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DOCUMENTOILEGIVEL, ORIGINAL
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NATIONAL GRDIER No,
NATIONAL SUPPLY

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7-4 E&P-BC/G XP/G DOE

Ldad ISK OL Maser

FOREWORD

This manual has been compiled to assist in the operation and maintenance of the OS-435 pedestal crane. A
great deal of effort was put into the development of this machine to assure ease of operation and
maintenance.

There are, however, certain precautions that should be taken to assure safe operation and long trouble free
service. We, therefore, urge the operator to become familiar with this manual before operating the crane.

NOTE: This manual applies only to cranes with serial no.’s above Serial No, 230.

NATIONALE

wep NATIONAL OILWELL

P.O. BOX 4638
HOUSTON, TEXAS 77210-4638
As used herein, any references to National
_shall be deemed tomean NationalOilwell,

Copies of this monual hove been furnished with each unit of

time of shipment on a ‘‘No Charge"' basis. A charge will be

assessed on all requests for additional or replacement copies.

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—, CRANE NOMENCLATURE

SHEAVE EXTENSION —

LOAD SHEAVES

TURN SHEAVES WITH

LOAD WEIGHING OPTION
| 0
PENDANT LINES —\

FLOATING BOOM \
HOIST BLOCKS.

BOOM HOIST LINES / /

(10 PARTS REEVING ) BLOCK — /
SUPPORTS ©
- | BOOM
POINT

WHIP__]|
LINE

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GANTRY
LANDING > Ye MAIN LINE
OVERHAUL,
BALL
GANTRY SHEAVES
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EXTENSION
GANTRY ey y // _— yy
LADDER
GUARD w/ oe
GANTRY s | ¥ - LOAD BLOCK

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BacksTops & /
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LT-160045
 TABLE OF CONTENTS
PAGE
Intraduction . . eet e eee bev eeet reece l
Safe Operating Practices . bee eee eee eee Settee verre 2
Inspection cee bee eee ne 2
Operating instructions . cn Lee 7
Lubrication eee a
Filters and Conditioners .... eee ee . 16
Electrical Schematic for Caterpillar Engine Cranes eee eee e eee eee 22
Electrical Schematic for Detroit Diesel Engine Cranes ...0....0000.0000.0000-......4... 23
Hydraulic Motor Compartment. ...0 0.0.0.6. rr rn vie, 24
Engine Compartment. bee Lecter ee beeen eee beeen cee - 25
Rear Cab Wall . Lees : ete eters nn)
Triple Pump Drive. . Bees 27
Hydrostatic Drive Poe ees beets . 29
Hydraulic Control Circuit. 0 eee 4)
Air Control System oe eee . 45
Operation of the Primary Functions . eee 53
Brakes . Deere ees 57
Swing Bearing Maintenance Requirements. . ot
Structural Maintenance... nee tee . 6)
Over-Center Cluich rece eee . 63
Boom Angle Limiter. 0 eee . 8
Line Travel Limiter . : eee beeen tee bec eee OF
Reeving and Wire Rope Specifications. an beets ...
Boom Hoist Block Supports . 60.6 ee 72
Wire Rope Maintenance and inspection. .0 0. ees 73
Reading Schematics 9000.2. .ee Lee 75
Trouble Shooting - Control Pressure Circuit. bocce Peeters ... 77
Trouble Shooting - Pump Drive Housing ...... bbe eens beeen eee pee e ee WF
Trouble Shooting . ee eden ete nee ne 4)
Air Valve Repair, Maintenance and Operation ................ rn coe BS
Hydrostatic Drive Trouble Shooting .............. 0. 0..0.00000% beter GI
Pump and Motor Replacement... eee 107
Pump and Motor Repair 108
Emergency Load Lowering 00066 ten eee 108
Crane Start-Up Procedure ofter Storage or Shipping . . Steen eens 109
Appendix
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA.

INTRODUCTION
The OS-435 crane incorporates all the standard crane functions and utilizes a lattice type, wire line supported
boom and high gantry permitting the reaching out with heavy loads and the use of long booms.

Here, however, is where the similarities end. The OS-435 is a pneumatically controlled hydraulic unit. Each
hoist drum is powered by its own hydraulic motor powered by a variable displacement pump. This motor
drives through a two stage planetary gear reduction that is completely enclosed within the drum.

The fluid flow to and from each motor is controled so that the speed of any function (hoist, lower, swing)
depends only on the engine speed and how far the contro! handle is moved from the neutral position. This
provides the ultimate in smooth control and ease of operation.

The swing is a completely independent hydraulic circuit. It utilizes a variable displacement pump driving a
fixed displacement motor. This motor drives the swing pinion through a totally enclosed three stage gear
reduction.

This modern hydraulic approach greatly simplifies maintenance. Rather than one large complex piece of
machinery, the hydraulic unit utilizes relatively small, completely independent modules. The modules can
be easily removed for repair or replacement.

The OS-435 has only one friction clutch to adjust; this is the throw-out clutch between the prime mover and
hydraulic pumps. All heavy braking is done hydraulically. The friction brakes are used only to hold the load
while the control handles are in neutral. This provides for long brake life and rare need for brake
adjustment.

The brakes and boom hoist lock pawl are spring set and pressure released. All hoist brakes release
automatically when the control handles are moved out of the neutral position. All the hoist brakes and boom
hoist lock pawl set automatically when the hoist control handles are returned to the neutral position.

A hydraulic drive provides for a more compact design. It also permits a more complete isolation of the
operator's cab for more efficient sound and temperature control.

The main frame is of welded steel construction utilizing high strength steels in critical locations. Its deep
beam design gives maximum rigidity with minimum weight.

ARMCO National Supply Company Rev. Dec. 1978} Page |

VW wssion of Armeo ine
NATIONAL
LITHO IN U S.A.
HYDRAULIC PEDESTAL CRANE OS-435

SAFE OPERATING PRACTICES

1. Know the weight of the load you are lifting.

2. Do not exceed the crane’s load chart.

3. Check the weight of unfamiliar loads if within 10% of the load chart capacity.

4, Attach the load properly to the hook with slings or chains and balance the load.

5. Do not wrap the hoist rope around the load.

6. Before hoisting, check the wire rope for kinking or twisting.

7. Bring the hook over loads in such a manneras to prevent swing.

8. If there is a slack rope condition, it should be determined that the rope is properly seated on the drum
and in the sheaves.

9. Move loads smoothly, without sudden acceleration or deceleration.

10. Do not allow personnel to ride the load or hook.

11. Avoid carrying loads over people.

12. Test the brakes each time a load approaching the rated load is handled.

13. Do not leave the crane unattended while a load is suspended.

14. The operator should respond to signals only from the appointed signal man, but should obey a stop
signal at any time no matter who givesit.

15. Never allow fewer than three full wraps of wire rope on any drum.

16. Do not refuel crane with engine running.

17. A carbon dioxide, dry chemical, or equivalent fire extinguisher must be kept in the operator’s cab or
vicinity of the crane.

INSPECTION

Asample inspection check list has been provided in order to acquaint an operator with the proper inspection
of NATIONALpedestal cranes. The inspection procedure has been divided into three general graups based
upon intervals at which inspection should be performed. The three inspection intervals are: daily, weekly,
and monthly. These intervals are recommended for normal operation, but may be adjusted to the customer's
operating conditions.

If adjustments or repairs are found to be necessary from an inspection, the inspector should promptly notify
the proper personnel to assure problem correction. The crane operator of the next shift should also be
notified of the defect if the problem has not been corrected prior to the shift change.

Inspection records should be signed and dated by the inspector, and kept available for future reference as
recommendedby the American Petroleum Institute.

P 2 Rev. Dec, 1978 _

age ev ARM National Supply Compeny
Devision of Armco Inc
NATIONAL HYDRAULIC PEDESTAL CRANE OS.4
LITHO INUSA

INSPECTION CHECK LIST — DAILY

CRANE SERIAL NUMBER. DATE INSPECTED.

NO. OF CRANE OPERATING HOURS INSPECTED BY.

CONDITION
“Correction
DAILY PROCEDURE O.K. Required COMMENTS

. CHECK FOR AND ELIMINATE SPILLAGE OF

FLAMMABLE MATERIALS SUCH AS FUEL & OIL.
Service engine, checking water and oi) Jevels,
and air cleaner.
Check engine fuel tank level.
nJoala}s|o

Gheck hydraulic oil tank level.

Lubricate boom foot bushings.

Check operation of horn.
Start engine and allow to warm up at idle speed.
Check engine gages.
8. Check clutch operation.
9. Engage clutch and allow hydraulic oil to warm up
at idle speed.
10. Observe charge pressures to see if they are in
proper operating range, 160/300 psi (11/20.7 bar).
14. Observe control pressure to see if it is in the
proper operating range, 700/750 psi (48.3/51.7 bar).
12. Observe the triple pump drive [ube off gage to see
if it is in the proper operating range, 20/40 psi
{1.4/2.8 bar) at 1800 RPM.
13. Check swing, boom, and hoist control handles for
adjustment and for proper centering when released |
14, Check air regulator to see if it is in the proper
operating range, 95/100 psi (6.6/6.9 bar).
15. Drain moisture from air receivers.
16. Check ail “brake-off”indicators.
17. Operate emergency brake set to assure its
operation.
18. Visually inspect all running wire rope and check
ali drums for proper spooling.
19. Check for jeakage or deterioration of components:
in hydraulic and pneumatic systems.

20. Observe condition of pump suction line filter at

engine speed of 1800 RPM.
21, Check boom pins and gantry leg pins for missing
or dislocated cotter pins.
22. Check condition of high pressurein-line filters
by depressing red button on filter while powering
down atfull speed. If button pops out, replace
element.
*When a checkmark has been placed under the “correction required column for a certain procedure, corrective work
must be performed. After correction of the defect, the date and initials of the person making the correction are to be
placed in the o.k. column of the procedure in question.

Rev. Dec. 1978 Page 3

ARMCO National Supply Company
VJ owision ot Area ine
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435

INSPECTION CHECK LIST — WEEKLY AND MONTHLY

CRANE SERIAL NUMBER DATE INSPECTED

NO. OF CRANE OPERATING HOURS_ INSPECTED BY

CONDITION
*Correction
WEEKLY PROCEDURE O.K. Required COMMENTS

1. Lubricate crane per instructions in operator's

manual
2. Check oil levels of all shaft assemblies, swing
gear housing, tripte pump drive.
3. Check boom saver system for proper operation.
4. Check boom angle limiter system for proper
adjustment (adjustment must beset to prohibit
boom angles greater than 80°.)
5. Check boom hoist lock pawl for correct engage-
ment and disengagement with ratchet wheel teeth.
6. Check brakes for adjustment and excessive wear
of lining, loose or missing components and
contamination by lubricants.
7. Check electrical apparatus such as lights and
switches for malfunction or signs of deterioration.
8. Check air line lubricator oil leveis.
9. Check clutch adjustment.

CONDITION
*Correction
OK. Required COMMENTS

1. Thoroughly inspect all wire rope and pendant lines|

for deterioration such as: reduction of rope dia. ;
broken and worn outside wires; corroded and
cracked end connections and severe kinking,
crushing and unstranding of wires.
2. Check hooks for cracks and deformation.
3. Inspect boom for deformed, cracked, corroded or
missing members.
4. Inspect gantry for deformed, cracked, corroded or
missing members.
5. Inspect main frame for deformed, cracked, or
corroded members.
6. Check for loose bolts on hydraulic pumps and
motors, swing bearing, gantry, swing gear
reducer, and shaft assemblies.
7. Inspect sheaves for cracks, exessive wear,
and that they operate freely.
8. Inspect ail load, angle and weight indicating
systems over their full range for significant
inaccuracies.
9. Check for worn, cracked, distorted, or dislocated
boom pins, wire rope rollers, and swing bearing
gear teeth.
10. Check tripte pump drive chain for excessive
stretch, and chain sprockets for wear.

*When a checkmark has been placed under the “correction required” column for a certain procedure, corrective work
must be performed. After correction of the defect, the date and initials of the persons making the correction are to
be placed in the o.k. column of the procedure in question.

Page 4 Rev. Dec. 1978 —_

ane National Supply Company
Division of Armeoinc
 NATIONAL HYDRAULIC PEDESTAL CRANE O$-435
LITHO IN USA

OPERATOR’S CAB

wee we . LT-160509
Figure |
or

Engine Tachometer . Control Air Pressure Regulator

NOOMPON >

Boom Hoist Pressure Gage Whip Hoist ‘Brake Off’ Indicator

Swing Pressure Gage Main Hoist “Brake Off’ Indicator
Main Hoist Pressure Gage Boom Hoist “‘Brake-Off"’ Indicator
Engine Water Temperature Gage Swing Hoist ‘‘Brake-Off”’ Indicator
Engine Oil Pressure Gage Emergency Brake Set Valve
Triple Pump Drive Low tube Swing Brake Control Valve
Pressure Indicator Emergency Load Release Valve
Low Hydraulic Tank Fluid Main/Whip Hoist Selector Control Valve
2

Level Indicator Engine Start Valve

Air Supply Low Pressure Indicator Engine Kill Valve
10. Control Air Pressure Gage Low Boom Limit Override Valve
VW. Control Pressure Gage Horn Valve
12. Swing Charge Pressure Gage Clutch Control Valve
13. Boom Charge Pressure Gage Cab Heater Power Switch
14, Main/Whip Charge Pressure Gage Cab Heater Thermostat Switch
15. Boom Hoist Control Pedal Boom, Beacon, Frame, and Cab Light Switches
16. Foot Brake Pedal Electrical Circuit Breaker Cabinet
V7. Foot Throttle Pedal Electrical Component Bax
18. Swing Control Handle Main and Whip Hoist (Hook) High Speed
19. Boom Hoist Control Handle Selector Valve
20. Main/Whip Hoist Control Handle Main and Whip Hoist High Speed Indicator
2. Hand Throttle Control Transformer

ony " Rev. July 1982 Page 5

RMCO National Supply Company
P.

NJ awison ot Aimea ine

NATIONAL
{IFHO IN USA
HYDRAULIC PE DESTAL CRANE OS-435

NOTES

Page 6 Rev. Dec. 1978 cc

A AMCO National Supply Company
Drvsian of Armco ing
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA

OPERATING INSTRUCTIONS

When the crane is transporting loads, the engine speed should be at least 1500 RPM. Maximum engine
speed is 1900 RPM. Minimum engine idle speed is }000 RPM.

Figure 1 shows a view of the operator’s cab and controls. These controls have been grouped for ease of
operation and to offer the operator a desirable field of vision.

SWING

The outside fever (18) on the jeff hand console operates the crane swing system. To swing the upper works to
the right, the lever (handle) is moved forward, away from the operator. Ta swing left, the lever is moved
toward the operator. Ata given engine RPM the swing speed depends on how far the control fever is moved
fram its neutral position. A valve (28) in the console is used to set or to release the swing brake. An indicator
(26) turns amber jo inform the operator when the brake is released.

BOOM HOIST

The boom hoist shaft assembly is the rear winch on the crane andis controlled by the inside lever (19) on the
left hand console. This lever is moved forward, away from the operator, to lower the boom and is moved
toward the operator to raise the boom. Ata given engine RPM the speed of booming (luffing) depends on
how far the control lever is moved from its neutral position. The boom hoist brake and lock paw! set
aviomatically when the control lever is returned to its neutral position, An indicator (25) turns amber to
inform the operator when ihe brake and lock paw! are released.

The boom hoist can also be operated with the left foot using the rocker pedol (15) on the floor. This method
of operating leaves the operator’s left hand free to operate the swing controls while booming.

The boom is equippped with an automatic stop for the high and low elevations. This stop should be checked
periodically for proper operation. When the stopis activated the contro! lever will only move the boom away
from the stop.

