Ramsey RAM-LIFT CRANE OWNER'S MANUAL
Below you will find brief information for crane RAM-LIFT CRANE. This document will help you understand the basic features and capabilities of the crane, including its capacity, dimensions, and how to safely operate and maintain it.
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OWNERS MANUAL
RAM-LIFT CRANE
REVISION 2/2000
PART NO. 999958
SERIAL NO. __________________________
RAMSEY WINCH COMPANY
PO BOX 581510, TULSA, OK 74158-1510
1600 N. GARNETT ROAD, TULSA, OK 74116
PHONE (918) 438-2760
SALES FAX (918) 438-6688 http://www.ramsey.com
For Parts Orders please contact:
Auto Crane Company
4707 North Mingo Road
Tulsa, OK 74117-5904
Phone: 918/836-0463 Fax: 918/834-5979
WARNINGS -
READ THIS PAGE!
WARNING!
Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle certify that the vehicle complies with all applicable federal regulations. Any modifications performed on the vehicle prior to the final stage are also considered intermediate stage manufacturing and must be certified as to compliance. The installer of this crane and body is considered one of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations, and is required to certify that the vehicle is in compliance.
WARNING!
It is the further responsibility of the installer to comply with the OSHA
Truck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL
POWER LINES!
Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
WARNING! NEVER
.............................
v
EXCEED
load chart capacities (centerline of rotation to hoist hook).
v un-reel last 5 wraps of cable from drum!
v wrap cable around load!
v attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
v weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.
v place a chain link on the tip of the hook and try to lift a load!
v use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!
v hold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING!
In using a hook with latch,
ALWAYS
make sure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
WARNING!
Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and/or personnel!
WARNING!
Auto Crane Company remote controlled cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
WARNING!
ALWAYS
operate the crane in compliance with the load capacity chart.
Do not use
the overload shutdown device to determine maximum rated loads, if your crane is equipped with this type of device.
warning 9/98
RAM-LIFT CRANE SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
Page
2-1.0.0
OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION OF UNIT / OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2.0.0
QUALIFICATIONS FOR OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3.0.0
INSPECTION, TESTING & MAINTENANCE . . . . . . . . . . . . . . . . . . . . .
SAFETY DECAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3-1.0.0
GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1.0.0
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1.0.0
LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . .
6-1.0.0
LIFE OF WIRE LINE / WIRE LINE LUBRICATION . . . . . . . . . . . . . . . .
7-1.0.0
GENERAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1.0.0
MANUAL WINCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2.0.0
ELECTRIC WINCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3.0.0
last page
GENERAL SPECIFICATIONS
RAM-LIFT CRANE SERIES
Dimensions
Width:
9.5 in. (.24 m)
Height:
4 ft 2.5 in. (1.28 m)
Length:
4 ft 3 in. (1.30 m)
Weight:
150 lb (68 kg)
Capacity
4,250 ft-lb (.59 tm)
[ft-lb = horizontal distance from centerline of rotation to free hanging weight (feet)
x amount of weight (pounds)]
Distance
4 ft 3in.
Lifting Capacity
Load
1,000 lb
Cable
25 ft (15.2 m) of 3/16 in. diameter 7 x 19 galvanized cable is standard.
This cable has a single line breaking strength of 4200 lb.
Chassis Requirements
5,200 GVWR minimum
Electrical System
Hoist Motor:
12 volt DC series wound
Electrical System Requirements
Alternator:
50 amp (minimum)
Battery:
100 minute reserve capacity (minimum)
Maintenance type
Rotation
360º Continuous manual rotation
1-2.0.0
GENSPEC 1/2000
--- IMPORTANT ---
OPERATING PRACTICES &
WARNINGS
1. Make certain the vehicle meets minimum chassis requirements. (These requirements do not guarantee unit stability)
2. Make certain the crane is installed per factory specifications. Contact your local Distributor or the
Auto Crane factory if any questions arise.
3. Keep the vehicle in as level a position as possible while loading or unloading.
4.
ALWAYS
set the vehicle emergency brake before beginning crane operations.
5.
ALWAYS
use outriggers from vehicle to the ground during crane operation. Make sure they are firmly positioned on solid footings.
6. All load ratings are based on crane capacity,
NOT
truck/crane stability.
7. Keep objects and personnel clear of crane path during operation.
8. Keep hoist cable pulled tight at all times.
9.
REMEMBER
, in lifting a heavy load, the weight can create enough tipping momentum to overturn the vehicle.
10.
ALWAYS
keep load as close to ground as possible.
11. Oil gears as required.
12. Periodic adjustment of hoist worm brake may be required (see automatic safety brake drawing in this manual).
13. Hydraulic hoses need to be inspected frequently for signs of deterioration, and be replaced as required.
14. The hoist hook is an important item that an operator should consider and use properly. It should be checked on a daily basis for distortion or cracks.
15.
ALWAYS
store outriggers before road travel.
16.
WARNING! NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES!
Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
17.
WARNING!
NEVER EXCEED
load chart capacities (centerline of rotation to hoist hook).
18.
WARNING! NEVER
un-reel last 5 wraps of cable from drum!
19.
WARNING! NEVER
wrap cable around load!
20.
WARNING! NEVER
attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
21.
WARNING! NEVER
weld, modify, or use unauthorized components on any Auto Crane unit!
This will void any warranty or liability. Also failure of the crane may result.
22.
WARNING! NEVER
place a chain link on the tip of the hook and try to lift a load!
23.
