same as original, if not, discard

the hook.
REASSEMBLY
a. In reassembling the Sheave Housing Assembly,
first reassemble an lubricate all bearing assemblies.
b. Insert bearing assemblies and spacers into the
first wheel. Put wheel into position between spacers,
bearing seals, wheel bearings and sheave wheel.
NOTE
c. With a suitable hoisting device attached to the

Hook Assembly, remove the tie bolts and tie pins that
hold the Sheave Housing Assembly together.
Outside sheave plates are wider than the two

divided plates, so the two wider bearings
spacers must go to the outside.
d. Remove the bolts that hold the retainer plates on

the sheave wheel pin. Remove the pin with caution.
c. Place Hook Assembly between sheave housing

plates.
NOTE
d. Repeat procedure b" in this section until all

wheels, bearing assemblies, spacers and seals are in
place and the sheave wheel pin is all the way through
sheave and divider plates.

wheels, wheel bearings, spacers, seals and
Hook Assembly.
e. Remove Hook Assembly to a prepared working
surface.
f.
Remove the cotter pin and 4inch hook nut and
carefully remove the hook itself so as not to damage the
bearing assembly.
g.
Remove the bearing assembly.
e. Replace sheave wheel pin retainer plates and

f.
Replace sheave housing tie bolts and tie pins and
at the same time replace the 3inch spacer pipes.
replace 11/2 inch nuts and keeper plates. Refer to the
CAPSCREW TORQUE CHART in the appendix of this
manual for the proper torque.
NOTE

a. Thoroughly clean all parts of the Hook and Block
Assembly.
b. Inspect all pins, wheels, bearing assemblies,
spacers and seals. Replace if damaged or worn.
NOTE
Hook wheels and pins are to be Magnetic
Particle Tested every four (4) years or if
disassembled.
NOTE
Check crane hooks for deformation or cracks.
Hooks will be discarded where cracks exist or
throat opening is 15 percent more than the
original throat opening. Hooks will also be
discarded where they are bent or twisted more
than 10 from the plane of the original hook
configuration. The shank of the hook shall
1ROM 1.1, 350SS
6/25/98 (Rev 8/31/01)

fitting on the end of the sheave housing wheel pin as
h. Lubricate the hook thrust bearing located on the
side of the swivel bearing block as specified in Figure 1,
PCM CRANE LUBRICATION SPECIFICATIONS, in Pub
lication OSM4, located in the OPERATING AND SER
VICE MANUAL.
i.
Perform a No Load Test" prior to putting back in
service.
NOTE
The Auxiliary Hook Assembly is a vendor
supplied item. Refer to the Parts Catalog for
ordering information.
COPYRIGHT 2002
LeTourneau, Inc.
31
PUBLICATION ROM1
1
2
3
24
23
23
7
8
5
4
22
6
9
10
7
11
8
1
21
20
3
14
2
19
11
18
10
13
12
17
16
1.
2.
3.
4.
5.
6.
7.
8.
SPACER PIPE
KEEPER PLATE
CAPSCREW
RETAINER ROD
NUT
RETAINER PLATE
GREASE FITTING
BOLT
15
9.
10.
11.
12.
13.
14.
15.
16.
SHEAVE WHEEL
BEARING SPACER
BEARING SPACER
SEAL
BEARING
COTTER PIN
SAFETY LATCH
HOOK
17.
18.
19.
20.
21.
22.
23.
24.
SWIVEL BLOCK
THRUST BEARING
NUT
TIE PIN
MOUNT PLATE
SHEAVE PIN
SIDE PLATE
DIVIDER PLATE
FIGURE 8. MAIN HOOK AND BLOCK - PCM 350SS (75TON)

1CG1852, P1056
32
TA8964CG
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
CABLE DRUM LOCK PIN

The cable drums for the main and auxiliary hooks and
boom luffing are equipped with a safety lock pin mount
structure to prevent the cable drum from turning if the
brake is released for service or repair or if the DC drive
motor must be removed. The pin for the applicable drum
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
should be installed anytime these operations or any

other operation which requires the drum to remain
stationary are being conducted. Refer to Figure 9 for
illustrations of the lock pin mount structure.
COPYRIGHT 2002
LeTourneau, Inc.
33
PUBLICATION ROM1
A
2
3
4
5
8
6
7
8
VIEW A-A
1.
2.
3.
4.
5.
6.
7.
8.
MACHINERY HOUSE
KING PIN AND SWING TABLE STR.
CABLE DRUM STR.
LOCK PIN STR.
BOLT
LOCK PIN MOUNT STR
BOLT
PLATE
VIEW B-B
FIGURE 9. LOCK PIN MOUNT STRUCTURE INSTALLATION - PCM 350SS

TA8949CG
1NGO1592, P1031, 6/1/98
34
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
PCM350SS STRUCTURAL REPAIRS

The following instructions pertain to structural repairs of
the crane and welding procedures which relate to safety
and integrity of the load bearing members.
BOOM DIAGONAL PIPES: 3" XHVY. X .300 wall

thickness and are made from A53 Gr.B or equal.
WELDING REQUIREMENTS
Before any structural repairs are made magnetic

particle and dye penetrant tests shall be conducted.
Certain materials are manufactured exclusively by

LeTourneau, Inc. Substitution of these materials is not to
be attempted without prior approval by LeTourneau,
Inc. due to the possible incompatibility of alternate
materials. Should the owner desire, LeTourneau, Inc.
will provide personnel and materials for repairs and/or
replacements if requested.
Instructions for welding of LeTourneau, Inc. structural
steel are included in LeTourneau, Inc. Publication LeT1,
FIELD WELDING PROCEDURES, located in the back of
Section 1, in the REPAIR AND OVERHAUL MANUAL. It is
ESSENTIAL to review these procedures and contact
both your distributor and LeTourneau, Inc. prior to
attempting ANY structural repairs to this crane.
NOTE
STRUCTURAL REPAIR PROCEDURES
BEFORE proceeding with any structural

repairs and/or replacements, BE SURE that
there is no load on the crane and power has
been disconnected from the crane.
CAUTION
It is essential to isolate the Load Moment

Indicator system from the crane's electrical
system prior to welding repairs or damage will
result.
The boom should be supported in either the boom rest
or temporary supports.
NOTE
Anyone performing structural repairs to the

crane shall meet the following qualifications:
American Welding Society Specifications for
Welding Machinery and Equipment Classifica
tion and Application of Welded Joints for AWS
D14.4 77.
No repairs and/or replacements shall be

undertaken without prior approval from
LeTourneau, Inc. and the certifying authority
under which the crane is operating. Any
repairs shall be witnessed by an attending
surveyor of the certifying authority.
STRUCTURAL MATERIALS
COLUMN PLATES: 1" thick and made from N20 BHT
MAIN BOOM PIPES: 65/8" O.D. LET. X .375 wall
thickness and are made from high strength steel
(70,000 minimum yield, 100,000 minimum tensile
charpy of 20 lb. at -40).
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
CAUTION
If emergency repairs and/or replacements are neces

sary, the certifying authority shall be provided with a
detailed description of the extent of the repair and/or
replacement, materials and procedures used, plus any
other pertinent data, at the earliest possible time.
Arrangements shall also be made for an inspection by
the certifying authority's representative.
COPYRIGHT 2002
LeTourneau, Inc.
35
36
COPYRIGHT 2002
LeTourneau, Inc.
PUBLICATION ROM1
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1

PAINTING RECOMMENDATIONS
These instructions cover surface preparation, coating
system and inspection requirements to be used in the
painting of LeTourneau, Inc. Electric Deck Cranes. The
recommended two coat system with two part inorganic
zinc silicate primer combats corrosion by the elimination
of rust creep" or undercutting of all blasted steel
surfaces including the crane's Machinery House, Col
umn, Gantry, Boom and other structural components.
These instructions are minimal requirements for normal
conditions. Local conditions and overall condition of the
crane's painted surfaces may require additional mea
sures to ensure quality paint work.
NOTE
Paint Equipment: Devilbiss Air Spray Gun - Model MBC

510 with air cap AU1239704; 10 gallon Pressure Feed
Tank with Air Motor Agitator Q.S.A. 503 or equivalent
NOTE
Materials and equipment listed above are
used successfully by LeTourneau, Inc. in the
manufacturing process. Substitute items that
meet specifications listed are acceptable.
SURFACE PREPARATION
a. Securely seal the ventilator fan, access door and
any other place blasting sand or paint overspray might
enter the Machinery House or Operator's Cab (option
al). Cover the glass and weatherstripping on the
Operator's Cab (optional). Use masking tape or other
suitable material to seal these areas.
Refer to paint manufacturer's specification

sheets for physical properties, performance
limitations, additional instructions for surface
preparation, application and safety precau
tions specific to the application of their
products. Specification sheets for the original
equipment paint are provided at the end of this
article.
Sandblast Equipment: Pangborn Blast System or

equivalent
b. Cover or remove the wire rope as necessary to

prevent contamination from blasting sand and paint.
c. Cover and seal the swing gear and swing pinion to
be sure no contamination from sand or paint occurs.
CAUTION
d. Protect any exposed electrical wiring or terminals

from damage by sandblasting.
Surface preparation and painting requires

working in close proximity with chemicals and
vapors which can cause skin and respiratory
injury. Read and follow all safety precautions
mentioned in paint manufacturers specifica
tions.
e. Sandblast to a commercial blast clean finish

(almost near white) per Steel Structures Paint Council,
Surface Preparation Specification SSPCSP1063T.
The grit size should be Mesh/U.S. Sieve Series and be
clean, washed silica such as Lone Star #1 or equal.
Nozzle velocity of the abrasive should not be less than
100 psi.
Also, follow these additional safety precau

tions:
1. Wear the appropriate respirators, eye
protection and protective clothing to prevent
injury. Do not use solvents or thinners to clean
skin.
Use caution to not damage seals when

sandblasting in close proximity to swing
gearbox and drivers.
2. Do not smoke, eat or drink in the surface

preparation and painting area. Also, keep
sparks, heat and open flames away from the
these areas.
NOTE
Do not reuse blasting sand. Oil and grease
should be removed by hosing or by wiping
with a suitable solvent.

RECOMMENDATIONS
a.
NOTE
MATERIALS RECOMMENDED
Sandblast Media: Lone Star #1 Bulk Blast Media or

equivalent
Paint and Primer: Refer to manufacturer's product
information following this article.
b.
EQUIPMENT RECOMMENDED
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
CAUTION
COPYRIGHT 2002
After sandblasting, ALL welds should be

inspected by a qualified person and any that
are suspected of being cracked are to be dye
penetrant and magnetic particle tested. Refer
to STRUCTURAL REPAIRS, and publication
LeT1, FIELD WELDING PROCEDURES, lo
cated in Section 1 in the REPAIR AND
LeTourneau, Inc.
37
PUBLICATION ROM1
OVERHAUL MANUAL before attempting ANY

welding repairs to the structural components
of the crane.
Care must be taken to minimize surface

contamination from atmospheric pollution
such as dust, industrial fallout etc.
f.
All rough welds, burrs, weld splatter and other
sharp surface projections should be ground smooth.
Any grinding done after sandblasting should be re
blasted to obtain a surface like the remainder of the area
to be painted.
g. Sandblasting and painting operations should be
scheduled so that they will not be in progress at the
same time or so that blasting is not in progress while
there is wet paint within the range of sandblasting
contamination. The blast cleaned surface should be
coated with one coat of primer as specified during the
same day as blasted and also before any visible rust
occurs. Sandblasted steel wet by rain or moisture prior
to priming should be reblasted.
NOTE
A color contrast has been purposely estab
lished between the primer and the finish coat.
The color contrast is designed to act as an
indicator to insure complete coverage with
both primer and finish coat. The contrast is not
to be so great as to markedly influence the
appearance of the top coat.
POST PAINTING INSPECTION AND

SERVICES
Post painting inspection and servicing should be
conducted by a qualified person to be sure the
requirements listed the paint manufacturer's specifica
tions are met and that no damage to crane components
by contamination from sandblasting and painting will
occur. The following inspections and services should be
performed:
NOTE
Surfaces which do not require painting should
be masked or otherwise protected during the
painting of adjacent work. Also, be aware of
possible damage to surrounding rig compo
nents from overspray and take appropriate
measures to protect them.
a. Inspect the paint to be sure that a film thickness as

listed in Figure 10 is met. Measurement should be made
by Dry FilmMikrotest or equivalent gauge.
PAINT APPLICATION
a. Primer and paint used should be the original used
in the manufacturing process or equivalent, conform to
the paint manufacturers specifications and be applied
listed in Figure 10.
b. Painting should be done in a neat and workman
like manner and all joints and crevices should be filled
where necessary and thoroughly painted. Paint should
be applied only on surfaces that are completely dry.
c. Painting should only be permitted within a range of
temperature and humidity recommended by the paint
manufacturer as published in specifications for the
particular product.
38
CAUTION
b. Inspect Machinery House, control panels, motors,

wiring, and terminals for contamination from sandblast
ing and painting. Vacuum out any contamination.
c. Inspect the slewing bearing, gear, gearbox pinion
and lubricant to be sure no contamination from
sandblasting and painting is present. Clean and
d. Inspect the wire rope to be sure no contamination
from sandblasting and painting is present. Clean and
e. Inspect pins and bushings for contamination from
sandblasting and painting and clean as required.
COPYRIGHT 2002
LeTourneau, Inc.
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
PUBLICATION ROM1
Component
Metal Prep
Outer Column and Gear Str.