MAIN AND WHIP LINE HOISTS

The main hoist shaft assembly is the front winch on the crane and the whip fine hoist is the center winch.
These winches are controted by the lever (20) on the right hand console. A two position valve (30) selects
which hoist is to be operated. The valve is pushed for the main hoist and pulled to use the whip hoist. The
main and whip line hoists cannot be operated simutaneously. The controt handle is pulled toward the
operator to raise the load and pushed forward to lower the load. The main and whip hoist brakes set
automatically when the lever is returned to its neutral position. indicators (23} and (24] turn amber to inform
the operator when the brakes are released.

NOTE: The hoist selectar control valve (30} MUST NOT be shifted while hoisting or lowering a load. Only
when the control handle (18) is in neutral should an operator switch from one winch to another.
This precaution must be observed by the operator to prevent possible pressure surges or loss of
laad cantrol from damaging the hydraulic motors.

MAIN AND WHIP LINE HOIST SPEED SELECTOR ANDO {NDICATOR

Bath the main and whip line hoists are equipped with two-speed motors for low speed high torque, or high
speed, low torque operation. The “hook speed selector valve’ (41) is used for both the main and whip hoist
motors. The valve is pulled for high speed and pushed for low speed.

-—— Rev, Dec. 1978 Page 7

ARMCO National Supply Company s
V7 oision ot Armeo ine
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
The main and whip hoist high speed indicator (42), in the right hand control panel, will be amber whenever
the main and whip hoist motors are in the high speed, low torque position (hoist speed selector valve (41) is
in the “up” position).

CAUTION: DO NOT change speeds while hoisting or lowering a load. If the hoist pressure exceeds 3500
psi, the main/whip control handle should be returned to neutral and the speed selector valve
pushedfor “low” speed.

EMERGENCY BRAKE SET

The emergency brake set valve (25) is located on the left hand console. To set all hoist brakes and boom
hoist lock pawl, push this valve. To reset for normal operation, pull the valve up.

EMERGENCY LOAD RELEASE

The emergency load release valve (29) is located on the right hand console. To release a load, push this
valve. To reset for normal operation, pull this valve up.

CAUTION: This valve shoutd ONLY be used in emergencysituations to release a load. Indiscriminate use
of this valve may cause damage to the main or whip hoist hydraulic motors.

ENGINE GAGES

The engine gages are located on the teft hand console panel. These are the oil pressure gage (6), engine
water temperature gage (5) and the engine tachometer (1). These gages should be checked periodically for
correct readings as specified in the engine manual. The minimum engine speed reading on the tachometer
should be 1000 RPM and the maximum should be 1800 RPM. If o gage shows an incorrect reading,
immediately shutdown the engine and determine the cause to prevent possible engine or hydraulic system
damage.

HYDRAULIC FLUID TANK LEVEL

A safe hydraulic tank level is demonstrated by the indicator (8), on the right hand console panel, displaying
“green’’. The indicator should be checked periodically during operation. If the hydraulic tank level indicator
turns “red” during operation, the quantity of hydraulic fluid has reduced to critical level. The reduction of
fluid quantity is caused by feakage. The leak shauld be located and repaired promptly. DO NOT operate the
crane when the indicator is red.

The hydraulic fluid must always be kept CLEAN and at the proper level to assure reliable operation of the
crane’s hydraulic system. If the presence of water or emulsification in the fluid is noticed, or if the fluid color
turns dark brown, the fluid should be changed as soon as possible.

The capacity of the hydraulic tank is 60 gallons (227 litres).

FUEL TANK LEVEL

The fuel tank level is checked with sight glasses installed in the wall of the tank. The capacity of the fuel tank
is 130 gallons (492 liters).

KILL VALVE

The kill valve (32), located on the right-hand engine panel, shuts off all the cab controls and kills the engine.
Prior to starting the engine this valve must be pulled up. To kill the engine, this valve is pushed down.

Page 8 Rev. Dec, 1978 -_-=

anwpe National Supply Company
Drasion of Armco Inc
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-4
LITHO IN USA

START VALVE

The star) valve (31) is located on the right hand engine panel. Jo start the engine first pul! the kill valve (32)
up. Pull up on the engine start valve to permit compressed air to pass to the engine’s air starter. Release the
start valve immediately after the engine starts. Refer to the engine manual for additional! starting
instructions.

ENGINE THROTTLE CONTROLS

The engine speed is controlled by on air throttle system consisting of a hand operated valve (21) and a foot
operated valve (17} working in conjunction by means of an air shuttle vaive. The hand operated valve may
be se! to any desired operating speed. When transporting Joods, the hand throttle should be set for a
minimum engine RPM of 1500. The foot throttle can then be used when the operator wishes to temporarily
increase engine speed.

CLUTCH OPERATION

A pneumatically operated, over-center, gear tooth clutch is installed between the engine and the triple
pump drive assembly. The clutch should be engaged only at low engine idle speed to prevent overheating
ond excessive fining wear. To engage the clutch pull up on the clutch controt valve (35) and hold for
approximately five seconds. To disengage the clutch, push down on the clutch valve and hold for
approximately two seconds.

HYDRAUUC SYSTEM GAGES

Three pressure gages located on the right hand control panel indicate the pressures of the cranes hydraulic
circuits. The “MAIN” gage (4) indicates the pressure required for operating the main or whip line hoist. The
“BOOM” gage (2) indicates the pressure required for operating the boom hoist. The “SWING” gage (3)
indicates the pressure required to swing the crane. The “MAIN, “BOOM” and “SWING” gages should
register approximately zero pressure with the control handles in the neutral position. Under normal
operating conditions the pressure registered by the above gages should not exceed 3500 psi (241.4 bar},

The three charge pressure gages, located in the right hand rear panel, indicate the pressures required to
insure safe operation of the hydraulic systems. The “BOOM” charge pressure gage (13) indicates the
pressure generated by the boom pump charge pump. The “MAIN” charge pressure gage (14) indicates the
pressure generated by the main/whip pump charge pump. The “SWING” charge pressure gage (12}
indicates the pressure generated by the swing pump charge pump. These gages should register pressure
varying between 160 and 300 psi (11/20.7 bar}. The pressure generally with increase with engine RPM.
Should the charge pressure not fall within these limits, a problem may exist with the hydrosiotic
transmission.

The “control pressure” gage (11) indicates the discharge pressure of the control pressure pump. For proper
brake operation, the control pressure must be from 700 to 750 psi (48.3 to 51.7 bar).

AIR PRESSURE REGULATOR AND GAGE

_« The air pressure regulator (22) and goge (10) are located in the right hand rear panel. The regulator should
be adjusted to maintain an air pressure between 95 and 100 psi (6.6 and 6.9 bar).

Rev. July 1980 Page 9

ARMCO Nations! Supply Company
WZ Geeasen ot sean ine
 NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
BRAKE PEDAL

A foot brake pedal (16) is provided in the cab for setting the main and whip hoist brakes. This brake pedal is
primarily used for “running in’ new brake linings. It may also be used for drying wet brake linings or
removing rust from the brake drum by depressing the pedal while hoisting an empty hook. The brake pedal
also provides the operator with control of a load when the emergency load release function is actuated.

LOW BOOM LIMIT OVERRIDE

The low boom limit override valve (33) is located in the right-hand engine contro! panel. This valve allows
the ope ator to lower the boom below the limit established by the low boom angle limiter system, This valve
must be pulled up and held to lower the boom. The air horn will sound as !ong as this valve is held up. °

NOTE: This valve is provided to permit the boom to be placed in ao rest. Caution should always be
exercised when using this valve and the maximum negative boom angle of five degrees (5°)
should never be exceeded. This system is only to be used when no load is suspended from the
hook or block.

HORN VALVE

The horn valve (34) 1s located on the right hand console control panel, This valve is pushed to sound the air
horn,

TRIPLE PUMP DRIVE HOUSING LUBRICATION PRESSURE AND WARNING INDICATOR

Located at the rear of the pump drive housing is a gage (Fig. 13) for indicating the pressure of the oil used to
lubricate the triple pump drive’s gears and bearings. With the clutch engaged, the lube (lubrication) oil
warm and the engine set at 1800 RPM,this gage should indicate a pressure of 20 to 60 psi (1.4 to 4.1 bar).

The “triple pump drive low lube pressure indicator’ (7) located in the right hand control panel should
display “green” when the engine is running and the clutch is engaged. The indicator directly senses the
drive lubrication pressure. A failure in the drive lubrication system and subsequent ioss of lubrication
pressure will cause the indicator to display “red”. Should the indicator display “red” during crane operation,
the crane should be shut down as quickly as possible and the drive lubrication system malfunction corrected.
See page 77 for the necessary trouble shooting procedures. —

TRIPLE PUMP DRIVE LUBE OIL RELIEF VALVE

To protect the lubrication system for the triple pump drive, a relief valve is mounted on the discharge side of
the pump. The vaive is factory set to open at 100 psi (6.9 bar). No field adjustment should be required.

AIR SUPPLY LOW PRESSURE INDICATOR

Under normal operating conditions, the air supply low pressure indicator (9) in the right hand control panel
will be green. Should the air pressure to the controls drop from the normal 95/100 psi (5.5/6.9 bar) range to
75 psi (5.2 bar) the indicator will turn red. At this point crane operation should be terminated as quickly as
possible until proper air pressure is restored to the crane. If air pressure to the controls drops to 50 psi (3.4
bar) operation of the main and whip hoist will stop automatically.

ELECTRICAL COMPONENT BOX

This enclosure (40) contains a rectifier to produce a direct current from the 24 volt alternating current ond o fuse
., for the 24 volt D.C. circuit.

Page 10 Rev. Juty 1982 .

anwpe National Supply Company
Division at Armee ine
 HYDRAULIC PEDESTAL CRANE OS-435
LITHO is USA

TRANSFORMER

The transformer (43} reduces the crane electrical supply (240 or 120 volts) to 24 volts for use with the defroster fan.

CIRCUIT BREAKER CABINET AND LIGHT SWITCHES

The circuit breakers in the electrical circuit breaker cebinet (39) are provided to protect the crane electrical
sysiems from sustained overloads and are clearly marked as to their function.

The toggle switches (38) are for the crane boom lights, engine compartmentlights, ond cab light.

CAB HEATER

The operator’s cab heater, located on the rear cab wall is o thermostatically controlled electrical resistance
heater. The thermostat (37) and power switch (36) are on the side of the heater.

HYDRAULIC TANK HEATER

Installed in the hydraulic tank is an-electrical immersion heater for maintaining the hydraulic fluid at a
suitable temperature to protect the crane’s hydraulic system from the harmful effects of cold weather
start-ups. Temperature control is provided by meons of an adjustable knob located on the outside face of the
heater’s steel housing. The knob should be positioned with the pointer to provide a temperature setting of
75° 10 100°F (24° to 38°C).
NOTE: In order to prevent overheating and possible oxidation of the hydraulic fluid, the A.C. voltage
supplied to the tank heater is one-half of the nameplate voltage stamped on the heater
nomeplate. Therefore, a heater stamped 240 V.A.C. must be wired with 120 V.A.C., and a heater
stamped 480 V.A.C. must be wired with 240 V.A.C.

ENGINE BLOCK HEATER

The diesel engines are equipped with an electrical jacket water heater to protect the engine from harmful
effects of cold weather and facilitate cold weather starting. This heater is turned on by a circuit breaker in
the operator's cab and controlled by a thermostat in the heater. The thermostat should be set at 90°F (32°C).
The heater circuit breaker can be left in the “‘on” position at all times without harmful effects.

DAILY CRANE START-UP

Daily crane starting should be performed in the following sequence: (1) Inspect the crane in accordance
with the maintenance schedule, (2) Position the hand throttle in the low idle position, (3} Pull the kill valve,
(4) Push the clutch valve and hold for two seconds, (5) Pull the start valve, releasing immediately after the
engine starts, (6) Check the engine gages, (7) Allow the engine to warm up at low idle, (8) Pull the clutch
valve and hold for five seconds to properly engage the clutch, (9) Check all the hydraulic system gages for
correct readings, (10) Allow the crane to warm up before lifting loads, (11) Check the operation of all the
crane controfs before lifting loads.

— Rev. July 1982 | Page #1

ARMCO Natrona! Supply Company ¥ 5
Dena or ot aemer an:
 NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

COLD WEATHER STARTING NOTE

Cranes Equipped with Ether Aid Kit - If ihe ombient air temperature is in the range of +35°F (2°C)
to -20°F (-29°C}, an ether starting aidshould be used to assist in starting the engine,

DAILY CRANE SHUTDOWN

Daily crane shutdown should be performed in the following sequence: (1) Position the boom in a rest,
(2) Reduce the engine speed to low idle, (3) Push the clutch valve and hold for two seconds, (4) Push the kill
valve down and wait for the engine to stop, (5) Close all cab windows and doors.

CRANE LOAD RATINGS AND LOAD CHARTS

The load ratings of the crane change with load radius, boom length and number of lines in main hoist
reeving. All of the factors must be considered together. The load chart plate in the operator’s cab is a
tabulation of the ratings of the crane. Each plate is matched to a boom length. When the weight of a load
and the radius of the load are known, the load rating versus load radius table should be consulted to confirm
the load does not exceed the rating of the crane at that radius. If the load is within the rating of the crane,
the reeving chart should be consulted to determine the minimum numberof lines of reeving needed to lift
the loods. Loadslifted by the main and whip hoists should not exceed load ratings given on the load chart
piate in the operator’s cab.

CAUTION: The operation of the crane during periods of high wind velocity is potentially dangerous. High
winds increase the stress on certain structural members. A combination of operator action,
heavy load and high winds could cause structural damage. Suspended loads may be tossed
obout and collide with the crane or other structures. Always exercise extreme care when the
crane is operated in high winds.

Page 32 Rev. July 1980 —?

ARMCO National Supply Company
TT an NP Denes ot armco me >>
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4 LITHO IN USA

LUBRICATION
HYDRAULIC FLUID*
CAUTION: When adding or changing the hydraulic fluid it is very important that every precaution be taken to
prevent any contamination of the hydraulic fluid.

Do not mix different types of hydraulic fluids.

The following fluids are recommended:

First Choice — Automatic Transmission Fluid, Type F

Second Choice — Automatic Transmission Fluid, “Dextron’’
Third Choice =— Hydraulic Oil, Premium Grade with Anti-Wear Additive,
48-55 SSU at 210°F (6.8-8.9 cSt at 100°C),
Minimum Viscosity Index 170

Tank Capacity — 60 U.S. Gallons (227 Litres)

Filters — Change Every 200 Hours or 2 Months

SHAFT ASSEMBLIES AND SWING GEAR REDUCER*

Use Industrial Mild EP Gear Oil

AMBIENT TEMPERATURE AGMA MILD-EP LUBRICANT NUMBER

40°F to 140°F AGMA Mild EP #5 SSU 918-1122 at 100°F
-20F to 60°F AGMA Mild EP #2 SSU 284-347 at 100°F

4,49C to 60°C AGMA Mild EP #5 cSt 198-242 at 37.89C

-299C to 16°C AGMA Mild EP #2 cSt 61-75 at 37,8°C

Capacity
Boom - 11 U.S. Quarts (10.4 Litres)
Main and Whip - 24 U.S. Quarts (22.7 Litres)
Swing Gear Reducer - 13 U.S. Quarts (12.3 Litres)

TRIPLE PUMP DRIVE*

It is recommended that the same oil that is used in the crane’s hydraulic system be used in this unit. Care
must be exercised NOT to overfill the drive case as severe damage to the chain will result if it is run
submerged in the lubricating fluid.

Capacity - 36 U.S. Quarts (34 Litres}

AIR LINE LUBRICATOR

The hydraulic fluid, as used in the crane’s hydraulic system, should be used in these lubricators. Do not
overfill.

BRAKE CYLINDER OIL RESERVOIRS

The hydraulic fluid, as used in the crane’s hydraulic system, should be used in these reservoirs. The reservoirs
should befilled only % full.