WARNING! NEVER
use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!
24.
WARNING!
In using a hook with latch,
ALWAYS
insure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
25.
WARNING! NEVER
hold any pendant Select
Switch on that will cause unsafe operating conditions!
WARNING!
Auto Crane Company remote controlled, stiff boom cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
SAFTIPS 2/98
2-1.0.0
--- IMPORTANT ---
OPERATION OF UNIT
26. Make sure this manual has been thoroughly read by all crane operating personnel and supervisors.
27. A routine inspection of the crane should be mandatory before each operating day. Any defects should be corrected immediately.
28. At a job site the vehicle should be positioned so that the crane can adequately reach the load within the rated capacity (centerline of rotation to hoist hook).
29. Keep the vehicle as level as possible during operation.
30. For electric cranes,
engage emergency brake
and leave ignition on with transmission in neutral (or in park for automatic transmissions). Activate any crane power switches. For units requiring battery and hydraulic operation,
engage emergency brake,
place gear selector in neutral, press clutch, activate PTO, release clutch and after hydraulic fluid is warm, set throttle control to proper engine speed.
31. Always use outriggers from the truck to the ground.
Be sure these are firm and adequately positioned.
When rotating,
keep load as low to the ground as possible.
32. Remove pendant control from cab or storage area. On smaller units, plug pendant into receptacle on crane.
On larger units, remove pendant control from guard and unwrap cable from boom. Do not operate crane until cable is unwound completely. On all cranes, detach hook from dead man. Crane is now ready for operation.
33. Always boom up before rotating so the boom will clear the required boom support.
34. When extending the boom, always maintain clearance between the boom crown and the traveling block or hoist hook.
35. Always observe safe and practical operation to avoid possible accidents. Refer to Safety Tips and
Precautions.
36. After completing lifting operations, return the boom to stowed position on the boom support. Avoid unneeded pressure on the boom support.
37. Store pendant control on proper location (in cab or on crane).
38. Return outriggers to stowed position. Make sure they are pinned in place or jacklegs are returned to compartment.
39. Check work area for any tools or equipment not stored.
40. Release throttle control, depress clutch and disengage
PTO. Deactivate any crane power switches
41. Report any unusual occurrence during crane operation that may indicate required maintenance or repair.
42.
NEVER
use two cranes to support a load too large for either crane.
43. Spray all electrical equipment with special corrosion resistant coating. This eliminates rust or corrosion due to melting and freezing action of condensation.
OPERATION OF
OUTRIGGERS
For hydraulic outriggers:
1. Shift crane/outrigger control valve to
"outrigger" position.
2. While operating the outrigger control valves
(located on the outrigger cylinders) simultaneously operate the boom-up control switch. This will allow the hydraulic system to build pressure.
3. After outriggers are positioned, return crane/outrigger selector to "crane" position.
4. Crane is now ready to operate.
For manual outriggers:
1. Pull lock pins to release jack leg or drop down outrigger and move to outermost lock position.
2. Make sure lock pins are reinstalled properly.
3. Lower outrigger pad to firm ground and adjust foot to take out slack.
4. Crane is now ready to operate.
2-2.0.0
RAMOPER 6/98
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
OPERATORS
2 No one other than the personnel specified above shall enter the operating area of a crane with the exception of persons such as oilers, supervisors, and those specified persons authorized by supervisors whose duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other persons.
QUALIFICATIONS FOR OPERATORS
7 Operators and operator trainees should have normal depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics.
1 Crane operation shall be limited to personnel with the following minimum qualifications:
A. designated persons
B. trainees under the direct supervision of a designated person
C. maintenance and test personnel (when it is necessary in the performance of their duties)
D. inspectors (crane).
8 In addition to the above listed requirements, the operator shall:
A. Demonstrate the ability to comprehend and interpret all labels, operator's manuals, safety codes and other information pertinent to correct crane operations.
B. Possess knowledge of emergency procedures and implementation of same.
C. Demonstrate to the employer the ability to operate the specific type of equipment.
D. Be familiar with the applicable safety regulations.
E. Understand responsibility for maintenance requirements of crane.
F. Be thoroughly familiar with the crane and its control functions.
G. Understand the operating procedures as outlined by the manufacturer.
CONDUCT OF OPERATORS
3 Operators shall be required by the employer to pass a practical operating examination. Qualifications shall be limited to the specific type of equipment for which examined.
9 The operator shall not engage in any practice which will divert his attention while actually operating the crane.
4 Operators and operator trainees shall meet the following physical qualifications:
A. Vision of at least 20/30 Snellen in one eye and
20/50 in the other, with or without corrective lenses.
B. Ability to distinguish colors, regardless of position, if colors differentiation is required for operation.
C. Adequate hearing with or without hearing aid for the specific operation.
10 Each operator shall be responsible for those operations under the operator's direct control.
Whenever there is any doubt as to safety, the operator shall consult with the supervisor before handling the loads.
11 The operator should not leave a suspended load unattended unless specific precautions have been instituted and are in place.
5 Evidence of physical defects or emotional instability which render a hazard to operator or others, which in the opinion of the examiner could interfere with the operator's performance may be sufficient cause for disqualification. In such cases, specialized clinical or medical judgment and tests may be required.
12 If there is a warning sign on the switch or engine starting controls, the operator shall not close the switch or start the engine until the warning sign has been removed by the appointed person.
6 Evidence that the operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical tests may be required to determine these conditions.