(PC 350); Inner Column and
Gear Str. (PC 120)
Swing Table, Gantry Boom
(except tip), Machine House
Exterior, Other crane structures
Near white
shot or
sand blast
SSPC10
Primer
Tie Coat
One coat inorganic One coat red

zinc primer 21/2
expoxy 1 MIL DFT
to 3 MLS DFT
One Coat Grey

HiSol expoxy
4-6 MILS DFT
One Coat Yellow
HiSolids epoxy
4-6 MILS DFT
One Coat Orange
HiSolids epoxy
4-6 MILS DFT
Boom Tip
Machine House
Interior
Wire brush to
remove rust
and loose
scale. Wash
to remove oil,
grease and
foreign matter.
Welded Hand
Railjoints
YELLOW
One coat epoxy

primer 4 MILS DFT
None
One Coat Whle

Polyurethane
1.5 to 2 MILS DFT
None
None
Two coats cold

galv. compound,
2-3 MILS
total DFT
ORANGE
FIGURE 10. PCM CRANE PAINT REQUIREMENTS

1CG1565, P1033
1ROM 1.1, 350SS

6/25/98 (Rev 8/31/01)
Top Coat
COPYRIGHT 2002
LeTourneau, Inc.
TA8941CG
39
FIELD WELDING PROCEDURE
PUBLICATION LeT-1
NOTES
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____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
COPYRIGHT 2001
LeTourneau, Inc.
7-LeT-1.3 GEN. EQUIP. (MSWord)

11-29-01
PUBLICATION LeT-1

!
To ensure that no damage occurs to solidstate components, the welding ground clamp
should be as close as possible to the area to
be welded.

controls while welding, maintenance or
repair work is being completed. Serious
injury or death is possible if the machine is
started or moved while maintenance or
repair operations are being conducted. For
the welders safety, always disconnect the
battery ground near the battery box to
prevent the machine from being started
while the welder is working.
CAUTION
Under NO circumstances should a bearing or

movable joint be between the grounding
point and the area to be welded.
CAUTION
Isolate ALL DDEC components before

beginning welding procedures. Damage to
components could otherwise result.
If inspecting the welds of making welding

repairs on the elevated structures of a Jib
Crane, Straddle Hoist, or Marine Crane
NEVER proceed beyond existing platforms.
Moving beyond the safety of hand-railed
platforms could cause injury or loss of life.
Wear a hard hat when performing any
inspections, maintenance operations or
welding repairs on a Jib Crane, Straddle
Hoist or Marine Crane. Be sure all power is
turned off before touching any electrical
connections or terminal. Only qualified and
experienced personnel should enter the
electrical control room of a Jib Crane or
Marine Crane.
NOTE
Machines with Detroit Diesel engines
equipped with the DDEC system (instead of
the governor system) are also equipped with
an electronic battery equalizer. To avoid
reverse polarity damage when disconnecting
battery terminals, always remove the
equalizer ground terminal first and replace
the equalizer ground terminal last.
1. For machines with an articulating joint,
make certain that the ground strap in the
pivot area is left firmly connected
because this cable electrically ties the
two frame sections together.
2. If the welding unit is connected to
commercial power such as in a shop
area, the machine must be isolated from
all other contacts to ground other than
the welding ground clamp if possible.
Machine attachments must not contact
any steel wear rails in the floor. If an
overhead crane is used to support any
part of the machine, a nonconductive
sling should be used.
BEFORE working in the pivot or pinch area

of an articulated machine, securely attach
the frame lock or steering locking pin to
prevent the machine from turning. Enter this
area only when necessary. Before operating,
be sure steering locking pin is disconnected
and properly stowed.
3. Do not disconnect the neutral from

ground in the master junction box.
Machines fitted with the optional ground
fault system have this connection at the
fault current limiting resistors.
NEVER, under any circumstances, weld or

use a cutting torch on a wheel with an
inflated tire. This could cause a tire
explosion resulting in serious injury or loss
of life.

11-29-01
CAUTION
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
GENERAL WELDING PRACTICES

PREHEAT AND INTERPASS
TEMPERATURES
Preheat and interpass temperature controls are crucial
elements in making a quality weld. Preheat is defined
as the temperature of the base metal in the
surrounding area of the starting point of welding
immediately before welding begins. Preheat is to be
applied using an oxy-fuel torch with a rosebud
attachment. The minimum preheat temperature shall
be maintained within 3 of the welding area. To
determine the proper minimum preheat temperature
and the maximum interpass temperature, follow the
information on. Where possible, preheat on opposite
side of the area in which welding is being done to
insure that the temperature has soaked through the
part. Temperature of the part shall be checked with
temperature crayons to ensure correct preheat.
Interpass temperature is defined as the temperature of
the weld between weld passes. The interpass
temperature shall be checked between each
successive weld pass with temperature crayons. The
start of another weld pass shall not begin until the
temperature of the part is below the maximum
interpass temperature at the arc initiation site.
ELECTRODE STORAGE AND HANDLING

All SMAW electrodes shall be removed from a fresh
hermetically sealed canister or from baking or storage
ovens. Electrodes shall be issued and held in quivers
or other small open containers by the welder until
used. After hermetically sealed containers are opened
or after electrodes are removed from baking or storage
ovens, the electrode exposure to the atmosphere shall
not exceed the values shown in Figure 1. Electrodes
exposed to the atmosphere for periods less than those
permitted by Figure 4 may be returned to a holding
oven maintained at 250F minimum for a minimum
hold time of four hours. Electrodes exposed to the
atmosphere for periods greater than those permitted in
Figure 4 shall be re-baked as follows:
All electrodes having low-hydrogen coverings
conforming to ANSI/AWS A5.1 shall be baked for
at least two hours between 500F and 800F.
All electrodes having low-hydrogen coverings
conforming to ANSI/AWS A5.5 shall be baked for
at least one hour at temperatures between 700F
and 800F.

11-29-01
After the electrodes have been re-baked, they may be

re-issued. Electrodes shall be re-baked no more than
once. Electrodes that have been wet shall not be used.
CERTIFIED WELDERS AND APPROVED

WPS
All welding done shall be performed by a certified
welder following an approved Welding Procedure
Specification (WPS). The WPS and welder must be
qualified according to AWS D 1.1 Structural Welding
Code - Steel or other recognized governing code
requirements.
WELDING TECHNIQUES
For multiple pass welds, starts and stops should
stagger for each weld pass. All starts and stops should
occur before or after the corner of a structure. No slug
welding will be permitted. Where possible, use run-off
tabs. All stops and starts should be on the tabs.
Remove all tabs by oxy-fuel cutting or arc gouging and
grind flush. No weave welding is allowed.
CLEANING REQUIREMENT
Prior to welding, all lose scale, cutting dross, grease,
oil, water, paint, rust, dirt and other contaminants are
to be removed at least 2 from the edge of the joint.
During welding, all individual passes are to be cleaned.
No slag welding is allowed. After welding, remove slag
and spatter from the weld and welding area by
appropriate means. Excessive grinding should be
avoided, but blend grind all repairs.
WELDING DEFECTS
The following discontinuities will cause the weld to be
deemed defective and will require for the discontinuity
and/or the defective weld to be removed.
Porosity (Pinholes) - any cavity type
discontinuity.
Overlap (Cold lap) - protrusion of weld metal
beyond the weld toe or weld root.
Crack - a fracture of the weld metal and/or the
base metal characterized by a sharp tip and high
length to width ratio.
Undercut - Removal of parent material at the toes
of the weld.
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
d. Prepare the joint as defined by engineering. Repair

all excessive gouges and nicks up to 3/16 by blending
the metal by grinding. All discontinuities about 3/16
are to be restored to the original joint profile using the
approved WPS for the structure.
e. Clean the joint as defined above.
f. Preheat the joint using guidelines defined in Figure
1, Figure 2 and Figure 3.
g. Weld using requirements and techniques as
described above.
h. Visually inspect the weld during and after welding.
If a defect is noted, refer to FIELD REPAIR OF A
DEFECTIVE WELD to make the repair.
PROPER ELECTRODE SELECTION

(refer to Figure 1 to determine class)
Class
Electrode
E7018-1
E7018-1
E8018C3
E9018-M
E9018-M
FIELD WELDING
Defined as any welding done outside of the original
fabrication environment in which an item is being
welded to the structure for the first time.
a. Check with the engineering print to ensure
dimensional accuracy.
b. Determine the base metals being joined to
determine the proper preheat and interpass
temperatures (refer to Figure 1, Figure 2,
Figure 3).
c. Preheat the weld joint.
d. Weld using
described above.
requirements
and
techniques
e. Visually inspect the weld during and after welding.

If a defect is noted, refer to FIELD REPAIR OF A
DEFECTIVE WELD to make the repair.
FIELD REPLACEMENT WELD

Defined as any welding done outside of me original
fabrication environment in which an item is being
welded to the structure to replace a worn or defective
item.
a. Before removing the old item, make any
dimensional markings as needed.
b. Preheat the area to be gouged to 250F.
c. Use Air Carbon Arc Gouging to remove the old
item. Be sure not to damage the permanent items in
the structure.
FIELD REPAIR OF A DEFECTIVE WELD

Defined as any welding done outside of me original
fabrication environment in which a structure is being
welded on to repair a defective weld or base material.
a. Determine the extent of the defect by using NonDestructive Examinations (NDE) such as Magnetic
Particle Inspection (MT) or Liquid Penetrant Testing
(PT).
b. Preheat the area of the defect to be removed to
250F.
c. Use Air Carbon Arc Gouging to remove the defect.
If the defect is a crack, remove the crack plus one inch
past the termination of the crack.
d. MT or PT the area to ensure the defect has been
removed.
e. Clean the weld joint as defined above.
f. Preheat the joint using guidelines defined in Figure
1, Figure 2 and Figure 3.
g. Weld using requirements and techniques
described above.
h. MT or PT and visually inspect the completed weld.
If a defect is still detected, repeat Steps a through h.
COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
Class 1
Class 2
Class 3
Class 4
Class 5
A-36
EH36
A-106-B
A500
1026
C1010
CMS10
Mild .33 Max Carbon
C23M (1506)
NC23M (1517)
C1035
A572 Gr-50
4820H
N20 Cl-1 (1518)
N20 Cl-2 (1518)
N20 Cl-3 (1518)
N20 Cl-5 (1518)
M&M Class 2 (1512)
M&M A/R (1512)
A516-70
8720-H
4130
8630M
NN30 (1508)
N20 HS (1503)
NN-20HS (1503)
N20 Hi Moly (1504)
N20 HMRB (1505)
NN25 (1507)
M&M Class 3 (1512)
M&M Tubing (1511)
N-20 Cl-6 (1518)
A710 Class 1
A710 Class 3
N40 FSC (1510)