*Change oil every six months or as frequently as operating conditions require to maintain a clean, sludge
free oil.

= Rev. Dec. 1978 Page 13

ARMCO National Supply Company ev. Dee. age
Dwision of Armco Inc
NATIONAL
UIHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
GREASEFITTINGS

Figure 2 shows the greasefittings on the OS-435 pedestal crane. The following fittings should be lubricated
daily:

A. Boom foot (2 fittings in frame woll beside the hydraulic tank)

The following fittings should be lubricated weekly:

B. Swing bearings and swing pinion (7 fittings in frame wall beside the hydraulic tank)

c, Air throttle actuator (2 fittings)

Radiator fan sheave bearing, roller sheave bearing, and turbocharger (where applicable)

Triple pump drive clutch (3 fittings)

Lock pawl pin

. Gantry sheaves (5 fittings)

Floating block sheaves(5 fittings)

Turn sheaves(6 fittings)

K. Main load sheaves(5 fittings)

L. Sheave extension sheave

M. Load block (sheaves and swivel)

N. Overhaut ball

The following bearings should be inspected monthly and lubricated as required:

Main, whip and boom hoist brake linkage bearings.

The recommeded greases are:

Warm Weather — Number 2 EP Lithium Base Grease

Cold Weather — Number | EP Lithium Base Grease

SWING GEAR AND PINION TEETH

The teeth should be kept coated with Jet Lube, Inc., ‘“Kopr-Kote” compound or an equivalent lubricant.

Page 14 Rev. Dec. 1978

ARMCO National Supply Company
Division a} Armeo ine
NATIONAL HYDRAULIC PEDESTALCRANE OS. ITHO INUSA

LUBRICATION POINTS

Figure 2 LT-160001

—_= Rev. Dec, 1978 Page 15

ARMGO National Supply Company " “
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435
FILTERS AND CONDITIONERS

Clean fluid is essential for the reliable operation of the crane’s hydraulic system. Therefore, filters have
been installed in the system to eliminate contaminants and increase the life of the hydraulic system
components.

SUCTION LINE FILTER - CHANGE EVERY 2 MONTHS OR 200 HOURS

The suction line filter (Figure 3) is located beneath the hydraulic fluid tank and contains two throw-away
elements separated by an adapter which must be retained when the elements are replaced. The elementsin
the suction line filter should be changed every two months or every 200 hours, whichever occurs first. There
is also an indicator in the filter head that can be used for daily checking of the condition of the filter elements.
If this indicator reads, ‘NEEDS CLEANING” when the hydraulic ail is warm and the engine is at full RPM, the
filter elements should be changed immediately.

NOTE: The recommended element change interval should be followed even if the indicator reads
“CLEAN” after 200 hours or two months of element usage.

To replace filter elements, first close the tank to filter valve, and drain the filter housing by removing the
magnetic plug located under the filter. Then remove the filter head, elements, and assembling rod. Clean
the magnetic plug and assembling rod magnetics and then reinstall. Insert new elements being sure that the
adaptor has been inserted between them. Carefully replace the filter head, taking precautions to properly
seal the filter cover ““O’’-ring in its groove.

IMPORTANT - OPEN TANK TO FILTER VALVE BEFORE STARTING CRANE ENGINE.

SUCTION LINE FILTER

INDICATOR - - COVER

BYPASS VALVE

MAGNET ASSEMBLY

ELEMENTS

ADAPTER

OUTLET

Figure 3 LT-160002

Page 16 Rev. Dec. 1978

ARMCO National Supply Company
Owision of Armeo Ing
NATIONAL HYDRAULIC PEDESTALCRANE =O
HIGH PRESSURE IN-LINE FILTERS - CHANGE ELEMENTS EVERY 2 MONTHS OR 200 HOURS

The main/whip, boom and swing high pressure hydraulic circuits are equipped with high pressure filters
designed for reversible flow operation. Thesefilters (Fig. 4) each contain a single element which should be
changed every two months or every 200 hours of operation, whichever occurs first. The main/whip circuit
filter is installed in the high pressure tubing line forward of the main/whip pump. The boom circuit filter is
installed in the high pressure tubing on the left side of the boom motor. The swing circuit filter is installed in
the high pressure tubing above and beside swing gear reducer.

A “Pop-out’” type indicator is installed in each filter head for periodic checking of the element. In order to
check the element's condition, the hydraulic oi! must first be warmed up and the red indicator bution reset
by pushing the button. Next the cab control lever associated with the filter to be checked should be pushed
forward completely with the engine at full RPM. This action will cause a full flow of oil through the filter. If
the red button pops out during this operation, the filter should be changed immediately.

To change an element of a high pressure in-line filter, first unscrew the bowl of the filter with a wrench
attached to the 1-1/8’ hex boss attached to the bottom ofthe filter bowl. Carefully lower the bowl away
from the filter head assembly and gently pry the element loose from its mounting. Push a new element into
the filter head and then screw the bowl back into place being careful not to damage the sealing “O” ring or
back-up rings in the filter head.

NOTE: Be certain the bowl is properly tightened when reinstalled in filter head.

IN-LINE FILTER

BYPASSING
DIRTY ELEMENT INDIGATOR—~“_ H— FITERING

REVERSE FLOW VALVE

-FSLTER ELEMENT

a
°N--DRAIN: PLUG

Figure 4 LT-160003

PUMP DRIVE HOUSING LUBEOIL FILTER

An oil filter is located in the suction line of the pump drive housing’s lube oil pump (Fig. 5). This filter is
mountedto the side ofthe triple pump drive housing. The wire cloth element in the filter should be cleaned
every two months.

To clean the wire cloth element, disconnect the hose from the top of the filter housing and then remove the
four 1/4” screws that hold the bowlto the filter head. Lift the head away from the filter bowl, and then
unscrew the element from the filter head. Clean the wire cloth element and bowl, and reassemble.

_—= Rev. Dec. 1978 Page 17

ARMCO National Supply Company 8
VY omsionot armeaine
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
LUBE Oil FILTER

TO LUBRICATION PUMP

CLEANABLE
ELEMENT——

FROM TRIPLE PUMP

ORIVE CASE SUMP ———

Figure 5 LT-160004

CONTROL PRESSURE SYSTEM FILTER - CHANGE ELEMENT EVERY 2 MONTHS OR 200 HOURS.

The control pressure system is provided with a separatefilter to isolate it from contamination generated by
the hoist and swing hydraulic systems. The filter is mounted on the inboard side of the triple pump drive in
the suction line of the control pressure pump.

The filter (Fig. 6) utilizes a disposable cartridge type element. To change filter elements, the used element is
unscrewedfrom the filter head and the new element is installed in its place. The element should be hand
tightened, only.

HYDRAULIC TANKFILL FILTER

Fluid is added to the hydraulic tank by means of a hand pump. This pump and the fluid fill filter are located
on the hydraulic tank. This single element filter is provided between the hand pump and the hydraulic tank
to filter all fluid being added to the hydraulic tank. This filter element should be changed whenever the
crane’s hydraulic fluid is changed. Directions for changing the element are included in each new element
box.

P; 18 Rev. Dec. 1978 -_

age ey. Dec ARMCO National Supply Company
Divis:on of Armco tne
NATIONAL HYDRAULIC PEDESTAL CRANE OS-43
LITHO IN USA

CONTROLPRESSURE SYSTEM FILTER

BYPASS VALVE HEAD
|

FLOW

_SPIN-ON
ELEMENT

Figure 6 LT-160043

AIR DRYER-PURIFIER

All crane control air is dried and filtered prior to being used. The compressed air dryer-purifier is located on
the outside of the rear wall of the operator’s cab. This is a desiccant type dryer and should be serviced every
six months.

To service the dryer, follow these steps:

1. Cut off air supply to the dryer-purifier and drain the air pressure from the small air receiver.

2. Remove the top retaining nut using a 13/16 end wrench and remove the cap and bypass spring.

Using the bail, remove the canister from the housing. It may be necessary to loosen the canister from the
housing by using a twisting back and forth motion while pulling upwards.

. Lightly lubricate all the O-rings.

Using a rotating motion to properly seat the O-ring below the housing shoulder, install the replacement
canister.

Replace the cap and bypass spring and secure with the retaining nut.

Restore the air supply to the dryer-purifier.

NOTE: Replacement desiccant canisters should be stored in a dry place.

—) Rev. Dec. 1978 Page 19

ARMCO National Supply Company
Vv Dwisian at Armco ine,
NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435
AIR DRYER-PURIFIER

DESICCANT CANISTER ——

——— FILTER SCREEN

sue” | - BLOW -DOWN VALVE

Figure 7 LT-160005

AIR LINE LUBRICATOR (CAB CONTROLS)

The air line lubricator is a dynamic device. Oil is delivered into the compressed air line only when air is
flowing through the lubricator. The lubricator is mounted on the small air receiver on the rear wall of the
operator's cab.

An oil feed adjusting screw is provided on the top ofthe lubricator. Rotating the oil feed adjusting screw
clockwise reduces the drip rate, counterclockwise increasesthe drip rate. Once the setting is established the
lubricator will automatically adjust the drip rate with changes in flow. The drip rate should be adequate to
provide a light film of lubrication for the seals and bearings of the air valves.

The drip rate is adjusted byfirst establishing a moderate air flow through the regulator. Next pull the red lock
ring up and turn the adjustment screw to the desired drip rate. Finally push the red tock ring back into place.
The rate of air lubrication should be observed for several days and adjusted further as may be required.

NOTE: DO NOT OVERFILL LUBRICATOR RESERVOIR,

Page 20 Rev. Dec. 1978 =_

8 ARMCO National Supply Company
VV awision of Armco ine.
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

AIR LINE LUBRICATOR

ADJUSTMENT SCREW
WITH LOCK RING

SIGHT GLASS

HEAD-

ORAIN

Figure 8 LT-160006

poe POW MoA netap ot

OE:

Nai Rev. July 1980 Page 21

Aap Oversion et Ater cotne,
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435

ELECTRICAL SCHEMATIC FOR CATERPILLAR ENGINE CRANES

neu {CRANE PEDESTAL @ELOW SWING BEARING NOT APPLICABLE)
POWER
| TO THIS ORDER

=
—COLLECTOR RING
z 415/230 VAC

_-~ CRANE FRAME

see prawine /G/Z009-E00 &
—
°

CIRCUIT GREAKER A P EN
aT 3 AAsrAmens cmeeree
{J gts Fo WHT, ENGINE BLOCK HEATER AN ° PPI DIX

CROWT BREAKER *Z

|
stole
ox
ate 12 WHT HYDRAULIC TANK HEATER

Z| zl CIRCUIT BREAKER “3
al2 |
4 stp
ek
wr. az
= BOOM LIGHTS
5) 8
sla
s| 5. CIRCUIT BREAKER “4
8| §
“14
Ty
aw WHT. BOOM BEACON

; GANTRY BEACON

CIRCUIT BREAKER ¢7
stpTor y
4 an WHT,

6
FRAME LIGHTS

CONVENIENCE OUTLETS
id “ek ae we. ==

| eaSra2 wart 1 CAB HEATER

ccuIT BREAKER “5
hii) ENGINE GLOW PLUGS
oad L

iene went CS |

ENGINE WATER TEMPERATURE

NOTE ; OPERATOR'S CAB MUST BE GROUNDED TO CRANE FRAME

Figure 9A LT-160007
rect mes ER oa on

Page 22 Rev. Jul —)

38 ev. July 1980 Aig National Supply Company
Dw:sion of Armee ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

ELECTRICAL SCHEMATIC FOR

DETROIT DIESEL ENGINE CRANES

urgr GETOMNE PEDESTAL BELOW Swng BEARING NOT APPLICABLE

POWER gO THIS ORDER

—COLLECTOR RING
98/230 Vac

_ERANE FRAME
__ENGINE BLOCK HEATER (IS VAC) ENGINE BLOCK HEATER (230 vac)

HES See) | PP
| cimcurr eneaKen “1 | { CIRCUIT BREAKER |
] T to] Tore

| eee)
Lae eS]| He
aan zal!
4 CROAT BrcAreR a
are LK
Ve 2wat Hana! HYORAULIC TANK HEATER

CIRCUIT QREAKER *3
| ht. .
Lhe soon Laws
CIRCUIT BREAKER “4

Te sn Tak “ 800M BEACON

2a a re GANTRY BEACON
8 g §
Za =
3 4 CIRCUIT BREAKER °7
qa— ot )
at Paaee wr,
73 Co
2 a FRAME LIGHTS
+ OHO
OF 0}
CONVENIENCE OUTLETS
aa "6 x ——e oe =e sy

Ly aa ta-2, eg ee {CAB HEATER

LS|
CIRCUIT BREAKER “5 .

i
—EABL_EAN -
; 1 wenn (ro1
te t cee
isiscoat + 5
GAGE LIGHTS .

Que ENGWE TACHOMETER

CF (Ps FY] enone OW PRESSURE

O “16 pin Pi] ENGINE WATER TEMPERATURE

NOTE: OPERATOR'S CAB MUST BE GROUNDED TO CRANE FRAME

Figure 9B LT-160049

Sage National Supply Company Rev. July 1980 Page 23

Dewsion of Armco inc
 S3ATWA ONY CIOdINVA
BATVA TOULNOD S>Iv¥E
Ol asnBiy NBL INTER! SIO NOOB
2£09T-11
OS-435

BATWA ONITOH L8IOH WOOS:

BATWA ¥OL0313S 1SIOH
BATWA SNICTOH LSIOH dIHm / NIV S
HLIM BiV1dENS 3AIWA YQLII1SS ISIOH:
d °
ee
HYDRAULIC PEDESTAL CRANE

a National Supply Company

i
Q
HOLYYSdO BATVA »
¥OLOIT3S LSIOK

Division ot Armco I Inc

Wy

—
HSONTIAD 3NVHG LSIOH dIHM.
NOINId ONIMS “HH
29NG3U YV3S ONIMS HY

Rev. July 1980

NATIONAL LITHO IN USA.

Page 24
HLIM UOLON SNIMS HT
Dive ONIMS HT LINIWLYVdWOD AOLOW SIINVIGAH
 60009T-47 LL aan6iy
LITHO INUSA

BAVA 43138 3YOSS3¥d TOYLNOD- ——— 3

TOdNVW NIVEA 3SVO— NOULINS—
OS-4

= i
BAIWO DWNd F1dIXL— ——7 f — _ ¥3Lg NOUSRS
WN 3H
i |

Page 25
Wg LSIOH WOOR |
SATA 430.045,
LOUNYL DNWAdAH
LOOT é
“
et { 7
Ee:
@
1 ¢
8 .