13 Before closing the switch or starting the engine, the operator shall see that all controls are in the "OFF" or neutral position and all personnel are in the clear.
14 If power fails during operation, the operator shall:
A. move power controls to the "OFF" or neutral position.
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QUAL 7/98
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
B. land the suspended load and boom, if practical.
15 The operator shall be familiar with the equipment and its proper care. If adjustments or repairs are necessary, the operator shall report the same promptly to the appointed person, and shall also notify the next operator.
16 All controls shall be tested by the operator at the start of each shift. If any controls do not operate properly, they shall be adjusted or repaired before operations are begun.
17 Stabilizers shall be visible to the operator while extending or setting unless operator is assisted by a signal person.
OPERATING PRACTICES
HANDLING THE LOAD
18 Size of load
A. No crane shall be loaded beyond the rated load except for test purposes.
B. The load to be lifted is to be within the rated load of the crane and its existing configuration.
C. When loads which are not accurately known are to be lifted, the person responsible for the job shall ascertain that the weight of the load does not exceed the crane rated load at the radius at which the load is to be lifted.
19 Attaching the load
A. The load shall be attached to the hook by means of slings or other devices of sufficient capacity.
B. Hoist rope shall not be wrapped around the load.
20 Moving the load
A. The operator shall determine that:
B. The crane is level and, where necessary, the vehicle/carrier is blocked properly.
C. The load is well secured and balanced in the sling or lifting device before it is lifted more than a few inches.
D. Means are provided to hold the vehicle stationary while operating the crane.
E. Before starting to lift, the hook shall brought over the load in such a manner as to minimize swinging.
F. During lifting care shall be taken that:
1.
there is no sudden acceleration or deceleration of the moving load.
2.
load, boom or other parts of the crane do not contact any obstruction.
G. Cranes shall not be used for dragging loads sideways.
H. This standard recognizes that articulating boom cranes are designed and intended for handling materials. They do not meet personnel lift or elevator requirements. Therefore, no lifting, lowering, swinging or traveling shall be done while a person is on the hook or load. Hook attached suspended work platforms (baskets) shall not be used with cranes covered by this standard. Work platforms attached to the boom must be approved by crane manufacturer.
I. The operator should avoid carrying loads over people.
J. When the crane is so equipped, the stabilizers shall be fully extended and set. Blocking under stabilizers shall meet the requirements as follows:
1.
strong enough to prevent crushing.
2.
of such thickness, width and length as to completely support the stabilizer pad.
K. Firm footing under all tires, or individual stabilizer pads should be level. Where such a footing is not otherwise supplied, it should be provided by timbers, cribbing, or other structural members to distribute the load so as to not exceed allowable bearing capacity or the underlying material.
L. In transit, the boom shall be carried in stowed position.
M. When rotating the crane, sudden starts and stops shall be avoided. rotational speed shall be such that the load does not swing out beyond the radius at which it can be controlled.
N. The crane shall not be transported with a load on the hook unless recommended by the manufacturer.
O. No person should be permitted to stand or pass under a suspended load.
21 Stowing procedure. Follow the manufacturer's procedure and sequence when stowing and un-stowing the crane.
2-3.1.0
QUAL 7/98
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
25 In transit with no load and boom lowered the clearance shall be specified in Table 1.
26 A qualified signalperson shall be assigned to observe the clearance and give warning before approaching the above limits.
A. Any overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities verify that it is not an energized line.
B. Exceptions to this procedure, if approved by the administrative or regulatory authority if the alternate procedure provides equivalent protection and set forth in writing.
C. Durable signs shall be installed at the operator's station and on the outside of the crane, warning that electrocution or serious bodily injury may occur unless a minimum clearance of 10 ft. (3.0m) between the crane or the load being handled and energized power lines. Greater clearances are required because of higher voltage as stated above.
These signs shall be revised but not removed when local jurisdiction requires greater clearances.
TABLE 1
22 Cranes shall be operated so that no part of the crane or load enters into the danger zone shown above.
EXCEPTIONS
A. The danger zone may be entered after confirmation by an appointed person that the electrical distribution and transmission lines have been de-energized and visibly grounded at the point of work; or
B. The danger zone may be entered if insulating barriers (not a part of nor an attachment to the crane) have been erected to prevent physical contact with the lines.
minimum required clearance normal voltage, kV
(phase to phase) ft (m) when operating near high voltage power lines over to 50 over 50 to 200 over 200 to 350 over 350 to 500 over 500 to 750 over 750 to 1000
10
15
20
25
35
45
(3.05)
(4.6)
(6.1)
(7.62)
(10.67)
(13.72) while in transit with no load and boom lowered
23 For lines rated 50 kV or below, minimum clearance between the lines and any part of the crane or load
(including handling appendages) shall be 10 ft. (3m).
For higher voltages, see Table 1.
24 Caution shall be excercised when working near overhead lines, because they can move horizontally or vertically due to wind, moving the danger zone to new positions.
2-3.2.0
over to 0.75
over 0.75 to 50 over 50 to 345 over 345 to 750 over 750 to 1000
4
6
10
16
20
(1.22)
(1.83)
(3.83)
(4.87)
(6.1)
QUAL 7/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSPECTION CLASSIFICATION
27 Initial inspection. Prior to initial use, all new, altered, modified or extensively repaired cranes shall be inspected by a designated person to insure compliance with provisions of this standard.
28 Regular inspection. Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as "frequent" and
"periodic" with respective intervals between inspections as defined below.