A514-Q
N30 FSC (1508)
N30 LVR (1508)
N30 HN (1509)
N25HN HTF S1 (1516)
4340
Figure 1. MATERIAL WELDABILITY GROUPING
Material Thickness
Class 1
Class 2
Class 3
Class 4
Class 5
< or = 3/4
100F
100F
125F
175F
200F
>3/4 to 1-1/2
125F
150F
225F
225F
250F
>1-1/2 to 2-1/2
150F
225F
250F
275F
300F
>2-1/2
225F
300F
300F
325F
350F
Figure 2. PREHEAT REQUIREMENTS
Material Thickness
Class 1
Class 2
Class 3
Class 4
Class 5
< OR = 3/4
500F
500F
500F
450F
450
>3/4 to 1-1/2
500F
500F
500F
450F
450F
>1-1/2 to 2-1/2
500F
500F
500F
450F
450F
>2-1/2
500F
500F
500F
450F
450F
Figure 3. INTERPASS MAXIMUM
A5.1
Electrode
Maximum
Exposure
Time (hours)
Electrode
Maximum
Exposure
Time (hours)
E70XX
E70XX-X
E70XXR
E80XX-X
E70XXHXR
E90XX-X
E7018M
E100XX-X
1/2
E110XX-X
1/2
A5.2
Figure 4. MAXIMUM EXPOSURE TIME

11-29-01
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
STRUCTURAL WELDING OF HIGH STRESS JOINTS

The following procedure is provided as a generic
procedure for the repair of cracks that may appear in
the load bearing components of LeTourneau, Inc.
Material Handling Equipment.
NOTE
This procedure applies only to crack repairs.
Replacement of a ball or socket should be
done in accordance with the Lower Ball,
Pivot Ball and Pivot Ball Socket Field
Replacement Procedures.
Figure 5. GRINDERS
PREPARATION
a. Steam clean the area to remove all contamination
on weld joints.
b. Clean the area to be welded of all rust, paint, oil,
grease, dirt and/or mill scale.
ELECTRODE
c. Before any cutting or air carbon arc gouging is

performed, ensure the area is dry.
GREATER THAN 3X
DIAMETER WEAVE
d. Preheat the area around the crack to at least

250F (121C).
NOTE
NOT ACCEPTABLE FOR STRUCTURAL REPAIRS

WEAVE WELD
1-NGO-2859, P03-53
If the crack is in a casting or a weld attached

to a casting, the preheat is 350F (177C).
The preheat area should extend 3 from the
crack. Maintain the preheat temperature
during the repair procedure.
Figure 6. WEAVE WELD
e. Use air carbon gouging to remove the crack.

f. Test the area after arc air has been completed with
die penetrant or mag particle to assure that the entire
crack has been removed. Continue to air carbon arc
gouge until the crack has been removed.
g. Grind the entire gouged area (100%) so that the
steel is free of any slag and carbon deposits. Shiny
steel material should be visible in all parts. This can be
done with either air powered or electric powered
grinders as shown in Figure 5.
d. Bake previously opened packages of electrodes in

a ventilated oven at 500F (260C) for two hours
before using.
e. Electrodes taken from cardboard boxes or a nonairtight container should also be baked at 500F
(260C) for two hours in a ventilated oven. Then they
should be placed immediately in a ventilated holding
oven set at 225F (107C).
f. Any electrode exposed to the air for more than four
hours should be re-baked per the instructions above.
g. Preheat the area to be welded with a heat blanket
or torch to a temperature of 250F (121C).
WELDING
a. Use AWS Class E7018-1 low hydrogen electrodes
for the repair. These electrodes must be clean and dry.
b. Control the moisture in low hydrogen electrodes by
purchasing electrodes in 10 pound (4.5 kg) sealed
packages.
c. Remove only one hours supply of electrodes at a
time. Keep the remainder in a ventilated holding oven
at 225F (107C).

11-29-01
TA-10310
NOTE
If the crack is in a casting or a weld attached
to a casting, the preheat is 350F (177C).
The preheat area should extend 3 from the
crack. Check periodically and maintain the
preheat temperature during the repair
procedure. The temperature should be
checked using heat crayons or heat sticks.
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
h. When welding use stringer beads. The bead width

must be no wider than 3 times the rod diameter. Refer
to Figure 7.
ELECTRODE
WELD BEADS
ELECTRODE
STRINGER BEAD WIDTH

MAXIMUM 3X ELECTRODE
DIAMETER
BACKUP STRIP
MAX
3X
ROOT PASS BEAD

STRINGER BEADS
ELECTRODE
GREATER THAN 3X
DIAMETER WEAVE
WELD BEADS
STRINGER BEAD
WIDTH OF BEAD = MAXIMUM 3X ELECTRODE DIAMETER
1-NGO-2860, P03-53
TA-10309
Figure 7. STRINGER BEAD
THIS WELD IS UNACCEPTABLE

1-NGO-2861, P03-53
i.
No weave welds are permitted. Refer to Figure 6.
TA-10311
Figure 8. BACKUP STRIP
j. Use a backup strip made from 1/4 thick mild steel

(when practical) if the crack penetrates completely
through the plate. Refer to Figure 8.
k. Weld the root pass bead for the complete length of
the bottom of the crack area.
l. Remove the slag from the root pass with an air
scaler or air chisel.
m. To ensure that the root pass has no cracks,
visually check the root pass weld. Use die penetrant or
mag particle if a crack is suspected. If cracks are
found, the root should be gouged out, edges ground
smooth with a grinder and re-welded.
EACH PASS MUST BE COMPLETED FOR THE

FULL LENGTH OF THE REPAIR AREA PRIOR
TO BEGINNING THE NEXT PASS.
NOTE
If there are problems with cracks in the root
pass using the 7018 electrode, then it is
permissible to use either 6013 or 6011
electrodes to make the root pass.
n. Continue the bead for a full pass the length of the
weld prior to beginning a second pass. Refer to Figure
9.
o. Interpass temperature (temperature in the base
material 1 away from the weld) should not exceed
10
1-NGO-2862, P03-
TA-10312
Figure 9. FULL PASS WELD

450F (232C). Use heat crayons or heat sticks
adjacent to the weld to check temperatures. Refer to
Figure 10.
p. Starts and stops on each pass should each be in
different locations from the previous passes. Refer to
Figure 11.
COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
HEAT CRAYON
OR
HEAT STICK

INTERPASS TEMPERATURE
1" AWAY FROM THE WELD
GRINDER
GRINDING TO BE ACROSS
THE WELD DIRECTION
SMOOTH FINISH
NO GRINDING
MARKS
1-NGO-2863, P03-53
TA-10313
Figure 10. INTERPASS TEMPERATURE
1-NGO-2866, P03-53
TA-10316
Figure 13. WELD FINISHING
STARTS AND STOPS FOR EACH BEAD

ARE STAGGERED IN DIFFERENT LOCATIONS
1-NGO-2864, P03-53
TA-10314
Figure 11. WELD STARTS AND STOPS

q. Remove the slag after each pass with an air
powered needle scaler or chipper. Refer to Figure 12.
GRINDING DIRECTION
ACROSS THE WELD
MUST BE SMOOTH POLISH FINISH
AFTER COMPLETION
1-NGO-2867, P03-53
TA-10317
Figure 14. WELD POLISHING

r. Peen each bead, except for the root and cap
passes, with the scaler or chipper to reduce stress
concentrations.
s. Grind the weld-repaired area to blend in with the
adjacent base material. No undercut is allowed. Grind
feed marks should not be visible when the grinding is
finished. If necessary, polish with an emery wheel or
disk. Refer to Figure 13 and Figure 14.
1-NGO-2865, P03-53
TA-10315
t. If surrounding air is above 40F (5C), post-heating

after welding is NOT necessary. If surrounding air is
below 40F (5C), post-heat the entire repaired area
uniformly at 350-400F (177-204C) then air cool.
Figure 12. NEEDLE SCALER KIT, SCALERS

11-29-01
COPYRIGHT 2001
LeTourneau, Inc.
11
PUBLICATION LeT-1
NOTES
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12
COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
UPPER BALL
FIELD REPLACEMENT PROCEDURE
accomplished by laying a straight edge on the ball
base and measuring out from the side plate ring to the
straight edge (refer to Detail 1, Figure 15).
For upper ball field replacement, perform the following

procedures:
a. Before removing the damaged ball, a locating
dimension must be established so that the new ball
can be located properly. This dimension is taken from
the shoulder of the ball base, across the weld joint, to
the face of the side plate ring. Make three or four
measurements around the ball (refer to View A,
Figure 15). The shoulder of the ball base may have its
corners beveled, as shown in Detail 1. Make sure the
locating dimension is taken from the original shoulder
corner and not from the beveled corner. This can be
b. Scribe a mark around the weld joint 1/4 out from

the side plate ring. This scribe mark is to be used when
cutting off the ball base (refer to View A, Figure 15).
c. Scribe a mark around the base of the ball 1-3/4 in
from the outer diameter of the ball base. This scribe
mark is to be used when cutting off the ball base (refer
to View A).
SCRIBE LINE
STEP "b"
DO NOT CUT
PAST THIS LINE
WHILE CUTTING
BASE OFF
REMOVE THIS SECTION

WITH AIR ARC
1/4"
STEP "e"
TUBE
BALL BASE
SHIMMING
DIMENSION
ORIGINAL
WELD AREA
1-3/4"
STEP "h"
DETAIL 2
B
1/4"
SCRIBE LINE
GRIND THE
END OF THE
TUBE CLEAN
STEP "c"
ADDITIONAL WELD
WILL BE REQUIRED
TO FILL THE ID OF
TUBE WHERE AIR ARC
UNDER CUT THE TUBE
CUT
VIEW C
STEP "d"
CUTS FOR
LOCATING
DIMENSION
AREA
REMOVED
STEP "f" & "I"
STEP "a"
LOCATION
DIMENSION
STEP "e"
VIEW A
VIEW D
AREA CUT
1-3/4"
SCRIBE LINE
STEP "d"
BALL BASE
16,965
VIEW B
1/8" RADIUS - BOTH ENDS

ORIGINAL
SHOULDER
CORNER
TOOL DRAWING
GAGE ROD - MAT. 1/4" ROUND

HEIGHT OF
6 TO 8 FT.
LOCATING
DIMENSION
NEW BALL + 2"

LIFTING LUG
1/2" PLATE
STEP "a"
SIDE PLAE
RING
DETAIL 1
1" DIA. ROD
BALL INSTALLATION TOOL
1-NGO-1281, P08-24
1/4"
1"
DRILL 7/16" DIA. HOLE
MUST BE IN THE SAME
PLANE AS THE LIFTING
LUG. INSERT 3/8" x 2"
BOLT FROM THIS SIDE
LOCATION FOR
1" FLAT WASHER
TA6075CG
Figure 15. UPPER BALL FIELD REPLACEMENT

11-29-01
COPYRIGHT 2001
LeTourneau, Inc.
13
PUBLICATION LeT-1
2. Place the ball in liquid nitrogen and freeze for

30 to 40 minutes. Watch the position of the
lifting lug on the ball installation tool so that the
3/8 X 2 bolt does not fall out.
d. Use air-arc to cut the ball off at the neck, as shown

in View A.
e. Use air-arc to cut the ball weld joint out. The
intersection of the 1/4 and 1-3/4 scribe marks is used
to locate the approximate root of the weld joint. Do not
undercut past the 1/4 scribe mark (refer to View A,
Figure 15).
f. Make two air-arc cuts 90 from each other as
shown in View B. Be careful not to cut into the tube.
g. Remove the pie shaped section of the ball base.
h. Before cutting and removing the other ball base
section, determine the dimension between the bottom
of the ball and the machined recess in the tube (refer
to Detail 2). A shim of this dimension will be used
when installing the new ball. This dimension should be
approximately 0.125.
i. Cut and remove the rest of the ball base section
(refer to View B, Figure 15).
j.
TUBE WELDING PREPARATION:

1. The end of the tube is to be replaced by
grinding clean and welding up any air-arc
undercut of the tube below the 1/4 scribe line.
Preheat the weld area to 300 F (149C) and
weld with material listed in Step o, 1 (refer to
View C).
2. Grind the end of the tube and, if necessary,
grind the I.D. as the machine surface of the
tube (refer to View C).
3. Install a shim, of your making, in the bottom of
the machined recess in the tube. The
thickness for this shim was determined in Step
h.
k. INSTALLATION TOOL FABRICATION:

1. Fabricate the ball installation tool, as shown in
tool drawings on Figure 15.
2. Make gage rod tool, as shown in tool drawing
on Figure 15.
l.
14
BALL FREEZING PROCEDURE:

1. Insert the installation tool through the new ball.
Place a 1 flatwasher over the 1 rod and put a
3/8 X 2 bolt through the 7/16 hole. Do not
put a nut on the 3/8 bolt.
m. TUBE EXPANSION:
1. Heat is required to enlarge the tube bore. The
five-inch slab around the tube is to be heated
first to about 300F (149C), and then the tube
can be heated to 300F (149C).
2. Use the gage rod to check expansion of the
tube. If gage rod will not go into tube, then
increase slab and tube temperature by 25F (4C) and recheck with gage rod.
n. BALL INSTALLATION PROCEDURE:
1. Be sure the shim install in Step j, 3 is still in
place. Hoist the frozen ball into position and
insert into the heated tube. You will have three
to four minutes to locate the ball. The ball
should bottom against the shim. Check the
locating dimension obtained in Step a. This
should be checked in three or four places
around the ball. Reposition, as necessary, to
hold this dimension until the ball temperature
increases to the point that the ball is held
snugly in place within the tube. This dimension
must be held for proper ball location (refer to
View D of Figure 15).
2. Allow the ball and tube to return to room
temperature.
3. Rotate the ball installation tool until the 3/8 X
2 bolt falls out. Remove the installation tool.
o. BALL WELDING PROCEDURE:
1. Preheat the weld area to 300F (149C) and
maintain this temperature while welding out
the joint. Arc weld with 1/8 diameter
E-8018C1 electrodes or MIG weld with TriMark TM-911N2 flux cored wire. The
electrodes must have been stored in a sealed
container and heated in a 250F (121C) oven
for 30 minutes before welding. Do not weave
weld.
2. The cap passes must be blended smooth. If
not, they must be ground smooth.
3. Paint the repair area.
COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
LOWER BALL
The following procedure is set forth for the field
replacement of the lower ball structure.
a. Before removing the damaged ball, a locating
dimension must first be established so that the new
ball can be located. This dimension is taken from the
edge of the side plate ring to the shoulder of the base
ball.
b. Scribe a mark around the weld joint one inch out
from the side plate ring. Do not cut past this line when
cutting the ball off. See View A, Figure 16.
c. Scribe a mark around the base of the ball
1-13/16 in from the outer diameter of the ball base.
d. Use air-arc to cut the ball weld joint out. Do not cut
past the one-inch reference line at the surface. The 113/16 reference line and the 2-9/16 depth dimension
can be used to locate the root of the weld joint.
e. The end of the tube is to be repaired by grinding
clean and welding up the air-arc undercut with
E-8018C1 electrodes. Preheat to 300F (149C) before
welding. Do not over weld I.D. or it will have be ground
by hand.
f. Grind the end of the tube clean and if necessary

grind the I.D. of the tube to the same I.D. as the
machined surface of the tube. See View B, Figure 16.
g. Install spacer ring in the tube bore to provide
positive stop when installing ball.
h. Install new ball. It should be loose fit into the tube.
If heat is required to enlarge the tube bore, the side
plate is to be heated first to about 300F (149C) and
then the tube can be heated to 300F (149C).
i. Use the dimension obtained in Step a to locate
the new ball in the end of the tube. Tack weld in place
four places. See View C, Figure 16.
j. Preheat the area to 300F (149C) and maintain
this temperature while welding out the joint.
k. Use 1/8 diameter E-8018C1 electrodes that have
been stored in a sealed container and heated in a
250F (121C) oven for 30 minutes to weld the joint.
Do not weave the electrode more than 1-1/2 times the
diameter of the rod.
l. The cap passes must be blended smooth. If not,
they must be ground smooth.
m. Paint the repair area.
Figure 16. LOWER BALL FIELD REPLACEMENT

11-29-01
COPYRIGHT 2001
LeTourneau, Inc.
15
PUBLICATION LeT-1
NOTES
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16
COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
PIVOT BALL FIELD REPLACEMENT PROCEDURE

For replacement of the pivot ball, perform the following
procedures:
a. Separate the pivot ball from the pivot socket as
described in the FRONT FRAME REMOVAL, in
Section 1, STRUCTURAL, in the REPAIR AND
OVERHAUL MANUAL.
b. Clean the repair area free of dirt and grease.
c. Preheat cross-member to 200F (93C) and cut off
old ball.
d. Repair any gouges or cracks in the slab while it is
still hot, using dry E-8018C electrodes. (If E-8018C
electrodes are not available, E-70l8 electrodes are
acceptable, but only for slab repairs.
first three root passes. Finish the weld by completing

each layer all the way around the ball before starting
on the next layer. (Rod size is not important after the
first three passes). Tri-Mark TM-911N2 gas shielded
flux cored wire may be used for all welding.
i. Do not exceed 400F (204C) in the neck area of
the ball at any time and never contact the carburized
area with the torch. Do not allow the heat transference
to cause the temperature of the ball to exceed 300F
(149 C).
j. Extend the weld out from the edge of the ball
1-3/8 and blend smooth the slab by grinding.
e. Grind cross-member surface smooth.
k. Wrap the ball and cross-member to extend the

cool down time. Ball must cool down to at least 100F
(38C) before reassembling.
f. Place a 1/16 diameter copper wire around the ball

base. Space wire away from the edge of the ball base
so the wire does not melt into the weld. Refer to Figure
17.
l. Follow
the
PIVOT
BALL
SOCKET
REPLACEMENT PROCEDURE. One socket must be
removed and reinstalled to insure correct alignment
and preload with the new ball.
g. Preheat the slab around the perimeter of the ball

base until the ball base temperature is 300F (149C).
Do not exceed this temperature.
m. Clean and paint the repaired area.
h. Weld the ball base to the cross-member using dry

E-8018C electrodes. Use a 1/8 diameter rod for the
n. Follow the re-assembly procedures outlined in

Section 1, STRUCTURAL, in the REPAIR AND
OVERHAUL MANUAL.
BEVEL AROUND BALL BASE
3/8 in. MINIMUM
PILOT STUD
1-NGO-1284, P08-25
1/16 in. DIA. WIRE

WIRE PART #151-0182
TA8246CG
Figure 17. PIVOT BALL REPLACEMENT

11-29-01
COPYRIGHT 2001
LeTourneau, Inc.
17
PUBLICATION LeT-1
NOTES
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
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18
COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
PIVOT BALL SOCKET

To replace the pivot ball socket, perform the following
procedures:
a. Separate the front and rear halves of the machine
as described in FRONT FRAME REMOVAL, in Section
1, STRUCTURAL, in the REPAIR AND OVERHAUL
MANUAL. If the pivot ball is also being replaced,
replace the pivot ball first. Refer to PIVOT BALL FIELD
REPLACEMENT PROCEDURE.
b. Clean the repair area free of dirt and grease.
c. Preheat the cross member to 200F (93C). Cut
the weld from around the socket using air-arc. Refer to
Figure 18 and dimensions of the new socket for depth
and angle of cut in cross-member.
d. Bevel slab as shown in Figure 18.
e. Repair cracks and gouges in slab while it is still
hot, using dry E-8018C1 electrodes. (If E-8018C1
electrodes are not available, E-7018 electrodes are
acceptable).
f.
Clean up notch in slab for re-welding.
g. Measure and record the dimension between the

upper and lower cross-members that the pivot balls
mount to. The measurement should be as close to ball
centerline as possible. The measurement must be .001
inch.
k. Heat the socket and cross-member area adjacent

to the socket to 250-350F (121-177C) and tack
firmly into place using dry E8018C1 electrodes or TriMark TM-911N2 gas-shielded flux cored wire.
l. E-8018C1 electrodes, 1/8 diameter, should be
used to make the first three root passes. Finish each
root pass by completing each pass all the way around
the socket before starting the next pass. Rod size may
be increased after the first three root passes are
completed. Welds are to be stringer beads, not weave
welds. Tri-Mark TM-911N2 gas-shielded flux cored
wire may also be used for all welding.
m. Wrap the cross-member and the socket to extend
the cool-down time. Allow to cool to at least 100F
(38C) before proceeding further.
n. Disassemble the ball cap and socket to install
shims. Follow the re-assembly procedure outlined in
ASSEMBLY OF REAR FRAME TO FRONT FRAME
AND BALL CAP SHIMMING PROCEDURES, located
in Section 1, STRUCTURAL, in the REPAIR AND
OVERHAUL MANUAL. Be sure to check the steering
pivot ball cap shim tolerance as indicated in this
section.
h. Hoist the ball cap and socket up to the ball base

and install around ball base using new liners. Omit the
spacer and shims between the ball cap and socket,
and snug up the capscrews.
i. Join the machine halves together allowing the
socket to seat firmly against the rear of the notch in the
slab.
j. Using a jack underneath the lower ball and socket,
push until the cross-member deflects to .010-inch
minimum and .015 inch maximum. Reference
dimensions in Step g.
Figure 18. PIVOT BALL SOCKET

REPLACEMENT

11-29-01
COPYRIGHT 2001
LeTourneau, Inc.
19
PUBLICATION LeT-1
NOTES
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____________________________________________________________________________________________
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20
COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
JC-40SS A-FRAME TIE PLATE INSTALLATION

The following procedure is for installing tie plates to
repair loose A-frame pin bores on JC-40SS Cranes.
NOTE
Before beginning these repairs, review
WARNINGS AND CAUTIONS. All weld and
heat treat procedures used in these repairs
should be per the welding instructions,
located in STRUCTURAL WELDING OF HIGH
STRESS JOINTS. Use 7018 electrodes.
INSTALLATION OF A-FRAME TIE PLATES

a. Move trolley to the outer end of the boom. This
places the counterweight boom cables in tension and
places the A-frame pins in a partially loaded
configuration.
1. After positioning trolley, lock out control
systems to prevent accidental crane operation.
2. Position ground leads close to repair area to
prevent possible damage to crane electronics.
3. Inspect A-frame ears and I-beam areas for any
cracks to be repaired before proceeding. Use
non-destructive test methods.
b. Install two tie plates, P/N 413-9717 (inside) and
413-4779 (outside) on each A-frame leg. Refer to
Figure 19.
NOTE
1. The tie plate slots (1-5/8) may require

trimming to fit the ears of the base beam. After
trimming, grind smooth all torch marks and
bevel edges as required. Refer to Figure 19.
Ensure plates are installed on the correct
sides of A-frame legs.
2. Weld tie plates on the counterweight boom
side according to welding installation
procedures shown in Figure 20, Figure 21 and
Figure 22.
3. The weld areas in the center of the plate
should be free of flaws and imperfections.
Grind if necessary.
CAUTION
DO NOT WELD TO THE TOP FLANGE OF

THE BASE BEAM.
4. Grind smooth all repaired areas and check for
cracks.
5. Paint all repaired areas.
6. Inspect at P.M. intervals.
NOTE
Although not expected to be required, the
same procedure applies to the boom side A
frame pin configurations.
USE SINGLE WELD PASS ONLY. DO NOT

USE WEAVE WELDS.
NOTES
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________

11-29-01
COPYRIGHT 2001
LeTourneau, Inc.
21
PUBLICATION LeT-1
A-Frame
Boom
A-Frame Pin
Locations
Counterweight Boom
1-NGO-2070, P10-94
TA-9347-CG
Figure 19. A-FRAME PIN LOCATIONS
22
COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION LeT-1
The 1-5/8" slot will be fitted to

the crane. Grind smooth any
torch marks. Prepare a 3/4"
bevel for weld.
P/N 413-9717
Tie Plate, Inside A-Frame
The 1-5/8" slot will be fitted to

the crane. Grind smooth any
torch marks. Pepare a 3/4"
bevel for weld.
P/N 413-4779
Tie Plate, Outside A-Frame
1-CG-2071, P10-94
TA-9348-CG
Figure 20. A-FRAME TIE PLATES