Rev. Dec, 1978

a
VAS + Wd SNIMS, ies ' \
HYDRAULIC PEDESTAL CRANE

YBONITAD NOSLNOD HOLM

-- yg.05 INT-NL |
ASIOH SHA / NIV
Hy dWAg SUNSSIYd TOMLNO: e3vaH Yiu
aS co oningadak |
HBONITAD
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\ . : AMSOWY3HL -—
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SNISNOH BELOIT 431114 NOLLONS / NS “ ao
BYNSSINd TOYLNOO— / Kept °

ape National Supply Company

Wd TMs ¥ ~~
on
ee

Division of Armes Inc

BaHLvaye WNVL—

mee
NATIONAL

~ ——— 831003 CMs IIAVEOAM

LIN3WL3¥dWOD INION3
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435

REAR CAB WALL

GHECK vane / DRYER

/ /

fp
RELIEF VALVE

SMALL AIR RECEIVER

CUT OFF VALVE =

DRYER BLOW-DOWN
/- VALVE

CONTROL AIR ‘
© LUBRICATOR :

AIR PRESSURE GAGE i

NN / |

MANIFOLD —
DRAIN VALVE —

Figure 12 LT-160010

Page 26 Rev. Dec. 1978 —

ARMCO National Supply Company
Vv Division of Ameo tne,
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA

TRIPLE PUMP DRIVE

TRIPLE PUMP DRIVE HOUSING

©

7 INPUT SHAFT

-iNSPECTION COVER
BREATHER

CONTROL PRESSURE
ORIVE LUBE OIL FILTER / PUMP SUCTION FILTER

LUBE OIL PRESSURE oe

CHAIN sae mee

!
LUBE OIL RELIEF VALVE—>
(OPENS ATIOOPSI] 7
/
RELIEF VALVE 7
DRAIN 4
OIL LEVEL
DIPSTICK
Sep ON
y \

LUBE OIL pump — ‘ \- contRon PRESSURE PUMP

—-LUBE MANIFOLD

AID
ay
SUMP DRAIN VALVE

|i
| INDICATOR IN OPERATOR'S caw»

Is NN PUMP DRIVE HOUSING LUBE OIL COOLER

Figure 13 LT-160011

_—, Rev. Dec. 1978] Page 27

ARMCO Nationa) Supply Company
Vv Dwision of Armco Inc
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
FIXED MOTOR AND VARIABLE PUMP

MANIFOLD

HIGH
PRESSURE
RELIEF VALVE

CYLINDER
BEAXING BLUCK TRUNNION

PUMP

-
A
OS
ee
i ier
oP STON
SERVO 4 “ —
CYLINDER SERVO
>1STON

Figure 14 LT-160012

Page 28 Rev. Dec. 1978 _

ARMCO National Supply Company
Vo owsianat armeaine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA

HYDROSTATIC DRIVE

With the exception of the charge pressure, lubrication and control pressure pumps, all pumps and motors are
of the axial piston type. These are incorporated for their high efficiency, long life and trouble free service.

Each system (main hoist, whip line hoist, boom hoist and swing) is a closed loop hydrostatic drive.

The hydrostatic drive offers infinite contro! of speed. The operator has complete contro} of the system with
one lever for starting, stopping, load hoisting, or foad fowering. The dynamic braking capabilities inherent
with the closed loop hydrostatic drive provide normal braking requirements.

Control of the variable displacement, axial piston pump is the key to controlling the hoist or swing functions.
Engine horsepower is transmitted to the pump. When the operator moves the contro! lever, the swashplate in
the pump is tilted from neutral (camming the pump). The position of the control lever will determine the
angle of the swashplate and, therefore, the volume of oil delivered by the pump. The contro! lever is
stepless; therefore, the speed of the hoist or swing is infinitely variable from zero to maximum.

The variable displacement, reversing swashplate pump is controlled by a servo system. The pump control
lever can be moved to some predetermined position with the servo system moving the swashplate of the
pump to this predetermined point. The use of a servo system on the variable pump controls permits a
minimum force requirement to move the pump control handie.

When the variable pump swashplateis tilted, a positive stroke of the pistons is created. This, in turn, at a
given input speed, produces a certain flow of oil from the pump. This flow is transferred through high
pressure lines to the motor. The ratio of the volume offlow from the pump to the volume displacement of the
motor will determine the speed of the motor output shaft. Moving the control lever to the opposite side of
neutral, the direction of flow from the pump is reversed and the motor output shafi turns in the opposite
direction. Speed of the motor output shaft is controlled by adjusting the volume displacement (flow) of the
pump. Working pressure is determined by the load and this establishes the demand on the system.

The crane’s hydrostatic drive system consists of: pumps, motors, selector valve, holding valves, and pump
manifold block.

amon National Supply Company . . 197}

ARMCO Rev. Dec. 1978 Page 29
Division of Armco ine.
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435
PUMPS

The main/whip hoist pump is a variable displacement axial piston type pump mounted on the top mounting
pad ofthe triple pump drive. It receives power from the engine through the drive shaft of the triple pump
drive. This pump supplies the high pressure fluid for both the main and whip line hoist operations.

The boom hoist pump is a variable displacement axial piston type pump mounted on the bottom right
mounting pad ofthe triple pump drive. It receives power from the engine through the chain and sprockets
contained within the triple pump drive housing. This pump supplies the high pressure fluid for the boom
hoist operation.

The swing pump is a variable displacement axial piston type pump mounted on the bottom left mounting
pad ofthe triple pump drive. It receives power from the engine through the chain and sprockets contained
within the triple pump drive housing. This pump supplies the high pressure fluid for the swinging operation.

CHARGE PUMPS

Mountedto the rear of each axial piston pump is a gear type charge pump. The purpose of the charge pump
is to provide an exchange offluid in the hydrostatic drive circuit. The charge pump also provides sufficient
fluid under pressure for pump servo control purposes and for internal pump and motor leakage make-up.
The charge pump addsfluid to the hydrostatic circuit through two check valves behind the pump.

BOOM AND MAIN/WHIP CHARGE SYSTEM

MAIN PUMP

let ~—CHEGK VALVE

a
BOOM PUMP
ADJUSTING SCREW

af \—rtow resucator

Figure 15 LT-160013

The charge pump of the main/whip pump has a displacement of 2 cubic inches per revolution. The charge
pump of the boom pump has a displacement of 4 cubic inches per revolution. The main/whip and boom
charge pumps are connected by way of flow regulator and check valve arrangement which permits a
portion of the boom charge pump flow to pass into the main/whip circuit. This arrangement provides greater
charge pressure flows and higher charge pressures for lubricating and cooling purposes than what could
normally be provided by having 2 cubic inch charge pumps on both the main/whip and boom pumps.

Page 30 Rev. Dec. 1978

Bs éamco National Supply Company
Division of Arenco inc.
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4
LITHOINUSA

ADJUSTMENT OF BOOM AND MAIN/WHIP CHARGE SYSTEM FLOW REGULATOR(Figure 15)

From fully closed (screwed-in) position, the adjusting screw of the flow regulator should be backed out
3-1/4 turns. This position of the adjusting screw will permit the correct proportion of flow to pass from the
boom charge pumpinto the main/whip charge system. Never operate the crane with the adjusting screw of
the flow regulator fully closed, in order to prevent excessive case drain pressures in the boom pump and
motor. After adjustment of the valve tighten the adjustment screw jam nut while holding the adjustment
screw.

CASE DRAIN FLUID

Case drain fluid is the hydraulic fluid which fills the cases surrounding the moving parts of the pumps and
motors. This fluid is made up of the internal leakage from the pump and motor and excess discharge flow
from the charge pump. Since the charge pump replenishes internal leakage, case drain flow should always
equal the discharge flow of the charge pump.

The cooling of a hydrostatic drive is accomplished by removing a requlated amount of fluid from the low
pressure side of the hydrostatic {oop and directing the hot fluid into the hydraulic motor case. From the motor
case the fluid flows to the hydraulic pump case and down to the suction - case drain manifold block. From
the manifold block, the hot fluid is directed to the thermostat valve and then through the oir-to-fluid heat
exchanger. The cooled fluid is then returned to the hydraulic tank. Since the amount of fluid in the
hydrostatic circuit must remain constant, the regulated amount of fluid removed fram the low pressure side
of the hydrostatic circuit is replaced by the fluid from the charge pump. The source of fluid for the charge
pump is the hydraulic tank. The regulation on the amount of fluid leaving the hydrostatic circuit is
accomplished by using a relief valve and a pressure sensing shuttle valve. NOTE: The maximum allowable
case drain pressure is 40 psi (2.8 bar). Normally case drain pressure is approximately 5 psi (.3 bar).

PUMP CONTROL _

The volume displacement and direction of the flow of fluid from an axial piston pump is controlled by a
displacement control valve mounted on each pump. The control valve is used to direct fluid from the charge
pump to the axial piston pump servo cylinders for tilting the swashplate, which produces flow from the
pump.The position of the swashplate is sensed by the control valve. The valve comparesthe position of the
external control lever and position of the swashplate and directs fluid to the appropriate servo cylinder.

The external control levers of the main/whip, boom and swing pumpsare actuated by air cylinders which
extend or retract due to air pressure from control valves in the operator’s cab. NOTE: When the cab control
levers are in neutral, the actuating cylinders should not be pushing or pulling on the pump control levers.

DISPLACEMENT CONTROL VALVE OPERATION(Figure 16)

The axial piston pumps incorporate a powered servo system to control the swashplate with minimum
external effort. The valve assembly is a closed center four-way valve with the servo cylinder ports exhausted
at the center position. The valve is operated through internal linkage connections with both the swashplate
and the external control lever or handle.

To put the pump in stroke, cam the pump, the control handle (1) moves the displacement control spool
(2) through a torsional spring (3). The spool ports fluid from the charge pump at charge pressure (4) toa
servo cylinder (5). The piston moves the swashplate (6) against the opposite servo spring (7). Both servo
springs are constrained so they can only force the swashplate toward neutral. When the swashplate has
movedto the angle set by the control lever, the feedback link (8) returns the displacement control spool to
neutral until either the swashplate or control lever changes position.

The orifice (11), when used,restricts the incoming charge supply to limit the maximum servo responserate.
The torsional spring (3} allows the operatorto rapidly pre-select the desired speed setting without waiting
for the swashplate to follow-up.

Rev. Dec, 1978 Page 31

tional Supply Company
1 of Armen Ine
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435
When the control lever is returned to neutral, the displacement control spool is returned to neutral by a coil
spring (10). This allows the fluid from both servo cylinders to flow into the pump case through the small
underlaps(9). Both servo cylinders are thus exhausted and oneof the servo springs mechanically forces the
swashplate to neutral.

DISPLACEMENT CONTROLVALVE OPERATION

DISPLACEMENT CONTROL VALVE IN NEUTRAL DISPLACEMENT CONTROL VALVE OUT OF

NEUTRAL AND SWASHPLATE CAMMING

Figure 16 LT-160014

MOTORS

The main and whip line hoist motors are variable displacement axial piston type hydraulic motors mounted
on the shaft assemblies and are connected to the main/whip pump byhigh pressure tubing. These motors
are each equipped with a two position valve controlling the speed range of the motor (high or low).

The displacement, thus the speed range, of the main and whip motors is changed by directing main/whip
hoist system charge pressure to the lower servo cylinder for high speed or upper servo cylinder for tow
speed. The charge pressure is taken from the motor valve manifold through a 1/4 inch (6.4 mm) steel tube to
the side of the motor. At the side of the motor, the tubing connects with the internal porting of the motor. The
internal porting connects with the two speed hoist control valve on top of the motor. This valve then directs
charge pressure (through internal porting) to the appropriate servo cylinder while exhausting the pressure in
the opposite cylinder to the motor case.

The boom hoist motor is a fixed displacement axial piston type hydraulic motor mounted on the boom hoist
shaft assembly and is connected to the boom pump by high pressure tubing.

The swing motoris a fixed displacement axial piston type hydraulic motor mounted below the swing gear
reducer assembly. The swing motor is connected to the swing pump byhigh pressure tubing and hoses.

All hoist motors are mounted to the shaft assemblies with port “A” on the right.

Page 32 Rev. Dec. 1978

ARMCO National Supply Company
Duwision of Armee ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4LITHO iN USA

MOTOR MANIFOLD VALVE ASSEMBLY (Figure 17)

A manifold valve assembly is attached to the rear of each hydraulic motor. This valve assembly contains wo
pilot operated high pressure relief valves which serve to prevent sustained abnormal pressure surges in the
two high pressure hydraulic lines of each motor. The relief valve on the left side of the motor monitors the
pressure on the right side of the motor. The relief valve on the righ? side of the motor monitors the pressure
on the left side of the motor. Each relief valve has a two digit number stamped on the exposed end stating
the valve’s setting. For the main and whip hoist motors the relief valve stamped “50” is set at 5000 psi and
monitors the pressure required for hoisting or lowering a load. For the boom haist motor the relief valve
stamped “60”is set at 6000 psi and monitors the pressure required for hoisting or lowering the boom. The
relief valves stamped ‘15” are set at 1500 psi and monitor the pressure required to power down an empty
boom or hook. The retief valves of the swing motor are both stamped “45” and are set at 4500 psi.

The manifold valve assembly also contains a shuttle valve and a charge pressure relief valve. The shuttle
valve functions to establish a circuit between the hydraulic tubing line that is at the lower pressure and the
charge pressure relief volve. This charge pressure relief valve has a lower setting than the charge pressure
relief valve in the charge pump.Therefore, charge pressure will be relieved at the motor anytime the shuttle
valve has moved from its center position. This provides a methad of not only controlling the charge pressure
level, but also a method of removing some hot fluid from the hydrostatic circuit. This hot fluid is then
replaced by cool, clean fluid from the charge pump.

—_, Rev. Dec. 1978 Page 33

anwpe National Supply Company v: Bee Be
Dwigion of Armco ine,
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

MOTOR VALVE MANIFOLD ASSEMBLY

SWING SWING
MOTOR MOTOR
PORT
a" PORT
rad

Ze | v4 I
SWING MOTOR AR
SHUTTLE VALVE

Wi
WL f _SWING MOTOR CHARGE
we “i, PRESSURE RELIEF VALVE

SWING
MOTOR
CASE

HOIST HOIST
MOTOR MOTOR
PORT
va PORT
'
|

HOIST MOTOR ~t —
SHUTTLE VALVE —=

A, SS
hy ] - {HOIST MOTOR CHARGE
“ yy . PRESSURE RELIEF VALVE
a !
HOIST
MOTOR
CASE

~S i HIGH PRESSURE
SA v RELIEF VALVE

HIGH PRESSURE
RELIEF VALVE Oo

SN SN |
MOTOR MOTOR
PORT
oa PORT
e

Figure 17 LT-160015

Page 34 Rev, Dec. 1978 zo

anwpe National Supply Company
Diversion of Armee Inc
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA

SUCTION - CASE DRAIN MANIFOLD BLOCK (Figure 18}

This block is mounted on the floor forward of the triple pump drive and serves a dual purpose. The block
contains two seperate chambers with each chamber having provisions for hose fittings. One chamber
receivesfluid from the suction line filter and distributes it to each of the three hydrostatic drive charge
pumps. The other chomber receives case drain flow from each of the three hydrostatic drive pumps and
provides an outletfor the fluid to pass to the heat exchanger. Between the two chambersis a relief valve set
ata cracking pressure of 25 psi (1.7 bar). This valve permits some of the case drain flow to pass from the case
drain chamberinto the suction line chamber in instances when case drain pressure becomes excessive; such
a case could occur during a cold hydraulic fluid start-up.

SUCTION - CASE DRAIN MANIFOLD BLOCK

GASE GRAIN CHAMBER:

CHARGE PUMP.
SUCTION CHAMBER

CASE DRAIN
RELIEF VALVE

Figure 18 LT-260016

HOIST SELECTOR VALVE (Figure 19)

The hoist selector valve functions to direct the main/whip pump flow to either the main hoist motor or whip
line motor. This valve is a four-way, three-position, spring-centered directional control valve. The selector
valve is pilot operated by means of an air operated directional contra! valve (P-16) mounted directly to the
selector valve. This small directional control valve directs control pressure to the ends of the selector valve
spool.

_— Rev. Dec. 1978 Page 35

ARMCO National Supply Company
Division af Armee ine
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

HOIST SELECTOR VALVE

DRAIN

TO OR FROM MAIN MOTOR

COMMON TO PUMP AND MOTORS

Figure 19 LT-160017

Page 36 Rev. Dec. 1978 -_

ARMCO National Supply Company
Vo dwssioneAreca ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

HOLDING VALVES(Figure 20)

Two valves, check and flow control, contained in the same body constitute the holding valve. When hoisting
the check valve provides a direct path for fluid flow to the motor, bypassing the flow control valve. When
lowering a load, the check valve closes requiring the fluid to pass through the flow control valve which
prevents overspeeding of the pump or motor. The flow control valve compares the pressure on each side of
the pump and regulates the flow ofoi! accordingly. The holding valve will function properly only when the
hydrostatic drive is in sound operating condition. Two holding valves are used on the crane, one for the main
and whip hoists and the other for the boom hoist.