A. frequent inspection - daily to monthly intervals
B. periodic inspection - one to twelve intervals, or as specifically recommended by the manufacturer
G. electrical apparatus for malfunctioning, signs of excessive deterioration, dirt and moisture accumulation
H. hydraulic system for proper oil level and leaks daily
I. tires for recommended inflation pressure, cuts and loose wheel nuts
J. connecting pins and locking device for wear and damage
PERIODIC INSPECTION
30 Deformed, cracked or corroded members in the crane structure and carrier.
31 Loose bolts, particularly mounting bolts.
32 Cracked or worn sheaves and drums.
33 Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and devices.
FREQUENT INSPECTION
34 Excessive wear on brake and clutch system parts and lining.
29 Inspection shall be performed by designated personnel.
A. control mechanisms for maladjustment interfering with proper operation - daily, when used
B. control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter
C. safety devices for malfunction
D. all hydraulic hoses, particularly those which flex in normal operation of crane functions, should be visually inspected once every working day, when used
E. hooks and latches for deformation, chemical damage, cracks, and wear. Refer to ANSI/ASME
B30.10
F. rope reeving for compliance with crane manufacturer's specifications, if optional winch is used
35 Crane hooks inspected for cracks.
36 Travel steering, braking, and locking devices, for malfunction.
37 Excessively worn or damaged tires.
38 Hydraulic and pneumatic hose, fittings, and tubing inspection.
A. evidence of leakage at the surface of the flexible hose or its junction with metal and coupling
B. blistering, or abnormal deformation to the outer covering of the hydraulic or pneumatic hose
C. leakage at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures
D. evidence or excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or fitting. Means shall be taken to eliminate the interference of
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INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
elements in contact or otherwise protect the components
necessary to determine origin of the problem before corrective action can be taken.
39 Hydraulic and pneumatic pumps and motors inspection.
A. loose bolts or fasteners
B. leaks at joints between sections
C. shaft seal leaks
D. unusual noises or vibrations
E. loss of operating speed
F. excessive heating of the fluid
G. loss of pressure
43 Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
44 A crane which has been idle for a period of over one month or more, but not less than six months, shall be given an inspection conforming with the initialregular- frequent inspections.
45 A crane which has been idle for a period of over six months shall be given a complete inspection conforming with the initial-regular-frequent inspection requirements.
40 Hydraulic and pneumatic valves inspection.
A. cracks in valve housing
B. improper return of spool to neutral position
C. leaks at spools or joints
D. sticking spools
E. failure of relief valves to attain or maintain correct pressure setting
F. relief valve pressure shall be checked as specified by the manufacturers
41 Hydraulic and pneumatic cylinders inspection.
A. drifting caused by fluid leaking across piston
B. rod seals leaking
C. leaks at welding joints
D. scored, nicked, or dented cylinder rods
E. damaged case (barrel)
F. loose or deformed rod eyes or connecting joints
42 Hydraulic filters. Evidence of rubber particles on the filter elements may indicate hose, "O" ring, or other rubber component deterioration. Metal chips or pieces on the filter may denote failure in pumps, motors, or cylinders. Further checking will be
INSPECTION RECORDS
46 Dated records for periodic inspection should be made on critical items such as brakes, crane hooks, rope, hydraulic and pneumatic cylinders, and hydraulic and pneumatic relief pressure valves. Records should be kept available to an appointed person.
OPERATIONAL TESTS
47 Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this section, including functions such as the following:
A. load lifting and lowering mechanisms
B. boom lifting and lowering mechanisms
C. boom extension and retraction mechanisms
D. swing mechanisms
E. safety devices
F. operating controls comply with appropriate function labels
Operational crane test results shall be made available to an appointed person.
RATED TEST LOAD
Prior to initial use, altered, modified, or extensively repaired cranes shall be load
2-4.1.0
INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL tested by or under the direction of an appointed person.
A. functional operating mechanism
B. safety devices
C. control systems
48 Test loads shall not exceed 110% of the manufacturer's load ratings.
49 Written reports shall be maintained showing test procedures and confirming the adequacy of repairs.
MAINTENANCE
PREVENTIVE MAINTENANCE
50 Before adjustment and repairs are started on a crane, the following precautions shall be taken as applicable:
A. crane placed where it will cause the least interference with other equipment or operations
B. all controls at the "off" position
C. starting means rendered inoperative
D. boom lowered to the ground if possible or otherwise secured against dropping
E. relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components
55 Repairs or replacements shall be provided as needed for operation.
The following are examples:
A. critical parts of functional operating mechanisms which are cracked, broken, corroded, bent, or excessively worn
B. critical parts of the crane structure which are cracked, bent, broken, or excessively corroded
C. crane hooks showing cracks, damage, or corrosion shall be taken out of service. Repairs by welding are not recommended
56 Instructions shall be provided by the manufacturer for the removal of air from hydraulic circuits.
LUBRICATION
All moving parts of the crane, for which lubrication is specified, should be regularly lubricated per the manufacturer's recommendations and procedures.
51 Warning or "OUT OF ORDER" signs shall be placed on the crane controls.
ROPE INSPECTION
52 After adjustments and repairs have been made, the crane shall not be returned to service until all guards have been reinstalled, trapped air removed from hydraulic system (if required), safety devices reactivated, and maintenance equipment removed.
ADJUSTMENTS AND REPAIRS
53 Any hazardous conditions disclosed by the inspection requirements shall be corrected before operation of crane is resumed, Adjustments and repairs shall be done only by designated personnel.