11-29-01
COPYRIGHT 2001
LeTourneau, Inc.
23
PUBLICATION LeT-1
LETOURNEAU, INC.
MATERIAL HANDLING EQUIPMENT
TABLE OF CONTENTS
PAGE
PAGE
SCOPE OF THIS PUBLICATION.................................................. 1
Figure 1.
MATERIAL WELDABILITY GROUPING ..................7
WARNINGS AND CAUTIONS ...................................................... 3
Figure 2.
PREHEAT REQUIREMENTS ..................................7
GENERAL WELDING PRACTICES.............................................. 5
Figure 3.
INTERPASS MAXIMUM ..........................................7
Figure 4.
MAXIMUM EXPOSURE TIME .................................7
Figure 5.
GRINDERS .............................................................9
Figure 6.
WEAVE WELD ........................................................9
PREHEAT AND INTERPASS TEMPERATURES...................... 5

ELECTRODE STORAGE AND HANDLING .............................. 5
CERTIFIED WELDERS AND APPROVED WPS....................... 5
WELDING TECHNIQUES......................................................... 5
CLEANING REQUIREMENT .................................................... 5
WELDING DEFECTS ............................................................... 5
Figure 7.
STRINGER BEAD ................................................. 10
Figure 8.
BACKUP STRIP .................................................... 10
Figure 9.
FULL PASS WELD................................................ 10
FIELD WELDING...................................................................... 6
Figure 10.
INTERPASS TEMPERATURE............................... 11
FIELD REPLACEMENT WELD................................................. 6
Figure 11.
WELD STARTS AND STOPS................................ 11
PROPER ELECTRODE SELECTION ....................................... 6
FIELD REPAIR OF A DEFECTIVE WELD ................................ 6
Figure 12.
NEEDLE SCALER KIT, SCALERS ........................ 11
STRUCTURAL WELDING OF HIGH STRESS JOINTS................ 9
Figure 13.
WELD FINISHING ................................................. 11
PREPARATION ........................................................................ 9
Figure 14.
WELD POLISHING................................................ 11
WELDING................................................................................. 9
Figure 15.
UPPER BALL FIELD REPLACEMENT .................. 13
UPPER BALL FIELD REPLACEMENT PROCEDURE ............... 13
Figure 16.
LOWER BALL FIELD REPLACEMENT ................. 15
Figure 17.
PIVOT BALL REPLACEMENT............................... 17
Figure 18.
PIVOT BALL SOCKET REPLACEMENT .............. 19
Figure 19.
A-FRAME PIN LOCATIONS .................................. 22
JC-40SS A-FRAME TIE PLATE INSTALLATION....................... 21
Figure 20.
A-FRAME TIE PLATES ......................................... 23
INSTALLATION OF A-FRAME TIE PLATES........................... 21
Figure 21.
WELDING INSTALLATION.................................... 24
Figure 22.
WELDING INSTALLATIONS ................................. 24
LOWER BALL FIELD REPLACEMENT PROCEDURE ............. 15

PIVOT BALL FIELD REPLACEMENT PROCEDURE................. 17
PIVOT BALL SOCKET FIELD REPLACEMENT
PROCEDURE ............................................................................. 19

Publication LeT-1, FIELD WELDING PROCEDURES,
provides instructions for welding structural components
on all LeTourneau, Inc. Log Stackers, Straddle Hoists,
Side Porters, Jib Cranes, Marine Cranes and Letro-Pik
Aircraft Cranes. To avoid personal injury or damage to
machine components, it is essential to follow the
instructions in this publication.

11-29-01
COPYRIGHT 2001
LeTourneau, Inc.
PUBLICATION LeT-1
A-Frame
Structure
Tie Plate
P/N 413-9717
Tie Plate
P/N 413-4779
Weld Areas
(both sides of eye)
Typ
I Beam
1-NGO-2072, P10-94
TA-9349-CG
Figure 21. WELDING INSTALLATION
A-FRAME
TYP
413-4779
TIE PLATE
413-9717
TIE PLATE
TYP
NO WELD
TYP
1-NGO-2073, P10-94
TA-9350-CG
Figure 22. WELDING INSTALLATIONS
24
COPYRIGHT 2001
LeTourneau, Inc.

11-29-01
PUBLICATION ROM6
AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS)

DESCRIPTION OF OPERATION
The purpose of the Automatic Overload Protection
System (AOPS) is to automatically (no operator inter
vention required) relieve hoist line tension in the event of
a sensed gross overload on the hook.
If the crane experiences an overload of 140% (user
adjustable) or more of maximum rated load, the Wylie
loadmoment system termination unit board will signal
the Gross Overload Sense card (mounted on the upper
righthand side wall of the cab relay box) to apply 24V to
wire GOL. Wire GOL applies 24V to the hoist controller,
which turns on the Gross Overload Light and causes the
hoist motor to automatically come to a stop (if moving),
regardless of operator control inputs. The hoist control
ler then energizes CR44, which energizes SOL1 (Brake
Master Solenoid) and SOL8. The hoist controller also
energizes CR44A, which energizes SOL9. SOL8 and
SOL9 route hydraulic pressure away from the top brake
canisters of the main and auxiliary hoist motors
respectively and to the proportional relief valve sole
noids, SOL3 and SOL5 (see machine hydraulic sche
matic). Since no current is sent to energize SOL3 or
SOL5 (these are only energized during Power Loss
Lowering System (PLLS) events), all hydraulic pressure
to the top canisters is bypassed to tank through SOL3
and SOL5, and the top canisters remain fully set.
At the same time, the hoist controller will also energize
CR43, which energizes either SOL2 if the main hoist is
selected, or SOL4 if the auxiliary hoist is selected, This
applies full hydraulic pressure to the selected motor's
bottom brake canister, releasing it fully.
The end result is that when the AOPS is triggered by the
Wylie system, the top brake canister of the selected
hoist motor will be fully set, and the bottom brake
canister will be fully released, resulting in a holding force
of approximately 150% of maximum rated load. If a true
gross overload exists, the load will pull through the one
brake canister without causing structural damage to the
crane.
4ROM 6.2e, Gorilla

9/25/01
This system is required by Norwegian Petroleum

Directorate (NPD) regulations for North Sea operations,
and may be disabled for other operations by positioning
the Overload Protection switch to Reset, and position
ing the rightmost circuit breaker in the cab junction box
(CB28) to the open (down) position.
OVERLOAD PROTECTION SWITCH - Leave in Reset
(AOPS disabled) unless told otherwise.
If told otherwise:
Overload Protection Switch ................................ON
Overload Protection Active Light (Green) ...........ON
To Reset the AOPS after an Activation:
Overload Protection Switch ..................Reset
Gross Overload Light............................OFF
Overload Protection Active Light ...........OFF
Overload Protection Switch ...................ON
Overload Protection Active Light.............ON
NOTES:
a. A flashing Gross Overload Light indicates that the
AOPS has malfunctioned and has disabled itself. Clear
the malfunction indication by taking the Overload
Protection Switch to Reset and back to On.
b. A flashing Hoist Brakes Light indicates that a brake
is dragging. This indication is generated by pressure
switches mounted on each hoist brake canister. Stop
hoisting until proper release of both hoist brake
canisters has been verified.
c. The AOPS needs to be tested every six months.
Refer to Publication OSM4 (Preventive Maintenance
Requirements and Recommendations) in the Operating
and Service Manual. The AOPS needs to be recali
brated if the Wylie loadmoment system is recalibrated.
See AOPS TEST AND CALIBRATION PROCEDURE of
this document.
COPYRIGHT 2002
LeTourneau, Inc.
83
PUBLICATION ROM6
AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS)

TEST AND CALIBRATION PROCEDURE
TEST PROCEDURE
To fully operationally test the AUTOMATIC OVERLOAD
PROTECTION SYSTEM (AOPS) would require actually
grossly overloading the crane, which is not a desirable
situation. The best alternative is to simulate a gross
overload and confirm that the proper system response
take place.
a. Position the hooks to a safe area. Remove the
cover from the Wylie load moment box in the cab.
Position the hook select switch to MAIN. Connect a
potentiometer (5k ohm ideal) or decade resistance box
across terminals T2 and T6 on the Wylie circuit board.
Varing the resistance across these terminals will
artificially cause the load readout on the Wylie display to
change. Turn the Overload Protection Switch and the
Master Switch to ON. Adjust the resistance until the
Gross Overload Light comes on (approximately 2.8k
ohms, start with high resistance and work down). This
should happen at approximate 140% of maximum rated
load (210,000 lbs. on the display for the PCM350
(maximum rated load = 150,000 lbs.); 140,000 lbs. for
the PCM120 (maximum rated load = 100,000 lbs)).
Visually check that the top canister of the main hoist
motor brake remains set, that the bottom canister
releases fully, and that LED 3 on the hoist controller
(GOL Veac Disable, visible through the window in the
hoist controller front cover) illuminates. The external cab
mounted alarm and the machinery house mounted
alarm, which should already be sounding from an
overload greater than 100%, will change from their
normal tones to a pulsating tone, indicating an AOPS
activation. Clear the alarms with the Acknowledge Horn
Button, remove the added resistance, switch to Aux
Hoist, and take the Overload Protection Switch to
RESET and then back to ON.
b. To test the AOPS on the Auxiliary hook, connect the
resistance across terminals T8 and T6 on the Wylie
circuit board. Increase the displayed load by varing the
4ROM 6.2e, Gorilla

9/25/01
resistance until the Gross Overload Light comes on

(approximately 900 ohms, start with high resistance and
work down). This should happen at approximately
140% of maximum rated load (28,000 lbs. on the display
for both the PCM350 and PCM120 (maximum rated load
= 20,000 lbs)). Visually check that the top canister of the
aux hoist motor brake remains set, that the bottom
canister releases fully, and that LED 3 on the hoist
controller (GOL Veac Disable, visible through the
window in the hoist controller front cover) illuminates.
The external cab mounted alarm and the machinery
house mounted alarm, which should already be sound
ing from an overload greater than 100%, will change
from their normal tones to a pulsating tone, indicating an
AOPS activation. Clear the alarms with the Acknowl
edge Horn Button, remove the added resistance, and
take the Overload Protection Switch to RESET.
CALIBRATION PROCEDURE
If necessary, the gross overload trip point for each hook
can be adjusted by pots on the Gross Overload Sense
Card (P/N 4227381). This card is mounted on the inside
righthand wall of the cab junction box; bottom pot
calibrates the main hook, top pot calibrates the aux
hook.
Adjusting a pot CW raises the trip point, CCW lowers the
trip point. To calibrate the AOPS trip point for a given
hook, turn the appropriate pot on the Gross Overload
Sense Card fully CW (maximum trip point). Adjust the
appropriate load readout with a variable resistor as
described in the test procedure above to the desired
gross overload trip level (factory recommendation is
140% of maximum rated load). Adjust the Gross
Overload Sense Card pot CCW until the Gross Overload
Light comes on and the Gross Overload alarms sound.
The AOPS for this hook is now calibrated. Reset the
AOPS, and test the calibration for accuracy as de
scribed in the test procedure above.
COPYRIGHT 2002
LeTourneau, Inc.
85
14
ON
SS8
BLK
WARNING
BLK
PB3
HORN
BLK
PB9
ACKNOWLEDGE
LEFT
SWING
LT9
POWER ON
BAT
SS1
BLK
OFF
1CG2458, P0222
LeTourneau, Inc.
COPYRIGHT 2002
MASTER
RIGHT
LT3
GREEN
ON
DRIVE SYSTEM
FAIL
RUN
RED
LT4
SWING BRAKE
ENGAGE
LT8
WARNING
BOOM LOWER
LIMIT OVERRIDE
POWER LOSS
HOIST LOWER
SPEED/TEMP
RED
PB8
RED
LT3
AMB
RED
LIGHTS
OFF
LT1
SET
SS3
BRAKE
LT34
RED
LT23
SS2
LT7
AUX
BOOM
SLACK WIRE
ROPE
LT5
LIMIT
SWITCHES
HOIST SELECT
MAIN
RAISE
LOWER
LT24
AMB
LT6
AMB
HOIST BRAKE
HYD. PRESS.
GREEN
AUX
EMERGENCY
HOOK RELEASE
ENABLE
RED
RUN
HOIST
GREEN
MAIN
SS7
ON
RED ONCONSTANT
TENSION
OFF
SS6
OFF
BAT
RUN
EMERGENCY
STOP
PB2
RED
LT2
GREEN
ELECTRIC DECK CRANE SAFETY INSTRUCTIONS

PUBLICATION OSM2
FIGURE 1. IDENTIFICATION GROUP (Sheet 1 of 7)
TA95806
1OSM 2.2a, 120SS Gorilla

7/13/99
11
10
WALL M
WALL G
12
13
14
PUBLICATION OSM2

1CG2459, P0222

7/13/99
TA97346
COPYRIGHT 2002
LeTourneau, Inc.
15
14
15
14
16
18
WALL B
19
17
18
19
PUBLICATION OSM2
18

1CG2460, P0222
16
TA95816
COPYRIGHT 2002
LeTourneau, Inc.