HYDRAULIC SYSTEM COOLING

The temperature of the crane’s hydraulic fluid is controlled by means of a thermostat valve located beside
the engine and an air to fluid heat exchanger mounted to the front of the engine radiator. When the case
drain fluid is cool the thermostat valve routes the fluid from the case drain chamber of the suction - case
drain manifold block back to the hydraulic tank, bypassing the air to fluid heat exchanger. After the
hydraulic fluid in the pump and motor cases reaches 145°F (63°C), the thermostat valve begins shifting to
direct the hot fluid to the air to fluid heat exchanger for cooling.

Rev, Dec. 1978 Page 37

ARMEO National Supply Company
Owision of Arma Ine
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

HOLDING VALVE OPERATION —

NEUTRAL

FLow control vaavet.{)

— . +i HOISTING
a te A LOAD
CHECK VAIYE —— é

FLOW CONTROL VALVE =

o—
LOWERING
A LOAD
CHECK VALVE

FLOW CONTROL vaLvE— cer

POWERING
kek wave DOWN WITH
ome NO LOAD

FLOW CONTROL valve =|

Figure 20 LT-160018

Page 38 Rev. Dec. 1978

ARMCO National Supply Company
Onvsion of Arma ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4
LITHO IN USA

HYDRAULIC TANK

The hydraulic tank is located in the engine compartment directly behind the operator’s cab. The tank is
equipped with a sight glass for checking the oil level, a micronic vent filter for protection from airborne
contaminants and a drain valve. The tank is also equipped with a hand pump and filter arrangement for
adding hydraulic fluid to the system. A valve installed between the hand pump andfilter must be closed
after adding fluid to prevent possible leakage back through the filter and pump.

Also installed in the hydraulic tank is an electric immersion heater for maintaining the hydraulic oil at a
suitable temperature to protect the crane’s hydraulic system from the harmful effects of cold weather
start-ups. The heater should be adjusted to a temperature setting of 75° to 100°F.

NOTE: THE HYDRAULIC FLUID LEVEL SHOULD BE CHECKED PERIODICALLY TO SEE THAT FLUID IS AT THE
PROPER OPERATING LEVEL.

SUCTION LINE SHUT OFF VALVE

Located between the hydraulic tank and suction line filter is a gate type shut off valve. This valve must never
be closed while operating the crane. Severe damage to the hydraulic system can occur if the hydraulic
pumpsare permitted to rotate with the suction line valve closed. The shut off valve should only be closedif
maintenance to the hydraulic system is to be performed. After the maintenance is completed the valve
should be opened immediately and locked with the valve stem lock.

HYDRAULIC FLUIDS

Only high grade hydraulic fluids, as specified on page 13, may be usedin the crane’s hydraulic system. If it is
necessary to add hydraulic fluid to the system, only the same type as in the tank should be used. The mixing
of different types of fluids is not advisable due to the possible incompatibility and neutralization of the
fluids’ additives.

If the presence of water or emulsification in the fluid is noticed, orif the fluid turns dark brown, the fluid
should be changed as soon as possible.

HOLDING VALVE ASSEMBLIES

HOIST SELECTOR VALVE

~ CHECK VALVE “Yyotoins

HOIST SELECTOR
‘VALVE OPERATOR a “FLOW CONTROLj VALVE
“d

CHECK Wi VALVE) or ong . of \e °

FLOW CONTRO! s } °

BOOM HOIST VALVE ASSEMBLY

MAIN / WHIP HOLDING VALVE ASSEMBLY

Figure 21 LT-160019

Rev. Dec. 1978 Page 39

al Nations! Supply Company
Owvisian of Armco tne
 NATIONAL
LITHO IN. USA.
HYDRAULIC PEDESTAL CRANE OS-435
HYDRAULIC SCHEMATIC

MAIN/ WHIP HOIST PUMP NOLIN VALVE,

MAIN HOIST MOTOR
401ST o—Lower —---- L\.-
oop Fire.
é MIGROS a)
(2 MICRONS Aas,

WHIP HOIST MOTOR~

¢
Lord
oom vow cnsnae
voistpate |
Sretetne Seras Le

|
|
|
cast on
(800m HOIST PUMP ocoins vauve

oe
rt) + — r oF
t{Zoran actuaron nowT—= Lowen i
: 71
ee ee i
| Sit | ssa sen rite i
| cba) / | |
bon LoweR—e Hover
i
iba
|i |i 11
di
Te coo
io
CARE DRAIN

LEFT —enicat

SWING PRESRURE SHUTTLE VALE

LOOP FILTER
2 WICKON HOM
1 MICRON ABS.

Lo Righter enert i
case onaie mC, RELEASING VALVES &—-
Suction
_—_—... mas 4 OOM HOIST BRAKE CYLINDER

SUCTION
|
:
| 1 CASE DRAIN,
om
c
lot encrn
say ont coun tw san exnasen Ey meres L
LOCK PAWL FLOW CONTOL VALVE
33 tigmow Now.
HORAULIC 1Tan ra Ly CHEEK VALVE,
‘Lock MAIN & WHIP HOIST BRAKE PEDAL,
as J.
CONTROL PressuRE
RELIEF VALVE:
: bao
CASE DRAIN ee itd
Pal
an worst
BRAKE CYLINDER
4
uu
SWING BRAKE CYLINOER

“Paes suRE TAP

Figure 22 17160020

Page 40 Rev. Dec. 1978

ARMCO National Supply Company
Dension at ArmesInc
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4
LITHO INUSA

HYDRAULIC CONTROL CIRCUIT

The purpose of this control circuit is to operate hydraulically the brakes, boom hoist lock pawl, and hoist
selector valve.

The hydraulic fluid enters the control circuit from the case drain manifold block through the control pressure
circuit filter and control pressure pump. Control pressure is maintained at 700/750 psi (48.3/51.7 bar) by the
control pressure relief valve.

The circuit consists of a control pressure pump, control pressure relief valve, control pressure filter, brake
releasing valves, check valve block, brake pedal, brake cylinders and lock pawl cylinder and hoist selector
valve pilot valve.

CONTROL PRESSURE PUMP (Figure 13)

The control pressure pump is a fixed displacement gear pump mounted on the engine side ofthe triple pump
drive housing. The suction line for the pump is connected through the filter to the top of the case drain
manifold block. The high pressure discharge hose from the pump is routed to the control pressure relief
valve and to the brake control manifold. See page 77 for trouble shooting procedures.

CONTROL PRESSURE RELIEF VALVE (Figure 23)

The control pressure relief valve maintains a 700/750 psi (48.3/51.7 bar) pressure in the control circuit. It is
mounted to the crane frame betow the hydraulic tank.

Control pressure is adjusted by observing the control pressure gage in the operator’s cab while screwing the
adjustment screw in to increase the pressure and out to lower the pressure. See page 77 for trouble shooting
procedures.

CONTROL PRESSURE RELIEF VALVE

DRAIN PORT—
\

JAM NUT

ADJUSTMENT
SCREW COVER

NN
L poyustwent
SCREW

\ PRESSURE PORT

Figure 23 \T-160021

_-= Rev. Dec. 1978 Page 41

ARMEO National Supply Company Bi
D w-sion of Armco Irs,
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435
BRAKE RELEASING VALVES (Figure 26)

Directional control valves are used to direct control pressure fluid to the boom hoist lock pawl and all brake
cylinders. The brake releasing valves are mounted to a manifold located above the swing geor reducerat
the rear of the main frame. The brake releasing valves are pneumatically actuated, 2-position, 3-way valves
equipped with manual over-rides to assist in trouble shooting.

HOIST SELECTOR VALVE OPERATOR (Figure 19)

The directional control valve (page 36) used to control the hoist selector valve is a pneumatically acutated,
3-position, 4-way valve mounted directly to the hoist selector valve. The spool of the hoist selector valve
operator is controlled by air pressure from the selector valve (V-4) in the operator’s cab. This small
directional control valve then directs control pressure to one end of the hoist selector valve spool as
determined by the choice of main or whip hoist.

CHECK VALVE BLOCK (Figure 27)

The check valve block is used to direct control pressure to the brake pedal when either the main or whip
brake is released. The check valve block is located above the brake valve manifold, and contains two check
valves and two pressure tap fittings. The pressure taps are provided for the quick and convenient checking of
control pressure to the main or whip brake cylinders. A hose-gage assembly equipped with a companion
fitting for the pressure taps is provided with each crane. :

BRAKE PEDAL (Figures 1 and 30)

The brake pedal is used to dry wet brake linings on the main and whip hoists, and to removerust from brake
drum on cranes that have not been worked frequently. It also provides the operator with control of a load
when the emergency load release function is actuated. The body of the brake pedal contains a direct acting,
pressure regulating valve that permits pressure in the main and whip hoist cylinders to be exhausted when
the brake pedal is depressed. See page 58 for adjustment procedure.

BRAKE AND LOCK PAWL CYLINDERS

These cylinders are all spring applied and hydraulically released by control pressure. Disc springs contained
within a hoist brake cylinder set the brake when a control handle is in neutral. When a hoist control handie is
moved out of neutral, control pressure is directed to the hoist brake cylinder where it compresses the springs
and releases the brake. The swing brake incorporates 6 coil springs which are compressed as control
pressure enters the brake cylinder. The swing brake is controlled by a valve (V-2) in the operator’s cab. The
lock pawl cylinder is returned by a tension coil spring. This spring is extended when control pressure enters
the lock paw! cylinder. The lock paw! cylinder and boom hoist brake cylinders operate simultaneously, being
controlled by the boom hoist control handle.

LOCK PAWL CYLINDER FLOW CONTROL VALVE (Figure 24)

A flow control valve is installed in the hydraulic line to the lock pawl cylinder. This valve permits free-flow
into the cylinder but provides controlled flow from the cylinder. This flow characteristics provide quick pawl
release when the control handie is moved out of neutral, but relatively slower paw! re-engagement when
the contro! handle is returned to neutral. The slower rate of pawl re-engagement permits the boom hoist
brake to set prior to the Jock paw! and provides for smoother operation of the boom hoist shaft assembly. The
flow control valve should be adjusted to regulate the rate of the cylinder’s full rod extension (engagement
stroke} to three seconds.

Page 42 Rev. Dec. 1978 —_—

ARMCO National Supply Company
VV owision of armeo ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

LOCK PAWLCYLINDER FLOW CONTROL VALVE

i. SPRING

\_/
\O / ~-ADJUSTMENT KNOS
With SET SCREW
a /f
FLOW CONTROL VALVE

LOGK PAWL CYLINDER --—

Figure 24 LT-160024

SWING BRAKE ACCUMLATOR AND ORIFICE (Figure 25)

To prevent the swing brake from momentarily setting when control pressure briefly drops below 700/750 psi
(48.3/51.7 bar), the hose to the swing brake is orificed and a small accumulator is located between the
orifice and brake. The charge on the accumlator should be 400/450 psi (27.6/31.0 bar) of dry nitrogen. The
accumulator charge should be checked yearly.

SWING BRAKE ACCUMULATOR

REMOVABLE CHARGE
PORT GUARO CHARGE PORT
f- WITH DUST CaP

TW \
\—pybRauuc FLUID INLET

Figure 25 iT-160023

Rev. Dec. 1978 Page 43

amcd National Supply Company
Division af Armeo Inc.
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435
BRAKE RELEASING VALVES

INTROL PRESSURE INLET. MANUAL OVERRIDE

BOOM HOIST BRAKE

CYLINDER PRESSURE TAP——-—

weeO BRAKE BOOM HOIST

GYLINDER I BRAKE
—

TO BRAKE wee
CYLINDER BRAKE
I

we10 BRAKE MAIN

CYLINDER BRAKE
SWING BRAKE CYLINDER ro
PRESSURE TAP- >
SWING
BRAKE
ORIFIGED FITTING ——~

TO BRAKE CYLINDER
——a__10

DRAINTO TANK

Figure 26 LT-160022

CHECK VALVE BLOCK

WHIP HOIST BRAKE CYLINDER

! PRESSURE TAP

| TO WHIP HOIST
A BRAKE CYLINDER
TO BRAKE
PEDAL

TO MAIN HOIST.
lh BRAKE CYLINDER

\
TO MAIN HOISTBRAKE \__MAINHOIST BRAKE CYLINDER
RELEASING VALVE PRESSURE TAP

Figure 27 LT-160046

Page 44 Rev. Dec. 1978 _-

8 ARMCO National Supply Company
VJ misono! armeotne
NATIONAL HYDRAULIC PEDESTAL CRANE OS-
LITHO IN USA.

AIR CONTROL SYSTEM

All control of the OS-435, hoisting, lowering and swinging, is accomplished using air control devices. With
pressure regulating valves, manually operated valves, piston operated valves, diaphragm operated valves,
shuttle valves and positioning cylinders, control of the hydrostatic drives is accomplished.

The controls were designed to meet the following requirements:

All brakes must set with the absolute loss of air pressure.
BON>

All hoist brakes must set and pump return to neutral with the loss of charge pressure.
The main and whip hoist brakes must set when the control handle is returned to neutral.
The boom hoist brake must set and the lock paw/ must engage when the boom hoist control handle is
returned to neutral.
The emergency brake set valve must apply all hoist brakes and the boom hoist lock pawl when
a

depressed. The emergency brake set valve musi also prevent the use of the hoist functions.
6. The emergency load release valve must release the main or whip brake (as determined by the
position of the hoist selector control valve) and permit the load to “freefall” when depressed.

The air control system consists of the following:

AIR COMPRESSOR (WHERE APPLICABLE)

Mounted to the engine is an air compressor. This compressor will supply an adequate air supply to operate
the controls of the crane. The discharge pressure of the compressor should be regulated to a maximum of
110 psi {7.6 bar) and a minimum of 100 psi (6.9 bar).

AIR COMPRESSOR UNLOADER (WHERE APPLICABLE)

The air compressor unloader regulates the discharge pressure and pressure differential of the air
compressor. This valve is located near the rear of the crane beneath the engine and above the large air
receiver. The unloader shauld be set to regulate the compressor discharge within the range of 100 to 110 psi
{6.9 to 7.6 bar).

This valve serves to control the unloading mechanism which lifts the intake valves of the air compressor. The
valve senses the air pressure in the large air reservoir. When the pressure reaches 110 psi (7.6 bar), the valve
directs air pressure to the unloading mechanism in the compressor. When the pressure in the reservoir drops
to 95 psi (6.6 bar), the valve shifts and permits the air pressure to the unloading mechanism to be exhausted.
Without pressure to the unloading mechanism the compressor begins increasing the reservoir air pressure.

UNLOADER VALVE ADJUSTMENT (Figure 28)

The unload pressure (maximum pressure) is adjusted by turning the pressure adjusting nut clockwise to
increase the pressure and counterclockwise to decrease the pressure.

Changing the differential (difference between load (minimum pressure) and unload (maximum pressure)
pressure] is accomplished by holding the lock nut closest to the body of the valve so it does not move, then
turning the targe nut next to it very slightly clockwise to increase the differential and counterclockwise to
decrease the differential.

= Rev. Dec. 1978] Page 45

ARMCO National Supply Company 8
VV owision of arco inc
NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435
UNLOADER VALVE

OIFFERENTIAL ADJUSTMENT

OFFFERENTIAL LOCK NUT:

FROM AIR
RECEIVER

UNLOAD PRESSURE
ADJUSTING NUT
COMPRESSOR

UNLOAD PRESSURE LOCK NUT

To

Figure 28 LT-160025

MAIN/WHIP HOIST CONTROL VALVE (C-4)

This is a pressure requlating valve. This valve is linked directly to the main/whip hoist control handle. As the
hoist control handle is moved, so is the lever on the side of the valve. The further the control handle is
moved out of the neutral position (in either the hoist or lower direction) the greater will be the discharge
pressure of this valve. This control valve is located beneath the right-hand console in the operator's cab.