54 Adjustments shall be maintained to assure correct functioning of components, The following are examples:
57 Frequent Inspection
A. All running ropes in service should be visually inspected once each working day. A visual inspection shall consist of observation of all rope which can be in use during the days operations. These visual observations should be considered with discovering gross damage such as listed below, which may be an immediate hazard.
1. distortion of the rope such as kinking, crushing, un-stranding, birdcaging, main strand displacement, or core protrusion.
Loss of rope diameter in a short length or unevenness of outer strands should be replaced
2. general corrosion
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INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
3. broken or cut strands;
4. number, distribution and type of visible broken wires. When such damage is discovered, the rope shall either be removed from service or given as inspection.
B. Care shall be taken when inspecting sections of rapid deterioration such as flange points, crossover points, and repetitive pickup points on drums.
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 protrude
ROPE REPLACEMENT
58 Periodic inspection
A. The inspection frequency shall be determined by a qualified person and shall be based on such factors as:
1. expected rope life as determined by experience on the particular installation or similar installations
2. severity of environment
3. percentage of capacity lifts
4. frequency rates of operation
5. exposure to shock loads
Inspection need not be at equal calendar intervals and should be more frequent as the rope approaches the end of it's service life.
This inspection shall be made at least annually.
B. Periodic inspection shall be performed by a designated person. This inspection shall cover the entire length of the rope. Only the surface wires need be inspected. No attempt should be made to open the rope. Any deterioration results in appreciable loss of original strength, such as described below, shall be noted and determination made as to whether use of the rope would constitute a hazard: points listed above reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires; severely corroded, cracked, bent, worn or improperly applied connections;
C. Care shall be taken when inspecting sections subject to rapid deterioration such as the following:
59 No precise rules can be given for determination of the exact time for replacement of rope, since many variable factors are involved.
Continued use in this respect depends upon good judgement by a designated person in evaluating remaining strength in a used rope after allowance for deterioration disclosed by inspection. Continued rope operation depends upon this remaining strength.
60 Conditions such as the following shall be reason for questioning continued use of the rope or increasing the frequency of inspection:
A. in running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand in one lay
B. one outer wire broken at the contact point with the core of the rope structure and protrudes or loops out of the rope structure. Additional inspection of this section is required
C. wear of one third of the original diameter of the outside individual wire
D. kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure
E. evidence of any heat damage from any cause
F. reduction from nominal diameter of more than 1/64 in. (0.4mm) for diameters up to and including 5/16 in. (8 mm), 1/32 in. (0.8 mm) for diameter 3/8 in.
(9.5 mm) to and including 1/2 in. (13 mm), 3/64 in.
(1.2 mm) for diameter 9/16 in. (14.5 mm) to and including 3/4 in. (19 mm). 1/16 in. (1.6 mm) for diameter 7/8 in. (22 mm) to and including 11/8 in.
(29 mm), 3/32 in. (2.4 mm) for diameters 11/4 in.
(32 mm) to and including 11/2 in. (38 mm)
2-4.3.0
INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
G. In standing ropes, more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection.
H. Replacement rope shall have a strength rating at least as great as the original rope furnished or recommended by the crane manufacturer. Any deviation from the original size, grade, or construction shall be specified by a rope manufacturer, or a qualified person.
65 Before cutting a rope, seizing shall be placed on each side of the place where the rope is to be cut to prevent unlaying of the strands. On pre-formed rope, one seizing on each side of the cut is required. On non-preformed ropes of 7/8 in. (22 mm) diameter or smaller, two seizings on each side of the cut are required, and for non-preformed rope 1 in. (25 mm) diameter or larger, three seizings on each side of the cut are required.
61 Rope not in regular use: all rope which has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed, shall be given and inspection in accordance with above information before it is placed in service. This inspection shall be for all types of deterioration and shall be performed by a qualified person.
66 During installation care should be exercised to avoid dragging of the rope in the dirt or around objects which will scrape, nick crush or induce sharp bends in it.
62 Inspection records
A. frequent inspection- no records required
B. periodic inspections- in order to establish data as a basis for judging the proper time for replacement, a dated report condition at each periodic inspection should be kept on file. This report shall cover points of deterioration listed above.
67 Rope should be maintained in a well-lubricated condition. It is important that lubricant applied as a part of a maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted. Lubricant applied shall be the type which does not hinder visual inspection. Those sections of rope which are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope. The object of rope lubrication is to reduce internal friction and to prevent corrosion.
ROPE MAINTENANCE
63 Rope should be stored to prevent damage or deterioration.
68 When an operating rope shows greater wear or well defined localized areas than on the remainder of the rope, rope life can be extended in cases where a section at the worn end, and thus shifting the wear to different areas of the rope.
64 Unreeling or uncoiling of rope shall be done as recommended by the rope manufacturer and with care to avoid kinking or inducing twist.
2-4.4.0
INSP 9/98
SAFETY DECAL SECTION
RAM-LIFT CRANE
PART NO.:
DECAL:
FUNCTION:
QUANTITY
:
040524
DANGER
To inform the operator of the proper procedure to follow for safe operation of this crane.