7/13/99
14
10
20
21
10
18
22
22
23
9CG2454-1, Ldgr2391
9OSM 2.2 (FO1) 120SS Gorilla

09/20/01
FIGURE 1. IDENTIFICATION GROUP-120SS (4 of 7)
COPYRIGHT 2002
LeTourneau, Inc.
TA97396
17
23
23
23
23
FIGURE 1. IDENTIFICATION GROUP (5 of 7)

1CG2462, Ldgr40
9OSM 2.2, FO2, 120SS Gorilla

09/20/01
TA97386
COPYRIGHT 2002
LeTourneau, Inc.
19
PUBLICATION OSM2
CONSTANT TENSION OPERATION
WARNING
POWER LOSS HOIST LOWER OPERATION
For use during crane power loss situations to lower load at a constant speed.
Emergency Hoist Release Switch: OFF
Before activating :
Constant Tension Switch:
OFF
(1) Inspect Power Loss Lowering Card, thermocouples
Master Switch:
BAT
and temperature transmitters as per OSM-4.
FLASHING
Power On Light:
(2)Place a man in the machinery house to monitor
Brake Switch:
ENABLE
Power Loss Hoist Lower Button:
PRESS and HOLDthe brakes and notify the operator to stop if
brakes begin overheating.
Hoist Joystick:
LOWER
For use (AUX HOIST ONLY) when a load is on the deck of a vessel that
is pitching up and down due to wave motion.
NORMAL
Emergency Hoist Release Switch:

Master Switch:
Power On Light:
Hoist Select Switch:
Brake Switch:
Constant Tension Light:
OFF
ON
ON
AUX
ENABLE
ON
ON
POWER
LOSS
OFF
BAT
FLASHING
AUX
ENABLE
BAT
ON
DO NOT USE THE BOOM

LOWER LIMIT OVERRIDE
BUTTON WITH LOAD IN
THE HOOK(S)
BEFORE OPERATING MACHINE, STUDY THE

OPERATING AND SERVICE MANUALS.
READ ALL SAFETY SIGNS ON MACHINE.
CLEAR THE AREA OF THE OTHER PERSONS.
LEARN AND PRACTICE SAFE USE OF
CONTROLS BEFORE OPERATING.
EMERGENCY HOIST RELEASE

3
OPERATION
For use if the hook becomes entangled in a vessel
that is moving away from the crane.
POWER
NORMAL
LOSS
Master Switch:
Power On Light:
Emergency Hoist Release Light:
ON
ON
ON
ON
It is the operators responsibility to understand and follow

the manufacturers instructions on machine operation,
service and to observe pertinent laws and regulations.
Maintenance Manuals and Operating & Service manuals,
may be obtained through your equipment dealer.
LeTourneau, Inc. P/N 4221605
BAT
FLASHING
ON
ON
KG KIPS
45359.7 100
NEUTRAL BUS (BLOCK)

IS NOT USED WITH
TWOPOLE BREAKERS
40823.7 90
36287.7 80
120VAC
31751.7 70
22679.8 50
LeTourneau, Inc P/N 6228869

CAPACITY
27215.8 60
18143.8 40
13607.9 30
9071.9 20
4535.9 10
0
REACH FEET
REACH CM
20
30
40
50
60
70
80
90
100
110
103108
762.0 914.4 1219.2 1524.0 1828.8 2133.6 2438.4 2743.2 3048.0 3352.8
10
MAIN HOIST (4)(2)(1)
LINE LIFT
MIN REACH 22.0 FT
MAX SWL 98,400 LBS.
LeTOURNEAU PCM120 CRANE
W/100 FOOT BOOM
BOOM
ANGLE
REACH
FEET
SWL (LBS.)
4 PART LINE
SWL (LBS.)
2 PART LINE
SWL (LBS.)
1 PART LINE
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ELECTRICAL EQUIPMENT
AUTHORIZED PERSONNEL
ONLY
11
EQUIPMENT
OPERATED BY
REMOTE CONTROL

1CG2463, P0222

7/13/99
TA97366
COPYRIGHT 2002
LeTourneau, Inc.
21
PUBLICATION OSM2
!
API SPEC 2C
12
FIFTH EDITION 1995
DATE MANUFACTURED
18
MANUFACTURERS MODEL NO.
DESIGN SERVICE TEMPERATURE
DEG.C.
MANUFACTURER SERIAL NUMBER

MANUFACTURED
BY
P.O. BOX 2307 LONGVIEW,TEXAS 75606
ADDRESS
HAZARDOUS VOLTAGE
Can shock, burn, or cause death.
Turn power off before servicing motor.
Hazardous A.C. voltage can be at

terminals when motor is stopped.
13
LeTourneau, Inc.
HAZARDOUS VOLTAGE
P/N 4149157
CAN CAUSE SHOCK, BURN

OR DEATH
OPEN 600 VOLT DRIVE

MOTOR FEEDER CIRCUIT
BREAKERS IN POWER
DISTRIBUTION PANEL
19
BRAKE DISC ON
ELECTRIC MOTORS
MAY BE HOT. BRAKE
DISC WILL ROTATE IF
MOTOR IS ENGAGED
14
20
600 VOLTS
21
15
THIS EQUIPMENT IS
SUPPLIED BY MORE THAN
ONE POWER SOURCE
CRANE SN PC1
SWL 7.43 T 6.7
SWL 49.20 T 80.3
MANUFACTURED BY:
LeTourneau, Inc.
DATE
PC 120 SN
SWL
REACH
TONS
FEET
49.20
22
7.43
103
BOOM
ANGLE
80.3
6.7
22
LOW
HEADROOM
16
DO NOT OPERATE CRANE

WITH HATCH CLOSED
LeTourneau, Inc.
P/N 4237045
LeTournean, Inc P/N 4228868
23
!
17
HIGHLY LOADED SPRING INSIDE THIS

HOUSING CAN CAUSE SERIOUS
PHYSICAL
INJURY OR DEATH
DO NOT REMOVE SCREWS
!
LADDERS:
FALLING HAZARD
Can cause serious
injury or death.
WATCH YOUR STEP.
WATCH FOR WIND
GUSTS.
ALWAYS face ladder

when climbing up
or down.
Keep one hand firmly
on ladder or handhold
at all times.
Keep ladder rungs,
steps and platforms
clean free of grease,
oil, etc.
LeTourneau, Inc.
P/N 4217858

1CG2464, P0222
22
TA97376
COPYRIGHT 2002
LeTourneau, Inc.

7/13/99
PUBLICATION OSM2
CRITICAL COMPONENTS
deck operators supervisor, operator and maintenance
personnel with regards to certification, inspection,
maintenance and prompt repair per the appropriate
guidelines. Instructions for the maintenance and repair
of these components are included in the OPERATING
AND SERVICE MANUAL and the REPAIR AND OVER
HAUL MANUAL for the crane.
D Electric drive motors for hoist, boom, and swing

D Boom chord members
D Boom section connection components
D Boom foot pins
D Primary load members of gantries, masts and
Aframes
D Load transfer members of the rotating upper struc
ture
D Pedestal and swing circle transition pieces

D All linkage between the brake control element and
the component to be controlled.
D Hoist, boom and swing brake systems
D Drums, shafts, and gears of hoisting and swing
systems

D All running wire ropes in hoist system
D All standing wire rope in load restraint and support
system
D Hook block assembly
D Slewing or swing bearing and gear
D Wire rope deadend connection devices
D Wire rope sheaves and sheave shafts
D Floating harness or bridle assemblies
NOTES

7/13/99
COPYRIGHT 2002
LeTourneau, Inc.
13
PUBLICATION OSM2
FORM H"
LOAD DIAGRAM
SEE CERTIFICATE NO. _____________________________ FOR THE APPROVED CONDITIONS FROM
THE ATTACHED LOAD CHART, WHICH HAVE BEEN SURVEYED AND TESTED AS A UNIT AFTER
INSTALLATION ONBOARD THE _____________________________.
AUX. HOIST SB
1 INCH WIRE ROPE
57.5 TONS BREAKING STR.
DYFORM 18 HSLR
ROTATION RESISTANT
SINGLE SHEAVE
BRIDLE PENDANTS
13/4 INCH WIRE ROPE
6 X 26 IWRC EIPS
168 TONS BREAKING STR.
TWO
SHEAVES
LUFFING
1 INCH WIRE ROPE
62.5 TONS BREAKING STR.
CONSTRUCTEX
THREE
SHEAVES
T.B., SWL
SINGLE
SHEAVE
R
D.B.
S.W.L.
TWO
SHEAVES
THREE
SHEAVES
HOOK LOAD
20,000 LB
UNDER HOOK
SINGLE
SHEAVE
SINGLE
SHEAVE
Lw
HOOK LOAD
98,400 LB.
UNDER HOOK
MAIN HOIST DB, 1 INCH WIRE ROPE
70.03 B.S., DYFORM 34 LR, GR 2160
ROTATION RESISTANT
Lw
Lw
(1)
The attached load chart indicates the approved

hook safe working loads and the approved rigging
arrangements which may be certificated under the
requirements of the American Bureau of Shipping.
(2)
Where sheaves are built into the structure they shall

be treated as structural parts and need not be
tested and certificated as loose gear.
(3)
The S.W.L. to be marked on the blocks should be

indicated on this diagram.
(4)
S.W.L. = SAFE WORKING LOAD

S.B. = SINGLE BLOCK
D.B. = DOUBLE BLOCK
T.B. = TRIPLE BLOCK
R
= RESULTANT LOAD
Lw
= LINE PULL TO THE WINCH
HOOK AND BLOCK WT OF 1600 LB HAS BEEN
DEDUCTED FROM THE MAIN HOIST HOOK LOAD.
PCM 120SS CRANE

TA8878CG
1CG1585, P1030, 5/8/00
9OSM2.2b.1, 120SS Gorilla

8/21/01
COPYRIGHT 2001
LeTourneau, Inc.
Insert1
Insert -2
PUBLICATION OSM-2
COPYRIGHT 2002
LeTourneau, Inc.
7-OSM-2.2b.1, 120SS Gorilla (MSWord)

REVISION: 05-01-02
PUBLICATION OSM2

8/21/01
COPYRIGHT 2001
LeTourneau, Inc.
Insert3
PUBLICATION OSM2
1" WIRE ROPE

1375' LONG
70.03 TONS B.S.
HOOK SHEAVE WHEELS
HOOK CABLE DRUM
PCM 120SS CRANE

TA8926CG
1CG1586, P1030, 5/4/00
COPYRIGHT 2001
Insert4
LeTourneau, Inc.

8/21/01
PUBLICATION OSM2
DEAD END
3
1 WIRE ROPE (9 x 40 CONSTRUCTEX)
1
GANTRY SHEAVE HOUSING
BOOM UP CABLE DRUM
PCM120SS CRANE
BOOM UP CABLE REEVING SCHEMATIC
TA8928CG
1NGO1588, P1030, 5/8/00

8/21/01
COPYRIGHT 2001
LeTourneau, Inc.
Insert5
PUBLICATION OSM2
GUIDE SHEAVE WHEEL

JIB BOOM
SHEAVE WHEEL
1 WIRE ROPE (19 X 19)

10 TON HOOK
AUX. HOOK CABLE DRUM
PCM 120SS CRANE

AUXILIARY HOOK CABLE REEVING SCHEMATIC
1CG2465, P1030
TA8927CG
COPYRIGHT 2001
Insert6
LeTourneau, Inc.