BOOM HOIST CONTROL VALVE (C-2}

Located beneath the left-hand console are two more pressure regulating valves. The lower valve is the boom
hoist control valve. This valve is linked directly to the boom hoist control handle and boom hoist pedal. As
the control handle or foot pedal is moved, so is the lever on the side of the valve. The further the control
handle or pedal is moved out of the neutral position (in either the hoist or lower direction) the greater will
be the discharge pressure of this valve.

SWING CONTROL VALVE (C-1)

The upper pressure regulating valve beneath the left-hand control panel is the swing control valve. This
valve is linked directly to the swing control handle. As the control handle is moved, so is the lever on the side
of the valve. The further the control handle is moved out of the neutral position (in either the swing left or
swing right directions) the greater will be the discharge pressure of this valve.

MAIN/WHIP HOIST PUMP ACTUATING CYLINDER (DC-3)

Mounted to the main/whip pump displacement control valve (see Pump Control) is a positioning cylinder
(pump actuating cylinder). This cylinder is designed to extend orretract in direct proportion to the pressure in
the cylinder. The greater the pressure on either the piston or rod end of the cylinder the greater will be the
extension or retraction of the rod. This cylinder piston rod is connected to the displacement control valve
lever and functions to operate the displacement control valve.

Page 46 Rev. Dec. 1978 —_

ARMCO National Supply Company
VJ owisionot armea inc
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

BOOM HOIST PUMP ACUTATING CYLINDER (DC-2)}

Mounted to the boom pump displacement control valve (see Pump Control) is a positioning cylinder (pump
actuating cylinder}. This cylinder is designed ta extend or retract in direct proportion to the pressure in the
cylinder. The greater the pressure on either the piston or rod end of the cylinder the greater will be the
extension or retraction of the rod. This cylinder piston rod is connected to the displacement control valve and
functions fo operate the displacement control valve.

SWING PUMP ACTUATING CYLINDER (DC-1)

Mounted to the swing pump displacement control valve (see Pump Control) is a positioning cylinder (pump
actuating cylinder). This cylinder is designed to extend or retract in direct proportion to the pressure in the
cylinder. The greater the pressure on either the pison or rod end of the cylinder the greater will be the
extension or retraction of the rad. This cylinder piston rod is connected to the displacement control valve
lever and functions to operate the displacement contro] valve,

HOIST BRAKE AND BOOM HOIST LOCK PAWL RELEASING VALVE (P-10, P-11 and P-13)

Each of the three hoist brakes, main, whip and boom, are spring set and hydraulically released. When a
control handle in the operator’s cab is moved out of neutral, an air pressure signal is sent by P-19 or P-20 to
the hoist brake releasing valve for the appropriate hoist. These valves are piston operated and require
approximately 35 psi (2.4 bar} pressure to the piston for actuation. When the valves shift they direct control
pressure in the brake cylinders and release the brakes. The three valves are mounted to the crane main
frame above the swing gear reducer.

AIR PRESSURE REGULATOR (R-1)

On the right-hand rear control panel in the operator’s cab is an air pressure regulator. This regulator supplies
air to all the controls and should be set to maintain a pressure of 95 to 100 psi (6.6 to 6.9 bar) on the air
pressure gage in the operator’s cab.

EMERGENCY LOAD RELEASE VALVES (V-5 & V-6)

When depressed, these valves perform two functions. First, valve V-5 will signal the brake releasing valve of
the hoist in use, as directed by the hoist selector control valve (V-3) in the operator’s cab, When the brake
releasing valve is signalled it shifts and supplies cantral pressure to the brake cylinder, releasing the brake.
Second,valve V-6 shifts the hoist selector valve operator (P-11). This action establishes an unrestricted path
for the flow of oi! through the hoist motor in use, thus permitting the motor to free-wheel and the load to
“free-fall”. Indescriminate use of the load release will cause damage to the hydraulic system. This valve is for
emergency use only.

EMERGENCY BRAKE SET VALVE (V-1)

This valve, when depressed, sets all hoist brakes and the boom hoist lock pawl. The air supply for all the hoist
controls comes through the brake set valve. Therefore, when this valve is depressed no hoisting or lowering
can be performedfrom the operator’s cab. Swinging of the crane is possible while the emergency brake se}
valve is depressed. The valve is pulled to resume normal operation.

SWING BRAKE VALVE (V-2)

The swing brake valve controls the air supply to the swing contro! valve (C-1} and the swing brake releasing
valve (P-12}. When this valve is depressed, no air is available to operate the swing controls. When the valve
is pulled up, air is supplied to the swing control valve and the brake releasing valve. Air pressure to the
brake releasing valve causes the spool to shift and direct control pressure to the swing brake cylinder.

Cmc Rev. . 1978 Page 47

ARMGO National Supply Company ev. Dec. 1978 a8 |
wis on ot Armen ine ,
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
HOIST SELECTOR CONTROL VALVES (V-3 and V-4)

The hoist selector control valve (V-4) signals the hoist selector valve operator (P-16) and V-3 functions to
determine which hoist brake (main or whip) will be released when the main/whip hoist control handle is
moved out of the neuiral position.

MAIN/WHIP HOIST LOW CHARGE PRESSURE BRAKE SET VALVE (P-7)}

After passing through the emergency brake set valve, the control air supply for the main/whip hoist controls
must pass through the low charge pressure brake set valve. This valve monitors charge pressure from the
main/whip pump, If the charge pressure drops to an unacceptable level [approximately 125 psi (8.6 bar)],
this valve closes off the air supply to the controls and permits the main or whip brake to sei and the
main/whip pump to return to neutral. If main/whip charge pressure is 125 psi (8.6 bar) or below, the cab
controls will not operate the main or whip hoist or release the main or whip hoist brake.

BOOM HOIST LOW CHARGE PRESSURE BRAKE SET VALVE (P-8)

After passing through the emergency brake set valve, the control air supply for the boom hoist controls must
pass through the low charge pressure brake set valve. This valve monitors charge pressure from the boom
pump. If the charge pressure drops to an unacceptable level [approximately 125 psi (8.6 bar)], this valve
closes off the air supply to the controls and permits the boom brake and lock paw! to set and the boom pump
to return to neutral. If boom charge pressure is 125 psi (8.6 bar) or below, the cab controls will not operate
the boom hoist or release the boom hoist brake and lock pawl.

ENGINE KILL CYLINDER (KC-1)

Mounted on the engine is a small brass cylinder. When the kill valve in the operator’s cab is pulled up, air
pressure goes to the piston end of this cylinder. If the kill valve (V-11) is depressed the air pressure is
removed from this cylinder and a spring in the cylinder closes the fuel rack of the engine, killing the engine.

ENGINE THROTTLE CONTROL (C-3 and C-5)

The foot and hand throttle are both pressure regulating valves. The two valves work through a shuttle valve
with the valve discharging the highest pressure controlling the engine speed, Both valves supply air pressure
to the throttle actuator on the side of the engine.

KILL VALVE (V-11}

All cab control air passes through the kill valve. If this valve is depressed, none of the cab controls will
function and the engine will not start. This valve must be pulled prior to starting the engine.

HYDRAULIC TANK LEVEL SENSING VALVE (V-17)

The level of the fluid in the hydraulic tank is monitored by using a float attached to a valve. When the fluid is
at the proper operating level, the float is holding the valve in the open position which directs air pressure to
the hydraulic tank low fluid level indicator. Air pressure to the indicator causes it to display ‘“green’’. If the
fluid level drops below an acceptable level, the float “closes” the valve and the pressure to the indicator is
exhausted. Lack of pressure to the indicator causes it to display ““red’’. If the indicator turns “red’’ during
crane operation, operation of the crane should be stopped until fluid has been added to the tank.

Page 48 Rev. Dec. 1978 =

8 ARMCO National Supply Company
Vo owiswon ot armeo ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

CLUTCH CONTROL VALVE (V-9)

The clutch between the triple pump drive and engine is operated by a double acting cylinder. This cylinder
receives air from the clutch control valve in the operator’s cab, Pressure to the piston end of the cylinder
engages the clutch and pressure to the rod end disengages the clutch. The control valve is pulled and held
for five seconds to engage the clutch or pushed and held for three seconds to disengage the clutch.

ENGINE START VALVE (V-10)

The engine is started by discharging a large volume of compressed air through a vane type motor. The start
valve in the operator’s cab, when pulled, supplies air pressure to the air start relay valve on the engine. The
relay valve (P-17) then opens and provides the required volume of compressedair to the air starting motor.
The air from the engine start valve also engages the starting motor gearing with the engine flywheel.

BLOW DOWN VALVE (P-18}

The blow down valve is shifted each time the clutch is engaged. When the valve shifts it closes the air supply
to the dryer and permits the dryer to “blow down”. This action prolongs the life of the desiccant. The blow
down vaive will spring return to the open position when the clutch control valve is in the neutral position.

LOW AIR PRESSURE WARNING AND STOP VALVES(P-6 and P-5)

The main/whip hoist system is equipped with a system to prevent the main or whip hoist brake from
releasing or the main/whip pump from pumping fluid if control air pressure drops below 50 psi (3.4 bar).
This system prohibits the possibility of hydraulic system pressure surges or unexpected system response
which may occur as air pressure drops below 50 psi (3.4 bar).

The operator will receive a warning of decreasing air pressure by the air supply low pressure indicator (I-5).
When the air pressure falls to 75 psi (5.2 bar), the indicator turns from green to red. At this point all systems
will continue to function until the pressure drops to 50 psi (3.4 bar).

The low are pressure warning valve (P-6) signals the air supply Jow pressure indicator. When the air pressure
drops to 75 psi (5,2 bar), the valve exhaust the air to the indicator allowing the indicator to turn red. The low
air pressure stop valve (P-5) closes off the air supply to the main/whip hoist control valve (C-4) and exhaust
any residual air pressure to the system when the control air pressure drops to 50 psi (3.4 bar).

TWO SPEED HOIST CONTROL VALVES (P-14 and P-15)

The main hoist motor and whip hoist motor are equipped with a pheunatically operated, 4-way, 2-position
valve to change the displacement of the motors. Two displacements provides for two motor speed ranges.
Air pressure to the valves from the hoist speed selector valve (V-8) places the motors in the high speed
(minimum displacement, low torque) range. Without pressure to the valves, the motors are in the low speed
(maximum displacement, high torque) range.

CONTROL AIR MASTER VALVE (V-18)

To facilitate service to the air control system, a master shut off valve has been provided. This valve is on the
large air receiver beneath the engine. The valve shuts off the air supply to the controls and exhausts the
residual air pressure in the control system. The valve can be locked in the “closed” position with a pad lock
to prevent unauthorized operation of the crane.

Rev. Dec. 1978 Page 49

aw National Supply Company
Drvision of Armco inc
NATIONAL
LITHO iN U.S.A
HYDRAULIC PEDESTAL CRANE OS-435

AIR RECEIVERS

The large (under the engine) and small (on the rear wall of the operator’s cab) oir receivers provide the
crane with a residual air supply. The residual supply provides for engine starting and temporary crane
operation should the normal air supply fail. The moisture should be purged from the receivers on a daily
basis.

HOIST BRAKE AND BOOM HOIST LOCK PAWL RELEASING SIGNAL VALVES (P-19 and P-20)

Each of the three hoist brakes (main, whip and boom) are spring set and hydraulically released. When a
control handle in the operator’s cab is moved out of neutral an air pressure signal is sent to the diaphram of
valve P-19 for the boom hoist, or P-20 for the main and whip hoist. Approximately 5 psi (.3 bar) pressure on
the diaphram shifts the valve which then signals the appropriate brake releasing valve. An appropriate
signal to the hoist brake and boom hoist lock pawl releasing valves will shift these valves which
subsequently direct control pressure to the brake and lock pawl cylinders.

Page 50 Rev. Dec. 1978

aRMcO National Supply Company
Division of Armeo ine.
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

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* Figure 28, LT-160333 i

Rev. July 1980 Page 51

ARMCO National Supply Company
VV Dwesion of armen ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
NOTES

Page 52 Rev. July 1980 _—

ARepNational Se
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

OPERATION OF THE PRIMARY FUNCTIONS

MAIN LINE HOISTING A LOAD, LOWERING A LOAD AND POWERING DOWN

With the hoist selector control valve (Fig. 1, Item 30) pushed for “MAIN”, the main hoist pheumatic system is
made operable and the hoist selector valve operator (P-16) receives an air pressure signal, shifts and directs
control pressure to shift the selector valve for operation of the main hoist. Control handle (Fig. 1, Item 20)
movement, in either the hoist or lower direction, sends air pressure to the main hoist brake releasing valve
(P-11) shifting the valve which directs control pressure into ihe main hoist brake cylinder. Pressure to the
brake cylinder releases the brake. The movement of the control handle aiso directs air pressure to the
“BRAKE OFF” indicator (I-6) which turns amber to indicate the main hoist brake has been signaled to
release.

When the control handle is moved in the hoist direction the main/whip pump actuator (DC-3) receives air
pressure on the piston end. The actuator then pushes the pump displacement control valve lever and causes
the pump the “cam’’. When the pump cams high pressure (6000 psi max) fluid is pumped out of port “A”
end through the tubing to the holding valve, through the hoist selector valve and then to port “A” of the
main hoist motor. At port “A” the high pressure fluid shifts the shuttle valve in the motor valve manifold and
then rotates the motor. The fluid leaves port ““B” of the motor at charge pressure. Part of the fluid passes
through the shuttle valve and charge pressure relief valve in the motor valve manifold and enters the motor
case. Most of the fluid leaving the motor goes through the tubing to the tee in the hoist selector valve
subplate, by-passes the in-line filter element and returns to port “BY of the main/whip pump. At pump port
“BY the fluid from the moter mixes with fluid from the charge pump and then re-enters the main/whip
pump.

When the control handle (Fig. 1, Item 20) is moved in the lower direction, with a load on the hook, the
main/whip pumps actuator (DC-3) receives air pressure on the rod end. The actuator then pulls on the pump
displacement control valve lever and causes the pump to ‘’cam’’. When the pumps cams, fluid is discharged
out of port “B” at charge pressure. As the fluid leaves the main/whip pump it mixes with fluid from the
charge pump. The fluid now passes through the tubing and is filtered by the in-line filter. The filtered fluid
now goes to the tee in the hoist selector valve subplate and then to port “’B’’ of the main hoist motor. At port
“BY” part of the fluid passes through the shuttle valve and charge pressure relief valve in the motor valve
manifold and enters the motor case. Most of the fluid enters the motor and is pressurized from charge
pressure to high pressure (5000 psi max). (While lowering a load the motor is pressurizing the fluid. The load
on the hook attempts to rotate the motor but the speed of the motor is limited by the amount of fluid passing
through it. The pump serves to regulate the amount of fluid passing through the motor.) The high pressure
fluid at motor port “A” shifts the shuttle valve and then passes through the tubing and hoist selector valve to
the holding valve. At the holding valve the fluid must pass through the flow control valve before it continues
on through the tubing to the main/whip pump “A” port. At pump port “A”, the fluid re-enters the cylinder
block and its pressure is dropped to charge pressure as it passes through the pump.

When the control handle (Fig. 1, Item 20) is moved in the lower direction, with no load on the hook, the
main/whip pump actuator {(DC-3) receives air pressure on the rod end. The actuator then pulls the pump
displacement control valve lever and causes the pump to “cam’’. When the pump cams, high pressure (1500
psi max) fluid is pumped out of port ’B’ of the pump and passes through the tubing to the in-line filter. After
filtration the oil continues on through the tubing to port ’B” of the main hoist motor. The high pressure fluid
then passes through the main motor, causing it to rotate, and leave port “A” of the motor at charge pressure.
The fluid now passes through the tubing, hoist selector valve and holding valve re-entering the pump at port
“A’’. During this operation the shuttle valve and charge pressure relief valve in the motor valve manifold do
not have fluid passing through them and the only fluid entering the system from the charge pump is fluid
replacing internal pump and motor leakage.