1
PLACEMENT
:
Quill weldment sideplate
3-1.0.0
S-18
RAMDECAL 2/2000
SAFETY DECAL SECTION
RAM-LIFT CRANE
Decal Kit P/N 370543 includes:
5
6
3
4
Item
1
2
Quantity
2
2
Part Number Description
040522 RAM LIFT DECAL
040527 STRIPING DECAL (15 in. LONG)
1
1
2
1
040527
999958
040524
040637
STRIPING DECAL (9 in. LONG)
INSTALLATION CHECKLIST
DANGER DECAL
RAMSEY DECAL with STRIPING
3-2.0.0
S-19
RAMDECAL 2/2000
GENERAL DIMENSIONS
RAM-LIFT CRANE SERIES
Crane MountingBase
4-1.0.0
RAMAW137 6/98
ASSEMBLY & INSTALLATION INSTRUCTIONS
RAM-LIFT
The Ram-Lift crane is shipped in three major assemblies: the pedestal assembly, the boom assembly and the winch assembly. The pedestal assembly consists of the base, pedestal, and quill sub-assemblies. It is recommended that the base be removed from the pedestal assembly and be installed on the truck first.
MOUNTING PLATE
AND GUSSETS
TRAILING SUPPORT
ARM
VERT.
MOUNTING
TUBE
SUPPORT
CROSSMEMBER
FRAME RAILS
FILLER MATERIAL
Figure 1 - Installation & Typical Mounting
1. Remove the base assembly from the shipping carton and locate in the truck bed in the desired location and check for proper clearance. A right rear corner mount is typical.
2. If the floor is made of wood, install a 3/8 in. thick plate approximately six to eight inches larger than the base plate on top of the wooded deck. If the floor is heavy metal and ribbed no metal plate is required under the crane base plate. Install fillers to level the ribbed floor if required. Place the base assembly in position and locate the mounting holes through the truck bed and the backup plate. See Figure 1 for a typical mounting arrangement.
3. Each truck has its own unique mounting difficulties. Construct the mount and additional bracing so the combined crane load of 5,000 ft-lb and a vertical load of 1,000 lb is directed over the largest area possible. Install a brace which crosses both sides of the truck and which may be used as pocket for an outrigger, stabilizer, or jackleg holder. Add other structural members as necessary depending on the strength of the truck structure.
An inadequate crane mounting structure can cause damage to the truck frame and body.
5-1.0.0
RAMINSTALL 1/2000
ASSEMBLY & INSTALLATION INSTRUCTIONS
RAM-LIFT
Bolt crane base to truck bed and mounting structure.
For models with an electric winch:
Drill a hole for power wires in the floor of the bed. Put a rubber grommet in the floor or seal the wires with silicone rubber compound (RTV) to protect wires from chafing.
Figure 2 - Installation of Battery Cable
4. Install the pedestal and quill assembly in the base and secure with a 5/8 in. bolt.
For models with an electric winch:
See Figure 2.
1) Drill 13/16 in. hole through structure. Install cable and bushing furnished with crane, as shown. Wrap electrical tape around cable so it will be snug in the bushing.
2) Run red power cable to positive battery terminal. Connect black cable to negative battery terminal or suitable chassis ground point. Locate cables so that they will be protected. Avoid sharp edges. Use the No. 083800 frame clips provided to hold cables securely in place.
3) If the battery is grounded to the engine it may be necessary to add an additional ground cable from the engine to the chassis frame to obtain maximum power at crane.
5. Assemble winch to boom assembly.
For models with a manual winch:
Attach manual winches with two hex head 3/8 in. bolts.
Locate the winch handle on the right side of the boom so the line coming off of the winch comes off of the top of the drum.
For models with an electric winch:
Remove the cover of the electric winch. Bolt electric
5-2.0.0
RAMINSTALL 1/2000
ASSEMBLY & INSTALLATION INSTRUCTIONS
RAM-LIFT
winches to the mounting plate on the boom with the hardware provided. When properly assembled, the winch drum is centered on the boom and the cable plays off of the bottom of the drum as it goes out to the crown sheave. Replace the electric winch cover.
6. Attach the boom and winch assembly to the pedestal assembly with the pins provided.
Figure 3 - Wiring Diagram
7.
For electric models with a pendant:
Attach wires from receptacle assembly to winch assembly. Plug in pendant and check for proper direction of winch operation. (Wires may be reversed at the winch to change the direction of rotation.)
Testing Crane Stability
With jackleg or outriggers installed and extended and boom set at the horizontal position, load test the crane to verify that the mounting is structurally sound. Test with a 500-lb load and observe any permanent deflections. If there is no bending of the mounting, test with a 1000-lb load and rotate load approximately 180 degrees.
While testing, keep the load as close to the ground as possible.
5-3.0.0
RAMINSTALL 1/2000
LUBRICATION & MAINTENANCE
SCHEDULE RAM-LIFT CRANE
SERVICE
PERFORMED
LOAD HOOK
CABLE DRUM
DAILY
WEEKLY MONTHLY
1 YEAR
X
X
HOIST CABLE
MOUNTING BOLTS
X
X
X MOTOR
CONNECTION
SHEAVE BEARINGS
ALL OTHER BOLTS
BATTERY
CONNECTIONS
POWER CABLE
X
X
X
X
HUMP REDUCER
HOSE
FOR ADDITIONAL
INFORMATION SEE:
X
1) OWNER'S MANUAL
2) OSHA SECTION 1910.180
3) ANSI B30.5-1989
NOTES
INSPECT HOOK & LATCH FOR DEFOR-
MATION, CRACKS, & CORROSION
MAKE SURE CABLE IS WOUND EVENLY
ON DRUM
CHECK FOR FLATTENING, KINKS, &
BROKEN STRANDS, SEE MANUAL
CHECK-TORQUE AS REQUIRED FOR
5/8 in. BOLT
CHECK TERMINALS FOR TIGHT
CONNECTIONS
SEALED BEARING, REPLACE IF ROUGH
OR LOOSE
CHECK-TIGHTEN AS REQUIRED
CHECK FOR CORROSION & TIGHT
CONNECTIONS. CLEAN & COAT AS
REQUIRED
CHECK INSULATION FOR DAMAGE OR
DETERIORATION
WATER PROOF BEARING GREASE
CAUTION: Routine maintenance insures trouble-free operation and protects your investment. All
warranties are void if maintenance is neglected.