8/21/01
WORKING
RADIUS
(FT.)
BOOM
ANGLE
(DEG.)
22.0
STATIC AND DYNAMIC

SAFE WORKING LOAD IN KIPS
PERSONNEL
4PART LINE
DYNAMIC
2.00
2PART LINE
STATIC
1.33
2PART LINE
DYNAMIC
2.00
1PART LINE
STATIC
1.33
1PART LINE
DYNAMIC
2.00
4PART LINE
2PART LINE
1PART LINE
80.3
98.40a
65.06h
48.40a
48.40a
23.40a
23.40a
32.32f
23.60a
11.00a
25.0
78.5
94.24f
62.29f
48.40a
48.40a
23.40a
23.40a
30.34f
23.60a
11.00a
30.0
75.6
79.10g
52.20g
48.40a
48.40a
23.40a
23.40a
25.30g
23.60a
11.00a
35.0
72.6
67.46g
44.44g
48.40a
48.40a
23.40a
23.40a
21.42g
23.41g
11.00a
69.5
58.95g
38.77g
48.40a
41.72g
23.40a
23.40a
18.58g
20.06g
11.00a
45.0
66.4
52.38g
34.39g
48.40a
36.66g
23.40a
23.40a
16.39g
17.53g
11.00a
50.0
63.2
47.08g
30.85g
48.40a
32.49c
23.40a
23.40a
14.63g
15.45c
11.00a
55.0
59.9
42.67g
27.91g
44.36c
29.04c
23.40a
23.40a
13.16g
13.72c
11.00a
60.0
56.5
38.88g
25.39g
40.05c
26.16c
23.40a
23.40a
11.89g
12.28c
11.00a
53.0
35.56g
23.19g
36.39c
23.73c
23.40a
23.40a
10.79g
11.06c
11.00a
70.0
49.2
32.58g
21.19g
33.26c
21.64c
23.40a
21.64c
9.79g
10.02c
11.02c
75.0
45.3
29.85g
19.36g
30.54c
19.83c
23.40a
19.83c
8.88g
9.11c
9.11c
80.0
41.0
27.29g
17.66g
28.13g
18.22g
23.40a
18.24c
8.03g
8.31g
8.32c
24.84g
16.02g
25.53g
16.49g
23.40a
16.85c
7.21g
7.44g
7.62c
31.0
22.41g
14.41g
22.97g
14.78g
23.40a
15.57g
6.40g
6.59g
6.99g
95.0
24.7
19.89g
12.73g
20.32g
13.01g
21.24g
13.62g
5.56g
5.71g
6.01g
100.0
16.1
16.94g
10.76g
17.25g
10.96g
17.89g
11.39g
4.58g
4.68g
4.90g
103.0
6.7
14.07d
8.90g
14.27d
9.04g
14.69d
9.32g
3.65g
3.72g
3.86g
40.0
COPYRIGHT 2001
LeTourneau, Inc.
65.0
85.0
90.0
36.3
NOTES
D
D
D
D
Insert7
This load chart meets API Spec. 2C (Fifth Edition, 1995)

Safe Working Load (SWL) - Load which may be carried below the hook.
API Static Rated Load = SWL plus 1.6 kip hook block.
A 1600lb. maintenance hook and block weight has been deducted from the total allowable
loads on the 4part, 2part and 1part lines.
D The design capacity of the crane is based on 50 tons at a 22ft. working radius.
D Main Hoist Line - 1" Bridon Dyform 34 LR GR 2160, rotation resistant, B.S. = 70.03 tons
D Aux. Hoist Line - 1" Bridon Dyform 18 HSLR, rotation resistant, B.S. = 57.5 tons
D Bridle Line - 13/4", 6 x 26 Class, IWRC,

EIPS, B.S. = 168 tons
D Boomup Line - 1", Bridon CONSTRUCTEX = 62.5 tons
D Ratings followed by a" are limited by the hoist line limit.
D Ratings followed by c" are limited by the foundation limit.
D Ratings followed by "d"are limited by the luffing line limit.
D Ratings followed by f" are limited by the boom axial load limit.
D Ratings followed by g" are limited by luffing system on gantry limit.
D Ratings followed by h" are limited by lifted load limit.
D This chart is to be used for mild sea conditions only.
4PART LINE
STATIC
1.33
PUBLICATION OSM2

8/21/01
LeTOURNEAU PCM120SS
MAIN HOIST CAPACITY CHART-100 FT. BOOM
WORKING
RADIUS
(FT.)
BOOM
ANGLE
(DEG.)
25.0
STATIC AND DYNAMIC

PERSONNEL
4PART LINE
DYNAMIC
2.00
2PART LINE
STATIC
1.33
2PART LINE
DYNAMIC
2.00
SINGLE LINE
STATIC
1.33
SINGLE LINE
DYNAMIC
2.00
4PART LINE
2PART LINE
SINGLE LINE
80.4
98.40a
57.13
48.40a
48.40
23.40a
23.40
32.30f
23.40e
11.00e
30.0
78.0
84.40c
46.42
48.40a
48.40
23.40a
23.40
29.40f
23.40e
11.00e
35.0
75.6
70.15c
39.25
48.40a
42.74
23.40a
23.40
27.09f
23.40e
11.00e
73.1
59.45c
34.06
48.40a
36.65
23.40a
23.40
25.19f
23.40e
11.00e
45.0
70.5
51.14c
30.1
48.40a
32.09
23.40a
23.40
23.58f
22.24f
11.00e
50.0
68.0
44.48c
26.95
44.48c
28.53
23.40a
23.40
22.20f
20.97f
11.00e
65.4
39.03c
24.36
39.03c
25.65
23.40a
23.40
20.99f
19.85f
11.00e
60.0
62.7
34.49c
22.18
34.49c
23.24
23.40a
23.40
19.91f
18.86f
11.00e
65.0
59.9
30.65c
20.29
30.65c
21.19
23.40a
23.00
18.94f
17.95f
11.00e
57.1
27.36c
18.64
27.36c
19.39
23.40a
20.91
18.04f
17.13f
11.00e
75.0
54.2
24.50c
17.16
24.50c
17.80
23.40a
19.10
17.22f
16.35f
11.00e
80.0
51.2
22.00c
15.81
22.00c
16.36
22.00c
17.52
16.44f
15.63f
11.00e
85.0
48.0
19.80c
14.57
19.80c
15.04
19.80c
16.05
15.69f
14.93f
11.00e
90.0
44.7
17.83c
13.41
17.83c
13.81
17.83c
14.67
14.97f
14.26f
11.00e
95.0
41.1
16.08c
12.31
16.08c
12.64
16.08c
13.37
14.26f
13.59f
11.00e
100.0
37.2
14.49c
11.24
14.49c
11.52
14.49c
12.13
13.55f
12.93f
11.00e
105.0
33.0
13.06c
10.19
13.06c
10.42
13.06c
10.93
12.83f
12.24f
11.00e
110.0
28.2
11.75c
9.11
11.75c
9.30
11.75c
9.71
11.75c
11.51f
10.55f
115.0
22.5
10.56c
7.96
10.56c
8.11
10.56c
8.43
10.56c
10.56c
9.80f
120.0
14.7
9.46c
6.58
9.46c
6.69
9.46c
6.91
9.46c
9.46c
8.84f
6.1
8.33d
5.23
8.33d
5.30
8.33d
5.45
8.33g
8.33g
7.80f
40.0
LeTourneau, Inc.
55.0
COPYRIGHT 2001
70.0
123.0
NOTES
D
D
D
D
Insert9
This load chart meets API Spec. 2C (Fifth Edition, 1995)

Safe Working Load (SWL) - Load which may be carried below the hook.
API Static Rated Load = SWL plus 1.6 kip hook block.
A 1600lb. maintenance hook and block weight has been deducted from the total allowable
loads on the 4part, 2part and 1part lines.
D The design capacity of the crane is based on 50 tons at a 22ft. working radius.
D Main Hoist Line - 1" Bridon Dyform 34 LR GR 2160, rotation resistant, B.S. = 70.03 tons
D Aux. Hoist Line - 1" Bridon Dyform 18 HSLR, rotation resistant, B.S. = 57.5 tons
D
D
D
D
D
D
D
D
D
Bridle Line - 13/4", 6 x 26 Class, IWRC, EIPS, B.S. = 168 tons

Boomup Line - 1", Bridon CONSTRUCTEX = 62.5 tons
Ratings followed by a" are limited by the hoist line limit.
Ratings followed by c" are limited by the foundation limit.
Ratings followed by "d"are limited by the luffing line limit.
Ratings followed by e" are limited by the hoist line limit.
Ratings followed by f" are limited by the boom limit.
Ratings followed by g" are limited by the luffing line limit.
This chart is to be used for mild sea conditions only.
4PART LINE
STATIC
1.33
PUBLICATION OSM2

8/21/01
LeTOURNEAU PCM120SS
MAIN HOIST CAPACITY CHART-120 FT. BOOM
PUBLICATION OSM2
LeTOURNEAU, INC.
PCM 120SS CRANE W/120' BOOM
AUXILIARY HOIST SYSTEM
DYNAMIC, STATIC AND PERSONNEL
LOAD RATING CHART, SINGLE LINE LIFT
API Spec 2C, Fifth Edition (1995)
WORKING
RADIUS (FT.)
BOOM
ANGLE (DEG.)
STATIC LIFT
SWL (KIPS) 1.33
DYNAMIC SWL
(KIPS) 2.00
PERSONNEL
LIFT
SWL (KIPS)
30.0
79.9
20.00a
13.33
9.80e
35.0
77.5
20.00a
13.33
9.80e
40.0
75.2
20.00a
13.33
9.80e
45.0
72.8
20.00a
13.33
9.80e
50.0
70.3
20.00a
13.33
9.80e
55.0
67.8
20.00a
13.33
9.80e
60.0
65.3
20.00a
13.33
9.80e
65.0
62.7
20.00a
13.33
9.80e
70.0
60.1
20.00a
13.33
9.80e
75.0
57.4
20.00a
13.33
9.80e
80.0
54.5
20.00a
13.33
9.80e
85.0
51.6
20.00a
13.33
9.80e
90.0
48.5
19.28c
13.33
9.80e
95.0
45.3
17.49c
13.33
9.80e
100.0
41.8
15.87c
13.33
9.80e
105.0
38.1
14.41c
13.23
9.80e
110.0
34.1
13.08c
12.15
9.80e
115.0
29.5
11.85c
10.96
9.80e
120.0
24.0
10.72c
9.70
9.80e
125.0
16.7
9.66c
8.23
9.63f
128.0
9.6
9.04c
6.93
8.81f
NOTES
D This load chart meets API Spec. 2L, Fifth Edition (1995). Safe Working Load (SWL) = Load which may be
carried below the hook. API Static Rated Load = SWL plus 500 lb. overhaul ball.
D Ratings followed by a" are limited by the auxiliary hoist line limit.
D Ratings followed by c" are limited by the foundation limit.
D Ratings followed by e" are limited by the auxiliary hoist line limit.
D Ratings followed by f" are limited by the boom limit.
D Main Hoist Line - 1" dia. Bridon Dyform 34 LR, GR 2160, rotation
resistant. B.S. = 70.03 tons.
D Aux. Hoist Line - 1" dia. Bridon Dyform 18 HSLR rotation resistant. B.S. = 57.5 tons.
D Bridle Line - 13/4" dia., 6 x 26 Class, IWRC, EEIPS, B.S. = 168 tons.
D BoomUp Line - 1" dia., Bridon CONSTRUCTEX = 62.5 tons
COPYRIGHT 2001
Insert10
LeTourneau, Inc.