Returning the control handle to neutral exhausts the air pressure to the piston of the main hoist brake
releasing valve (P-11) and the valve returns, exhausting the pressure in the brake cylinder. With the release
of the pressure in the main hoist brake cylinder, the main hoist brake sets. At the same time, the air pressure
to the pump actuating cylinder (DC-3) is exhausted and the main/whip pump returns to the neutral, no flow
of fluid, position.

Rev. Dec. [978 Page 53

ARMCO National Supply Company
Drvision of Armeo inc.
NATIONAL
LITHO INUS.A
HYDRAULIC PEDESTAL CRANE OS-435
WHIP LINE HOISTING A LOAD LOWERING A LOAD AND POWERING DOWN

With the hoist selector control valve (Fig. 1, Item 30) pulled for “WHIP”, the whip hoist pneumatic system is
made operable and the hoist selector valve operator (P-16) receives an air pressure signal, shifts and directs
control pressure to shift the selector valve for operation of the whip hoist. Control handle (Fig. 1, Item 20)
movement in either the hoist or lower direction sends air pressure to the whip hoist brake releasing valve
(P-10), shifting the valve which directs control pressure into the whip hoist brake cylinder. Pressure to the
brake cylinder releases the brake. The movement of the control handle also directs air pressure to the
“BRAKE OFF” indicator (I-7) which turns amber to indicate the hoist brake has been signaled to release.

When the control handle (Fig. 1, Item 20) is moved in the hoist direction the main/whip pump actuator
(DC-3) receives air pressure on the piston end. The actuator then pushes the pump displacement control
valve lever and causes the pump to “cam”. When the pump cams, high pressure (5000 psi max) fluid is
pumped out ofport “A’’ and through the tubing to the holding valve, through the hoist selector valve and
then to port “A” of the whip hoist motor. At port “A” the high pressure fluid shifts the shuttle valve in the
motor valve manifold and then rotates the motor. The fluid leaves port “B” of the motor at charge pressure.
Part of the fluid passes through the shuttle valve and charge pressure relief valve in the motor valve
manifold and enters the motor case. Most of the fluid leaving the motor goes through the tubing to the tee in
the hoist selector valve subplote, by-passes the in-line filter element and returns to port “BY of the
main/whip pump. At pump port “B’, the fluid from the motor mixes with the fluid from the charge pump
and then re-enters the main/whip pump.

When the control handle (Fig. 1, tem 20) is moved in the lower direction, with a load on the hook, the
main/whip pump actuator (DC-3) receives air pressure on the rod end, The actuator then puils the pump
displacement control valve lever and causes the pump to ““cam’’. When the pump cams, fluid is discharged
out of the port ’B” at charge pressure. As the fluid leaves the main/whip pump it mixes with the fluid from
the charge pump. The fluid now passes through the tubing and is filtered by the in-line filter. The filtered
fluid now goes to the tee in the hoist selector valve subplate and then to port “B” of the whip hoist motor. At
port ’’B” part of the fluid passes through the shuttle valve and charge pressurerelief valve in the motor valve
manifold and enters the motor case. Most of the fluid enters the motor and is pressurized from charge
pressure to high prssure (5000 psi max). (While lowering a load the motor is pressurizing the fluid. The load
on the hook attempts to rotate the motor but the speed of the motor is limited by the amount of fluid passing
through it, The pump serves to regulate the amount offluid passing through the motor.) The high pressure
fluid at motor port “A” shifts the shuttle valve and then passes through the tubing and hoist selector valve to
the holding valve. At the holding valve, the fluid must pass through the flow control valve before it continues
on through the tubing to the main/whip pump “A” port. At pump port “A”, the fluid re-enters the cylinder
block and its pressure is dropped to charge pressure as it passes through the pump.

When the contro! handle (Fig. 1, Item 20) is moved in the lower direction, with no load on the hook, the
main/whip pump actuator (DC-3) receives air pressure on the rod end. The actuator then pulls the pump
displacement contro! valve lever and causes the pump to “cam”. When the pump cams, high pressure (1500
psi max) fluid is pumped out of port ’B” of the pump and passes through the tubing to the in-line filter. After
filtration, the fluid continues on through the tubing to port “B’’ of the whip hoist motor. The high pressure
fluid then passes through the whip motor, causing it to rotate, and leaves the motor port “A” at charge
pressure. The fluid now passes through the tubing, hoist, selector valve, and holding valve re-entering the
pump at port “A”. During this operation the shuttle valve and charge pressure relief valve in the motor valve
manifold do not have fluid passing through them and the only fluid entering the system from the charge
pump is fluid replacing internal pump and motor leakage.

Returning the control handle (Fig. 1, [tem 20) to neutral exhausts air pressure to the piston of the whip hoist
brake releasing valve (P-10) and the valve returns, exhausting the pressure in the brake cylinder. With the
release of the pressure in the whip hoist brake cylinder, the whip hoist brake sets. At the same time, the air
pressure to the pump acctuating cylinder (DC-3) is exhausted and the main/whip pump returns to the
neutral, no flow of fluid, position.

BOOM HOISTING, LOWERING AND POWERING DOWN ——,

With the control handle (Fig. 1, Item 19) in neutral, the boom hoist brake is set and the lock pawl is engaged.
Control handle movement, in either the hoist or lower direction, sends air pressure to the boom hoist brake
releasing valve (P-13) shifting the valve which directs control pressure into the boom hoist brake cylinder

Page
Bs
54 Rev. Dec. 1978 —_=
ARMCO Nationat Supply Company
J oisision of Armee ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN U.S.A.

and boom hoist lock pawl cylinder. Pressure to the brake cylinder releases the brake. Pressure to the lock
pawl cylinder releases the pawl, The movement of the control handle also directs air pressure to the “brake
off” indicator (1-2) which turns amber to indicate the hoist brake has been signaled to release.

When the contro! handle is moved in the hoist direction, the boom pump actuator (DC-2) receives air
pressure on the piston end. The actuator then pushes the pump displacement control valve lever and causes
the pump to “cam’’. When the pump cams, high pressure (6000 psi max) fluid is pumped out of port “A” and
through the tubing to the halding valve. From the holding valve the fluid goes through the tubing to port “A”
of the boom hoist motor. Ai port “A” the high pressure fluid shifts the shuttle valve in the motor valve
manifold and then rotates the motor. The fluid leaves port ’’B” of the motor at charge pressure. Part of the
fluid leaving the motor passes through the shuttle valve and charge pressure releif valve in the motor valve
manifold and enters the motor case. Most ofthe fluid leaving the motor goes through the tubing, by-passing
the in-line filter element, to port “B” of the boom pump. At pump port BY the fluid from the motor mixes
with fluid from the charge pump and re-enters the boom pump.

When the control handle (Fig. 1, Item 19) is moved in the jower direction, the boom pump actuator (DC-2)
receives air pressure on the rod end. The actuator then pulls the pump displacement control valve lever and
causes the pump to “cam’’. When the pump cams, fluid is discharged out of port “B’ at charge pressure. As
the fluid leaves the boom pump it mixes with fluid from the charge pump. The fluid now passes through the
tubing and is filtered by the in-line filter. The filtered fluid now goes through the tubing to port “B” of the
boom hoist motor. At port B’, part of the fluid passes through the shuttle valve and charge pressure relief
valve in the motor valve manifold and enters the motor case. Most of the fluid enters the motor and is
pressurized from charge pressure to high pressure (6000 psi max}. (While lowering the boom, the motoris
pressurizing the fluid. The weight of the boom and load attempt to rotate the motor, but the speed of the
motoris limited by the amount offluid passing through it. The pump serves to regulate the amount offluid
passing through the motor.) The high pressure fluid at motor port ’’A”’ shifts the shuttle valve in the motor
valve manifold and then pases through the tubing to the holding valve. At the holding valve, the fluid must
pass through the flow control valve before it continues through the tubing to the boom pump “A” port. At
pump port “A”, the fluid re-enters the pump cylinder block and its pressure is dropped to charge pressure as
it passes through the pump.

When the contro! handle (Fig. 1, tem 19) is moved in the lower direction, with the boom at high angles and
no load on the hook, the boom pump acivator (DC-2) receives air pressure on the rod end. The actuator then
pulls the pump displacement control valve lever and causes the pump to ‘‘cam’’. When the pump cams, high
pressure (1500 psi max) fluid is pumped out of port “B’ of the pump and passes through the tubing to the
in-line filter. After filtration the fluid continues on through the tubing fo port ’’B’’ of the boom motor. The
high pressure fluid then passes through the boom motor causing it to rotate and leaves port “A” of the motor
at charge pressure. The fluid now passes through the tubing to the holding valve and on to re-enter the pump
at port “A”. During this operation the shuttle valve and charge pressure relief valve in the motor valve
manifold do not have fluid passing through them andthe only fluid entering the system from the charge
pump is fluid replacing internal pump and motor leakage.

Returning the control handle (Fig. 1, Item 19) to neutral exhausts the air pressure to the piston of the boom
hoist brake releasing valve (P-13} and the valve returns, exhausting the pressure in the brake and lock pawl
cylinders. With the release of pressure in the cylinders the boom brake and lock paw! set. At the same time,
the air pressure to the pump actuating cylinder (DC-2) is exhausted and the boom pump returns to the
neutral, no flow of fluid, position.

SWING CIRCUIT OPERATION

With the swing handle (Fig. 1, Item 18) in neutral, pulling the swing brake valve (Fig, 1, Item 28) supplies air
pressure to the swing brake releasing valve (P-12) piston and acutates the swing control system. The brake
releasing valve shifts and directs control pressure to the swing brake, releasing the brake.

With the swing brake released, control handle (Fig. 1, Item 18) movement toward the operator (swing left)
directs air pressure to the piston end of the pump actuator (DC-1). The actuator then pushes on the pump
displacement control valve lever and causes the pump to “‘cam’’. When the pump cams, high pressure (4500
psi max) fluid is pumped out port “A” of the pump, through a hose by passing the in-line filter element, to

Rev. Dec. 1978 Page 55

ARMCO National Supply Company
Owision of Armee Int
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
port “B” of the swing motor. At port “B” the high pressure fluid shifts the shuttle valve in the motor valve
manifold, The fluid then passes through the motor causing rotation and leaves the motor at charge pressure.
At motor port “A”, part of the fluid passes over the shuttle valve and charge pressure relief valve in the
motor valve manifold and enters the motor case. Most of the fluid leaving the motor returns to the swing
pump “B” port through the hose. At pump port ’’B” the fluid from the motor mixes with fluid from the charge
pump and re-enters the swing pump.

With the swing brake release, control handle (Fig. 1, jt~em 18) movement away from the operator (swing
right) directs air pressure to the rod end of the pump actuator (DC-1}. The actuator then pulls on the pump
displacement control valve lever and causes the pump to “cam’’. When the pump cams high pressure (4500
psi max) fluid is pumped out of port ‘’B’’ of the pump, through the hose to port A’ of the swing valve
manifold. The fluid then passes through the motor causing rotation and leaves the motor at charge pressure.
At motor port ‘B”’, part of the fluid passes over the shuttle valve and charge pressure relief valve in the
motor valve manifold and enters the motor case. Most of the fluid leaving the motor passes through the
in-line filter and returns to the swing pump A” port through the hose. At port “A”, the fluid from the motor
mixes with fluid from the charge pump and re-enters the swing pump.

To reset the swing brake, the swing brake valve (Fig. 1, Item 28) is pushed. This action exhausts the air
pressure to the swing control valve (C-1) and the piston of the swing brake releasing valve (P-12). When air
pressure is removed from the brake releasing valve piston, the valve returns, exhausting the control pressure
to the brake cylinder, permitting the brake to set.

Page 56 Rev. Dec. 1978

ane National Supply Company
Duwision of Armes ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4 LITHO INUSA

BRAKES

HOIST BRAKES

The brakes on the three hoist drums are identical. These are on the right hand end of the hoist drums and are
protected by easily removable rain shields. They are band type brakes on a 29-1/2” diameter drum that is an
integral part of the shaft assembly.

Each of these brakes has a cylinder in the motor compartment that operates the brake through a rocker arm
assembly. The rod end of these cylinders contains springs to maintain the brake in the set position. The
springs of the brake cylinder are lubricated for protection against rust and wear. A reservoir is mounted to
each cylinder to provide for lubricant displacement when the brake is released. The brakes are released by
applying control pressure under the piston. This hydraulic pressure compresses the springs and releases the
brakes.

Whenever a hoist control handle is returned to the neutral position, the brake sets automatically to hold the
load and prevent creeping. When the control handle is moved out of neutral, in either the hoist or lower
direction, the brake is fully released. During load lowering, the load is controlled entirely through the
hydraulic system. This gives sure, precise control that makes the spatting of heavy loads safe and easy.

HOIST BRAKE ADJUSTMENT (Fig. 31)

If the crane has not been working regularly it should be worked for a short period to dry the linings and
remove any rust that may be on the drum. This can be done easily by hoisting the empty hook and boom
(simultaneously) a few times with the brake pedal depressed.

The control pressure should be in the 700/750 psi (48.3/51.7 bar) range while adjusting the brakes.

The pressure at the main and whip brake cylinder pressure taps, Fig. 27, should also be checked. If this reads
less than the control pressure the foot operated brake valve needs adjusting (see “Brake Pedal” page 58).
This should be done before proceeding with brake adjustment.

The brake bands are suspended from the main frame with coil springs (two springs are used on the boom
brake). These should be adjusted so that they life the upper most brake block clear of the drum about 1/32”
(0.8 mm) when the brake is released.

There are also two threaded rods protruding from the main frame that restrain the brake band in the fore and
aft direction when the brake is released. These should be set approximately 1/32” (0.8 mm) from the brake
band when the brake is set.

When the adjustments have been made the brake can be adjusted with the brake adjusting nut. This requires
two men; one to release the brakes by operating the crane and the other to adjust the brake.

There are two holes through the top of the main frame in line with the main and whip brake cylinders and
one hole below the boom hoist wire rope drum. These holes give easy access to the brake adjusting nuts. A
1-1/2” deep socket is required for the adjustment. A brake adjusting tool which incorporates a 1-1/2” deep
socket is shipped with each crane.

For proper hoist brake adjustment the brake cylinder rod travel should be 1/4” (6 mm). The brake should
then be checked under load. If the load creeps down with the control handle in neutral, the brake band is
not holding. If the brake is properly adjusted and will not hold the load, check the brake lining and drum for
oil or the brake cylinder for broken springs.

uch National Supply Company . Dec, P. 5

ARMCO Rev. D 1978 ‘age 57
VJ bwision of armeoinc
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435
SWING BRAKE(Fig. 32)
The swing brake is a caliper disc brake with the disc mounted on the top end of the input pinion of the swing
gear reduction. It is spring applied, hydraulically released for fail-safe operation. The brake is adjusted by
two nuts located under the tower spring retaining plate of the brake assembly. With the brake set, these nuts
should be adjusted to set the space between the top of the lower spring retaining plate and the bottom of the
cylinder housing at 1/8’.

BRAKE PEDAL(Fig. 30)

When the emergency load release button is depressed, the load can be controlled by modulating the
pressure in the end of the brake cylinders. This is done with the foot brake pedal (see Fig, 22 for a schematic
of the brake system). The valve in the brake pedal is a direct acting pressure regulating valve. This valve
controls the pressure to the main or whip brake cylinders when the pedal is depressed.

Fig. 30 shows the linkage adjustment between the foot pedal and the valve. With the brake pedal all the
way up and while hoisting the whip line, the pressure at the whip hoist brake cylinder pressure tap (Fig. 27)
should read the same as the control pressure (700/750 psi). With the brake pedal depressed all the way
down and while hoisting the whip line, the pressure at the pressure tap should read 150 psi or less. To
increase pressure lengthen the linkage. To decrease pressure shorten the linkage. The linkage is adjusted by
loosening the jam nut. This is most easily accomplished by removing the hinge pin and then the upper half
of the brake peda}. CAUTION: Do Not remove the plunger from the vaive body or attempt to adjust the brake
pedal when the clutch is engaged and the engine is running.