NOTES:
1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts
is not covered by Warranty or Product Liability.
2. Once a bolt has been torqued to its rated capacity and then removed, the bolt should be replaced with a new one.
6-1.0.0
RAMMNSCH 2/2000
LIFE OF WIRE LINE
So many variable factors can cause the deterioration of wire line cable that it is not possible to determine a definite life expectancy. Some of these factors are:
• Load being handled.
• Corrosive conditions.
• Maintenance of the unit:
Keep the sheaves turning freely.
Maintain tension on cable to insure proper spooling.
Avoid kinks in cable.
Avoid abrasive action and contact with sharp corner.
• Frequency of use.
Auto Crane units, up to 2,400 pound ratings use 3/16 inch diameter galvanized pre-formed 7 x 19 aircraft cable. This cable has a working strength, when new, of 4,200 pounds.
It is recommended when 1,200 pound loads are exceeded to use a two part line with a traveling block. This will ensure a 3.5 to 1 safety factor when the cable is new.
Keeping the above factor of safety in mind and knowing the kind of loads that will be handled, the user can determine by inspection of the cable as to when it should be replaced.
Items to look for while inspecting the cables are:
•
Broken strands.
•
Kinks and flattened sections.
•
Corrosion and abrasion.
WIRE LINE LUBRICATION
Lubrication of the wire line serves two important purposes:
•
Prevent corrosion.
• Reduce wear due to flexing and abrasion caused by contact with the sheaves, rollers, and cable on the drum.
Preparation
Remove rust and foreign matter with a wire brush and wipe clean. Be sure cable is dry.
Application
Method 1: Dip a brush into a light weight motor oil and apply. In some cases, dip a rag or a piece of sheepskin into the lubricant and swab the lubricant on to the rope.
Method 2: Apply a heavier lubricant such as a grease gun lubricant with hands while wearing leather gloves. (Leather gloves give greater protection and less penetration of the grease than canvas gloves.)
7-1.0.0
WIRE 1/2000
GENERAL ASSEMBLY - P/N 370530-300
RAM-LIFT CRANE SERIES
Ram-Lift with Manual Winch
8-1.0.0
3705303R 1/2000
GENERAL ASSEMBLY - P/N 370530-300
RAM-LIFT CRANE SERIES
Item
1
2
3
4
5
6
7
8
9
Quantity
1
1
1
2
1
1
1
1
1
10
11
12
13
14
15
16
17
18
19
1
3
1
1
2
1
1
1
1
1
21
22
1
1
23
24
1
1
25 1
Note:
Item number not used: 20
Part Number
370545
370547
370536-002
370002
370539
012200
018300
370542
370532
REF
REF
REF
REF
272052
272055
005500
370535
370543
012202
330028
015900
020200
020300
999958
Description
PEDESTAL WELDMENT
QUILL WELDMENT
BOOM WELDMENT
PIN ASSEMBLY w/ LANYARD
SHEAVE ASSEMBLY
CAPSCREW 5/8 UNF x 1 3/4
LOCK NUT 5/8 UNF
HUMP REDUCER HOSE
MANUAL WINCH
CAPSCREW 3/8 UNC x ¾ (008400)
CARRIAGE BOLT 3/8 UNC x ¾ (370544)
NUT 3/8 UNC (330372)
LOCK WASHER 3/8 (021100)
BRAKE HANDLE
HAND GRIP
CAPSCREW 1/4 UNC x ¾
REMOVABLE BASE ASSEMBLY
RAM-LIFT DECAL KIT (
not shown
)
CAPSCREW 5/8 UNC x 1 1/4
CABLE WITH HOOK 25 ft
NUT ¼ UNC
LOCK WASHER ¼
FLAT WASHER ¼
INSTALLATION CHECKLIST
8-1.1.0
3705303R 1/2000
GENERAL ASSEMBLY - P/N 370530-500
RAM-LIFT
Refer to page 5-3.0.0
for wiring diagram.