8/21/01
PUBLICATION OSM2
CRITICAL COMPONENTS
deck operators supervisor, operator and maintenance
personnel with regards to certification, inspection,
maintenance and prompt repair per the appropriate
guidelines. Instructions for the maintenance and repair
of these components are included in the OPERATING
AND SERVICE MANUAL and the REPAIR AND OVER
HAUL MANUAL for the crane.
D Electric drive motors for hoist, boom, and swing

Boom chord members
D Boom foot pins
D Boom section connection components
D Primary load members of gantries, masts and
Aframes
D Load transfer members of the rotating upper struc
ture
D Pedestal and swing circle transition pieces

D All linkage between the brake control element and
the component to be controlled.
D Hoist, boom and swing brake systems
D Drums, shafts, and gears of hoisting and swing
systems

D All running wire ropes in hoist system
D All standing wire rope in load restraint and support
system
D Hook block assembly
D Slewing or swing bearing and gear
D Wire rope deadend connection devices
D Wire rope sheaves and sheave shafts
D Floating harness or bridle assemblies
NOTES

7/13/99
COPYRIGHT 2002
LeTourneau, Inc.
13
14
ON
SS8
BLK
WARNING
BLK
PB3
HORN
BLK
PB9
ACKNOWLEDGE
LEFT
SWING
LT9
POWER ON
BAT
SS1
BLK
OFF
1CG2458, P0222
LeTourneau, Inc.
COPYRIGHT 2002
MASTER
RIGHT
LT3
GREEN
ON
DRIVE SYSTEM
FAIL
RUN
RED
LT4
SWING BRAKE
ENGAGE
LT8
WARNING
BOOM LOWER
LIMIT OVERRIDE
POWER LOSS
HOIST LOWER
SPEED/TEMP
RED
PB8
RED
LT3
AMB
RED
LIGHTS
OFF
LT1
SET
SS3
BRAKE
LT34
RED
LT23
SS2
LT7
AUX
BOOM
SLACK WIRE
ROPE
LT5
LIMIT
SWITCHES
HOIST SELECT
MAIN
RAISE
LOWER
LT24
AMB
LT6
AMB
HOIST BRAKE
HYD. PRESS.
GREEN
AUX
EMERGENCY
HOOK RELEASE
ENABLE
RED
RUN
HOIST
GREEN
MAIN
SS7
ON
RED ONCONSTANT
TENSION
OFF
SS6
OFF
BAT
RUN
EMERGENCY
STOP
PB2
RED
LT2
GREEN

PUBLICATION OSM2
TA95806

7/13/99
11
10
WALL M
WALL G
12
13
14
PUBLICATION OSM2

1CG2459, P0222

7/13/99
TA97346
COPYRIGHT 2002
LeTourneau, Inc.
15
14
15
14
16
18
WALL B
19
17
18
19
PUBLICATION OSM2
18

1CG2460, P0222
16
TA95816
COPYRIGHT 2002
LeTourneau, Inc.

7/13/99
10
14
18
20
21
22
46
10
46
22
23

9CG9869-1, Ldgr40-1
9OSM 2.3, (FO1) 350SS Gorilla

09/20/01
TA98696
COPYRIGHT 2002
LeTourneau, Inc.
17
23
23
23
23

1CG24621, Ldgr40-1
9OSM 2.3, FO2, 350SS Gorilla

09/20/01
TA98706
COPYRIGHT 2002
LeTourneau, Inc.
19
PUBLICATION OSM2
CONSTANT TENSION OPERATION
WARNING
POWER LOSS HOIST LOWER OPERATION
For use during crane power loss situations to lower load at a constant speed.
Emergency Hoist Release Switch: OFF
Before activating :
OFF
(1) Inspect Power Loss Lowering Card, thermocouples
Master Switch:
BAT
and temperature transmitters as per OSM-4.
FLASHING
Power On Light:
(2)Place a man in the machinery house to monitor
Brake Switch:
ENABLE
Power Loss Hoist Lower Button:
PRESS and HOLDthe brakes and notify the operator to stop if
brakes begin overheating.
Hoist Joystick:
LOWER
POWER
LOSS
For use (AUX HOIST ONLY) when a load is on the deck of a vessel that
is pitching up and down due to wave motion.
NORMAL

Master Switch:
Power On Light:
Hoist Select Switch:
Brake Switch:
Constant Tension Light:
OFF
ON
ON
AUX
ENABLE
ON
ON
OFF
BAT
FLASHING
AUX
ENABLE
BAT
ON
DO NOT USE THE BOOM

LOWER LIMIT OVERRIDE
BUTTON WITH LOAD IN
THE HOOK(S)
BEFORE OPERATING MACHINE, STUDY THE

OPERATING AND SERVICE MANUALS.
READ ALL SAFETY SIGNS ON MACHINE.
CLEAR THE AREA OF THE OTHER PERSONS.
LEARN AND PRACTICE SAFE USE OF
CONTROLS BEFORE OPERATING.
EMERGENCY HOIST RELEASE

3
OPERATION
For use if the hook becomes entangled in a vessel
that is moving away from the crane.
POWER
NORMAL
LOSS
Master Switch:
Power On Light:
Emergency Hoist Release Light:
ON
ON
ON
ON
It is the operators responsibility to understand and follow

the manufacturers instructions on machine operation,
service and to observe pertinent laws and regulations.
Maintenance Manuals and Operating & Service manuals,
may be obtained through your equipment dealer.
LeTourneau, Inc. P/N 4221605
BAT
FLASHING
ON
ON
8
4
KG KIPS
68039.5 150
63503.5 140
NEUTRAL BUS (BLOCK)

IS NOT USED WITH
TWOPOLE BREAKERS
58967.6 130
120VAC
54431.6 120
CAPACITY
49895.6 110
45823.7 100
40823.7
90
36287.7
80
31751.7
70
27215.8
60
22679.8
50
18143.8
40
13607.9
30
9071.9
20
VENDOR:
4535.9
10
VENDOR:
VENDOR:
FEET 30 35 40
CM
50
60
70
80
90
100
110
120
130135
914.4 1219.2 1524.0 1828.8 2133.6 2438.4 2743.2 3048.0 3352.8 3657.6 3962.4
4114.8
REACH
10
5
LETOURNEAU PCM350 CRANE
WITH 123.5 FT. BOOM
BOOM
ANGLE
REACH
FEET
SWL (LBS.)
6 PART LINE
MIN REACH 30.0 FT

MAX SWL 146800 LBS.
SWL (LBS.)
4 PART LINE
___
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1CG24631, P02221

7/13/99
ELECTRICAL EQUIPMENT
AUTHORIZED PERSONNEL
ONLY
SWL (LBS.)
2 PART LINE
11
EQUIPMENT
OPERATED BY
REMOTE CONTROL
FIGURE 1. IDENTIFICATION GROUP-350SS (Sheet 6 of 7)

COPYRIGHT 2002
LeTourneau, Inc.
TA98686
21
PUBLICATION OSM2
!
12
API SPEC 2C
FIFTH EDITION 1995
DATE MANUFACTURED
18
MANUFACTURERS MODEL NO.
DESIGN SERVICE TEMPERATURE
DEG.C.
MANUFACTURER SERIAL NUMBER

MANUFACTURED
BY
P.O. BOX 2307 LONGVIEW,TEXAS 75606
ADDRESS
HAZARDOUS VOLTAGE
Can shock, burn, or cause death.
Turn power off before servicing motor.
Hazardous A.C. voltage can be at

terminals when motor is stopped.
13
LeTourneau, Inc.
HAZARDOUS VOLTAGE
P/N 4149157
CAN CAUSE SHOCK, BURN

OR DEATH
OPEN 600 VOLT DRIVE

MOTOR FEEDER CIRCUIT
BREAKERS IN POWER
DISTRIBUTION PANEL
19
BRAKE DISC ON
ELECTRIC MOTORS
MAY BE HOT. BRAKE
DISC WILL ROTATE IF
MOTOR IS ENGAGED
14
20
600 VOLTS
21
15
THIS EQUIPMENT IS
SUPPLIED BY MORE THAN
ONE POWER SOURCE
CRANE SN PC3
SWL 17.95 T 0.0
SWL 73.40 T 79.5
MANUFACTURED BY:
LeTourneau, Inc.
DATE
PC 350 SN
SWL
REACH
TONS
FEET
73.40
30
17.95
129
BOOM
ANGLE
79.5
0.0
22
LOW
HEADROOM
16
DO NOT OPERATE CRANE

WITH HATCH CLOSED
LeTourneau, Inc.
P/N 4237045
LeTournean, Inc P/N 4228868
23
!
17
HIGHLY LOADED SPRING INSIDE THIS

HOUSING CAN CAUSE SERIOUS
PHYSICAL
INJURY OR DEATH
DO NOT REMOVE SCREWS
!
LADDERS:
FALLING HAZARD
Can cause serious
injury or death.
WATCH YOUR STEP.
WATCH FOR WIND
GUSTS.
ALWAYS face ladder

when climbing up
or down.
Keep one hand firmly
on ladder or handhold
at all times.
Keep ladder rungs,
steps and platforms
clean free of grease,
oil, etc.
LeTourneau, Inc.
P/N 4217858
FIGURE 1. IDENTIFICATION GROUP-350SS (Sheet 7 of 7)

1CG24641, P02221
22
TA98676
COPYRIGHT 2002
LeTourneau, Inc.

7/13/99

Crane Inspection

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Crane Inspection

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LETOURNEAU, INC.

QUALIFIED CRANE INSPECTOR

PREVENTIVE MAINTENANCE SCHEDULES AND CRANE

Module 1: Pre-Use or Daily Inspections and Service

PUBLICATION OSM-5 WIRE ROPE USE, HANDLING AND

PUBLICATION OSM-6 BRAKES

EXCERPTS FROM PUBLICATION OSM-4

Lubricating Oil Analysis

Power Loss Lowering System Inspection and Test

PUBLICATION ROM-1 STRUCTURAL COMPONENTS

PUBLICATION LET-1 FIELD WELDING PROCEDURES

EXCERPTS FROM PUBLICATION ROM-6

Automatic Overload Protection System Test and

EXCERPTS FROM PUBLICATION OSM-2 SAFETY

7-OSL, Crane TOC (MSWord)

Identification and Safety Label Group

Load Charts PCM 120/350 SS

Wire Rope Reeving Diagrams

Return to Main Page

PRE-USE OR DAILY WALK AROUND INSPECTIONS AND SERVICES

Check hourmeter (located in Machinery House) for proper operation. Record

Check all controls for proper operation.

Check load moment indicator for proper operation.

Check personnel warning horn for proper operation.

Check all brakes for proper stopping action.

Check all drive motors for proper operation.

Check swing gearbox and drivers for overheating and leaks.

Check all sheave pins and retainers.

Check Machinery House ventilation system.

Check the swing gear lubricant for shavings.

Check hoist driver for visible oil leaks.

Lubricate components and correct deficiencies as required based on these in

Check hourmeter (located in Machinery House) for proper operation. Record

Check all controls for proper operation.

Check load moment indicator for proper operation.

Check personnel warning horn for proper operation.

Check all brakes for proper stopping action.

Check all drive motors for proper operation.

Check swing gearbox and drivers for overheating and leaks.

Check all sheave pins and retainers.

Check Machinery House ventilation system.

Check the swing gear lubricant for shavings.

Check hoist driver for visible oil leaks.

PREVENTIVE MAINTENANCE REQUIREMENTS AND RECOMMENDATIONS

Check all electrically operated functions for proper operation.

Correct deficiencies as required based on these inspections.

MONTHLY INSPECTION AND LUBRICATION REQUIREMENTS

Lubricate main hook sheaves. (1)

Lubricate main hook swivel bearing. (1)

Lubricate auxiliary hook bearings (optional). (2)

Lubricate auxiliary sheaves (optional). (3)

Lubricate boom sheaves (optional). (4)

Lubricate floating block and equalizer sheave. (5)

Lubricate boom selfaligning bushing (until new grease appears). (6)

Lubricate swing roller bearings. (7)

Lubricate swing gear and gearbox pinion. (8)

Lubricate gantry sheave. (9)

Lubricate swing bearing (PCM 350SS). (10)

Lubricate spherical and thrust bearing (PCM 120SS). (10)

PREVENTIVE MAINTENANCE REQUIREMENTS AND RECOMMENDATIONS

CAUTION: PROPERLY STOW BOOM BEFORE LUBRICATING CRANE.

PREVENTIVE MAINTENANCE REQUIREMENTS AND RECOMMENDATIONS

NOTE: The quarterly inspections includes an inspection of electric motors, servic

Check hourmeter (located in Machinery House) for proper operation. Record