Ram-Lift with electric winch and pendant
8-1.4.0
AW3705305 1/2000
GENERAL ASSEMBLY - P/N 370530-500
RAM-LIFT
7
8
9
10
4
5
6
Item
1
2
3
Quantity
1
1
1
2
1
1
1
1
1
3
Part Number
370545
370547
370536-002
370002
370539
012200
018100
370542
272419
REF
Description
PEDESTAL WELDMENT
QUILL WELDMENT
BOOM WELDMENT
PIN ASSEMBLY with LANYARD
SHEAVE ASSEMBLY
CAPSCREW 5/8 UNF x 1 ¾
LOCK NUT 5/8 UNF
HUMP REDUCER HOSE
ELECTRIC WINCH
CAPSCREW 3/8 UNC x ½ (010000)
18
19
20
23
24
25
26
27
11
12
13
14
15
16
17
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
REF
REF
REF
272052
272055
005500
370535
REF
012202
370552
REF
REF
370625
REF
015900
CARRIAGE BOLT 3/8 UNC x ¾ (370544)
NUT 3/8 UNC (330372)
LOCK WASHER 3/8 (021100)
BRAKE HANDLE
HAND GRIP
CAPSCREW ¼ UNC x ¾
REMOVABLE BASE ASSEMBLY
* PENDANT ASSEMBLY (10 ft) (370129)
CAPSCREW 5/8 UNC x 1 ¼
RAM-LIFT DECAL KIT (
not shown
)
POWER CABLE (602005) (
not shown
)
GROUND CABLE (602006) (
not shown
)
STANDARD SHIP KIT (
not shown
)
* TIE WRAP (750737) (
not shown
)
NUT ¼ UNC
28
29
30
1
1
1
020200
020300
999958
LOCK WASHER ¼
FLAT WASHER ¼
RAM-LIFT INSTALLATION CHECKLIST (
not shown
)
31
32
1
1
370624
370022-001
* SHIP KIT with PENDANT (
not shown
)
* RECEPTACLE ASSEMBLY
33 3 REF LOCK WASHER ½ (021500)
Notes:
Item numbers not used: 21, 22.
* These items and drawing 370626 are in the ship kit.
AW3705305 1/2000
8-1.5.0
MANUAL WINCH - P/N 370532
RAM-LIFT
8-2.0.0
AW370532R 6/98
14
15
16
17
18
19
20
21
22
23
28
29
30
31
24
25
26
27
ITEM
1
2
3
7
8
9
10
11
12
13
4
5
6
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
QTY
1
1
1
MANUAL WINCH - P/N 370532
RAM-LIFT
370568
370569
570570
370571
370464
272179
272180
370572
370573
370574
370575
370460
370577
370578
370579
370580
370581
370582
P/N
370555
370556
370557
370558
370559
370560
370561
370562
370563
370564
370565
370566
370567
DESCRIPTION
WINCH BRAKE ASSEMBLY
BEARING
RATCHET WHEEL
REEL BOLT
BRAKE LINING PRESSURE PLATE
BRAKE WINCH HUB ASSEMBLY
SELF TAPPING SCREW
GEAR COVER
DRIVE SHAFT ASSEMBLY
REEL ASSEMBLY 1 1/8 HUB
REEL ASSEMBLY 2 1/8 HUB
ROLL PIN
WINCH HANDLE ASSEMBLY
RATCHET PAWL SPACER BUSHING
BRAKE RATCHET SPRING
RATCHET PAWL
RATCHET PAWL BOLT
CARRIAGE BOLT
HEX NUT ¼
ROPE CLAMP
LOCK NUT 3/8
SPACER SLEEVE
NEEDLE BEARING
SPACER WASHER
RETAINING RING
WASHER
SPRING
SHAFT EXTENSION
RETAINER WASHER
HEX BOLT
OPTIONAL GEAR COVER
8-2.1.0
AW370532R 6/98
ELECTRIC WINCH ASSEMBLY P/N 272419
RAM-LIFT CRANE SERIES
Item
1
2
3
4
5
6
7
8
9
10
Quantity
1
2
1
1
2
1
1
1
1
1
Part Number
272500
272151
272152
272153
272154
272155
272501
272158
272159
272160
Description
BEARING HOUSING ASSEMBLY
PRIMARY DRIVE SHAFT ASSEMBLY
RETAINING RING
BUSHING
GEAR 56 T
HANDLE ASSEMBLY
DRIVE SHAFT BEARING HOUSING ASSEMBLY
INTERMEDIATE DRIVE SHAFT ASSEMBLY
“E” RING
BASE
8-3.0.0
272419R 1/2000
ELECTRIC WINCH ASSEMBLY P/N 272419
RAM-LIFT CRANE SERIES
Item
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
39
40
41
42
43
30
31
32
33
34
35
Quantity
1
1
1
5
3
1
1
1
2
1
7
1
2
1
1
1
1
1
4
1
2
2
2
1
1
1
1
1
2
1
Part Number
330011
330012
330018
272502
330015
272434
272162
272163
272164
272165
330019
330022
272433
272170
272171
272172
272173
272174
272175
272176
272503
272179
272180
272504
272505
330028
272435
272436
272437
272184
Description
LOCK NUT 7/16 UNF
CLUTCH STUD
LOCK NUT 1/2
WASHER
GEAR ASSEMBLY
BRAKE SPRING ASSEMBLY
CAPSCREW ¼ UNC X 1 1/16
SPACER
FRONT PLATE
LEVEL WIND PIN
LEVEL WIND
LOCK NUT 10 UNF
BRAKE DISK ASSEMBLY
12 T PINION GEAR
“E” RING
BASE SPACER
REEL SHAFT
RETAINING RING
CAPSCREW ¼ UNC X ¾
WASHER
REEL ASSEMBLY
NUT ¼ UNC X ¾
ROPE CLAMP
CARRIAGE BOLT ¼ UNC X ¾
COVER
CABLE & HOOK 3/16 X 25 FT)
SPACER
BRAKE SPRING SPACER
CAPSCREW 10 UNF X 1
MOTOR ASSEMBLY
Note:
Item numbers not used: 36, 37 & 38.
8-3.1.0
272419R 1/2000
Advertisement
Key features
- 4,250 ft-lb capacity
- 360º continuous rotation
- 25 ft cable length
- Hydraulic outriggers
- Electric winch
- Safety decals