BRAKE PEDAL

—,
Figure 30 LT-160028

Page 58 Rev. Dec. 1978 =

ae ARMCO National Supply Company
Dwisien of Armco tne
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN U.S.A

HOIST BRAKES

BAND LIFTING SPRING

LUBRICATOR
13

ADJUSTING WUT

CYLINDER
LUBRICATOR
[ A0.USTING NUT

@AND LIFTING SPRING

: MAIN AND WHIP

BRAKE CYLINDER

Figure 31 LT-160026

_ Rev. Dec. 1978] Page 59

ARM National Supply Company
Division of Armco Inc
NATIONAL
LITHO IN U.S.A
HYDRAULIC PEDESTAL CRANE OS-435

SWING BRAKE

ADJUSTING NUTS

Figure 32 LT-160027

Page 60 Rev. Dec. 1978 co

aap National Supply Company
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHOINUSA

SWING BEARING MAINTENANCE REQUIREMENTS

The swing bearing of the crane is a forged alloy steel ball type bearing with hardened and ground races. The
inner race of the bearing is attached to the crane frame and the outer race is attached to the pedestal flange.
The gear teeth of the bearing are an integral part of the outer race. The bearing must be mounted to the
pedestal flange as directed by the National Supply Company technical standard TD-16001.

In order to assure trouble free operation of the swing bearing, several maintenance operations must be
regularly performed. The bearing balls and races must be thoroughly lubricated once a week with a suitoble
grease as specified in the lubrication section. There are six lubrication fittings for the swing bearing in the
wall of the main frame below the left-hand end plate of the main and whip hoist winches. Hoses are
attached from these fittings to the inner race of the swing bearing for piping the grease to the bearing. The
bearing and swing pinion teeth must have an adequate coating of a high quality lubricant such as Jet Lube,
Inc. ““Kopr-Kote’” compound for lubrication and corrosion resistance.

A spot check of the tightness of the inner and outer race swing bearing bolts should be performed monthly.
Every six months the inner and outer race bolts should be re-torqued. Loose bolts can lead to fatigue failure
of the bolts and to detrimental binding and wear of the swing bearing balls and races. The required bolt
torque is 2400 ft-lbs (332 m-kg) for 1-1/2” bolts and 5000 ft-lbs (692 m-kg) for 1-3/4” bolts.

STRUCTURAL MAINTENANCE

The structural members of the OS-435 crane are coated with a zinc-base undercoat, epoxy second coat and
acrylic top coat. The boom, main frame and gantry should be inspected for deformed, cracked, corroded or
missing members on a monihly basis. Corroded areas should be cleaned of corrosion, properly primed and
painted. Cracked and deformed members should be repaired. Missing members should be replaced. Prior to
conducting structural repair or replacement the National Supply Company should be contacted for feasibility
of repair, material specifications and welding procedures,

Crane assembling cap screws should be checked for tightness every six months. The fallowing chart can be
used as a guide for proper torque requirements.

Rev. Dec. 1978 Page 61

Arup National Supply Company
Division of Armea lnc.
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435

CRANE ASSEMBLING SCREW TORQUE VALUESIN FT-LBS*

\~ eo 7
SCREW / WS a
SIZE
INCHES] GRADE 2 GRADE 5 GRADE 7 GRADE8 HEX SOCKET HEAD

va |6 (.8) 19 (1.2) [12 (1.6) |13 (1.8) [14 (1.9).

5716 [1 C.5) fe (2.5) [24 (3.3) [28 (3.9) [30 (4.1)
378 19 (2.6) [31 (4.3) [43 (5.9) [46 (6.4) [50 (6.9)
7/16 {30 (4.1) [50 (6.9) [69 (9.5) [75 (10) [a ay
172) 45 (6.2)|75__(10.4)]106__—(14) (115 (15) 121 (16)
W161 66 (FAjs[i10__(15)[150__—(20) [165 (22) |176 (24)
5/8 [93 _(12.9)[150 _(20)(209 —-(28)|225 (31) |240 (33)
374 150 (207}[250 _(34)|[350___—-(48) [370 (51) [395 (54)
7/g [202 (27.9)[378 (52) [550__(76) [591 (81) [629 (86)
1 300 _(41.5)[583 (80) [825 (114) [893 (123) (964
1-178 [474 __(65.5)[782__(108)[1304_ (180) 1410 _(195)}1523__(
1-174 [659 (91.1) [1097__(151) 1815 (251) [1964 (271) |2150__ (293)
1-3/8 [884 (122.3)[1461 _(202)[2400 (331) [2400__(331)]2400
1-1/2 1057 (146.2)]1748 (241)|2400
} (331) {2400 (331) }3000 ( 414)
1-578 1448 (200)|2392 (330)|3985
} (551}]4311__ (596) ]4655 (643)
1-3/4 = = 5000 (691) = =

*VALUES IN PARENTHESES ARE iN M-Kg. LT-160044

Page 62 Rev, Dec. 1978

8 oes famco National Supply Company
Owision ot Armen inc
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

OVER CENTER CLUTCH

ADJUSTMENT

The clutch adjust collar on the over-center units is of the threaded type and is easily adjusted for normal
service and wear ofthe clutch linings by rotating by hand until the proper operating tension is obtained. In
order to retain the adjustment and prevent the collar from coming out of adjustment during operation, a
spring-loaded thumb latch is provided. To rotate the collar it is necessary to press down on the latch, thus
lifting the end of the latch clear of the slot in which it seats. After adjustment the latch is released and should
engage the collar with a locking action that will prevent the collar fram turning in operation.

Hf the handle lever jumps out of the engaged position, or if the clutch overheats and does not pull the load,
depress the adjus! collar lock plunger and rotate the toggle assembly clockwise until the hand lever requires
a distinct pressure and over-center snap to engage. New clutch facings may require several adjustments
until they are properly ‘““worn-in’, that is, until high spots on the linings are removed.

IMPORTANT POINTS FOR SUCCESSFUL OPERATION

1. Avoid overloads. Do not exceed maximum rating.

2. Do not exceed recommended speeds.

3. Be sure clutch does not drag or wipe when disengaged. This causes overheating.

4. Align clutch carefully.

5. Lubricate shift collar when necessary, but not more than good judgment and experience indicate.

LUBRICATION

These units are shipped already greased with a litholine multi-purpose grease. When necessary to add
lubricant use any high grade, lithium-base gun grease free from fillers and having low temperature
pumpability, water resistance, mechanical stability and heat resistance characteristics. Amount of
lubrication depends upon daily use. DO NOT OVER-LUBRICATE. Over-lubrication can result in overheating of
the bearing and grease getting on the linings.

The toggle assembly should be lubricated on a schedule appropriate to prevent corrosion and binding. The
shift sleeve and shaft should be lubricated on a schedule consistent with the toggle assembly. The toggle
assembly, clutch steeve and shaft should be lubricated with a light weight petroleum lubricant with good
lubricating and protecting properties. Do not allow lubricant to contaminate the clutch linings.

Rev. Dec. 1978 Page 63

ARMCO National Supply Company
Division af Asmeo inc
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435

NOTES

Page 64 Rev. Dec. 1978

ARMCO National Supply Company
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

BOOM ANGLE LIMITER

installed on the OS-435 crane is a pneumatically operated boom angle limiter system which automatically
prevents hoisting or lowering of the boom whenever the desired high or low boom angle is reached. The
two limiting devices operate independently of each other thus permitting the boom to be lowered when the
high limit is reached or raised when the low angle is reached. The system consists of two cams and two air
valves mounted at the right-hand boom foot clevis, and two air valves in the cab. The cams are rotated by
means of a shaft connected to a drive fork. The drive fork engages @ pin that is ottached to the boam foot
casting.

OPERATION

The boom angle limiter system is actuated whenever the boom is raised or lowered far enough for one of
the cams to depressthe roller arm of an air valve. Depressing the arm of the air valve (V-13 or V-14) permits
air to pass into the actuating cylinder or either valve P-1 ar valve P-2. Whenever valve P-1 (Boom Up Stop) or
valve P-2 (Boom Down Stop) shifts, if prohibits the boom hoist control valve from releasing the boom hoist
brake and tock pawl, and from camming the boom pump. The shifting of valve P-1 or valve P-2 also permits
the pump to return to the neutral position and the boom hoist brake and lock paw! to set.

LOW BOOMLIMIT OVERRIDE

The low boom limit override valve (V-12) permits the operator to place an unloaded boom into a rest which
may be below the minimum working angle of the boom, The valve exhausts the air pressure to the actuating
cylinder of valve P-2 and directs compressed air to the air horn. The valve must be held up during boom
lowering and the horn will sound as long as the valve is up.

ADJUTMENT (Figure 33)

The maximum high and low angles to which the boom can be raised or lowered are determined by the
position of the two cams mounted on the rotating shafts. One of the cams limits the hoisting of the boom, and
the other cam limits the lowering of the boom.

CAM ADJUSTMENT PROCEDURE:

1. Raise or lower the boom to the desired throw-out or limiting angle.

2. Loosen cam adjusiment set screw.

3. Rotate the cam unti the arm of the air valve is depressed and the air valve in the cab is shifted.

4. Retighten the adjustment set screw.

5. Operate the boom to check the adjustment.

NOTE: The maximum allowable load working angle is 799. The minimum allowable load working boom
angie is 0°.

Rev. Dec. 1978 Page 65

ARMCO National Supply Company
Draigion of Asmeo Ing
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
BOOM ANGLELIMITER

PIN (PART NO. 1613637) IN BOOM BASE

CASTING WITH LOCKING NUTS
7 FORK

° aaa UPPER LIMIT CONTROL “eT

AIR SUPPLY
INLET

ADJUSTABLE CAMS SIGNAL PORT

WITH SET SCREWS, UPPER LIMIT

SIGNAL PORT
LOWER LIMIT

| : _ f

LOWER LIMIT CONTROL VALVE |

Figure 33 LT-160029

Page 66 Rev. Dec. 1978 _

8 aR! National Supply Company
Omision of Armco Ing
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA

LINE TRAVEL LIMITER

The line travel system (boom saver) is an accessory mounted on the crane to prevent a hook or block from
accidentally being run into the boom point sheaves. There are two ways a hook or block can be pulled into the
boom point sheaves: 1) Hoisting the main or whip until the hook or block engages the boom point sheaves and ~
2) Lowering the boom without compensating for the increasing distance between the boom point sheaves and
the main and whip winches. As the boom is lowered, the distance between the boom point and the main and
whip winchesincreases.If the main and whip contro! handles are in neutral and the boom is being lowered, the
line length between the boom point and winches must increase. This causes line take-up on both the main and
whip systems and therefore, the main block and whip hook will approach the boom point, eventually striking the
point and causing damage.

Theline travel limiter system prevents: 1) Hoisting the whip hook into the sheave extension sheave, 2) Hoisting
the main block into the boom point sheaves and 3) Lowering the boom into the whip hook or the main block.

The fine travel limiter system consists of two valve assemblies, one shutile valve, two valve assembly supports,
two hoist line followers and the necessary tubing, fittings, and chain.

OPERATION

The hoist line followers are supported by 1/4’’ (6 mm) chain from the clevis on the end of the valve assemblies.
The weight of the follower holds the valve assembly clevis down which closes the valve in the valve assembly.
Air pressure is supplied the valve assemblies by 3/8" (10 mm) tubing. Any time either followeris lifted so as to
remove its weight from the vaive assembly clevis, air pressure will be sent back down the boom through 1/4°”
(6 mm) tubing to valve P-4 in the operator’s cab, This valve then shifts and permits air pressure to go to the pilot
cylinders of valves P-2 and P-3 in the operator’s cab. Valve P-3 then shifts and prohibits air pressure from the hoist
control valve C-4 from releasing the hoist brake or camming the main/whip pump to hoist the block or hook.
When valve P-3 shifts, the hoist brake sets and the main/whip pump swashplate returns to the neutral position.
When valve P-2 shifts, the boom hoist brake and lock pawl set, and the boom pump swashplate returns to the
neutral position to prohibit lowering of boom. Atthis point, the hoist handle may be moved forward to lower the
hookor block, but no further hoisting or boom lowering can be accomplished. Once the block or hook has been
lowered, the line follower closes the valve in the valve assembly and permits resumption of norma! crane
operation.

NOTE: (f either line follower has been lifted, both the main ond whip hoists will be prevented from hoisting
and the boom will be prevented from lowering.

INSTALLATION

Figure 33 shows the air piping diagram andthelocation of the components usedforthe line travel limiter system.
The valve assemblies should first have the necessary fittings and the shuttle valve installed on the main hoist
valve assembly support (Part #1615997) is mounted in the forward position of the sheave extension. The main
hoist valve assembly support is mounted behind the whip hoist valve assembly support. Mounting plates for both
valve assembly supports are integral parts of the sheave extension. The valve assemblies are attached te the sup-
ports by a pin (Part #1615992) and a cotter pin (Part #G-6501 620-5).

The whip hoist line follower is suspended by a 12’-0" (3.7 m) long piece of 1/4”° (6 mm) chain using openlinks to
attach the chain to the follower and clevis. The main hoist line follower is suspended by a 8'-0"' (2.4 m) piece of
1/4” (6 mm) chain using open links to attach the chain to the follower and clevis.

The air supply tubing [3/8’’ (10 mm) Synflex} and signal tubing [1/4’’ (6 mm) Synflex] should be attached as shown
in Figure 33. The tubing should be placed in the tray along the left side of the boom and secured by nylon wire
ties. The hoses should be positioned to prevent the possibility of excessive wear or detrimental binding.

A striker plate (Part #1615845) must be welded to the main block to provide a striking surface for the main hoist
line follower. This plate is shipped separately from the main hoist block and is to be welded in place during the
limiter installation.

Rev. July 1982 Page 67

anwpe National Supply Compeny
Devrs0n of Ateneo ine.
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435

VALVE ADJUSTMENT PROCEDURE x,

The air valve in the volve assemblies are to be adjusted to meet the following requirements:

1. The adjusting nut should be turned one way or the other until the spring in the valve assembly causes the
valve roller to be pressed completely down without any weight on the clevis as shownin Figure 33A. Air will '
then flow from port “A” to port ‘“‘O"’. This is the ‘shutdown’ position.

2. Whentheclevis is pulled down, the hex screw head should not be touching the roller but be as close as possi-
le. Supply air pressure ot port “A” ie caw blocked from port ’O". This is the normal operating position.

NOTE: Normally, adjustments are m. .'. without being able to see inside the valve assernbly. Therefore,
severaltrial and error attempts have to be made before good adjustment is obtained. This is a simple
task since the adjustment can be tested by pulling down on the clevis by hand and checking to seeif
the applicable hoist function operates properly. When the clevis is released, the corresponding hoist
function should be shut down. Also, if the adjusting nut is turned too far up, the system will be
rendered inopérative. This should be avoided since it results in a dangerous operating condition.

Page 67A Rev. July 1982 -_—

ARMCO Nationa! Supply Company
Deg on OF Armee ane
 ARS ges
OS-435

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NATIONAL
LUTHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

LINE TRAVEL LIMITER ADJUSTMENT

VALVE

ADJUSTING SCREW —~
SSSSSSSSSASEL

oe

ADJUSTING NUT ADJUST NUT FOR AIR FLOW

FROM PORTA’ TO PORT “O" IN
POSITION SHOWN. AIR FLOW
5 WILL BE BLOCKED FROM PORT
oo ‘AY WHEN GLEVIS IS PULLED &
CLEVIS DIMENSION "X"IS ZERO.

FIGURE 33A

\.

Rev. July 1982 —_ -

Page 68A
nisin OF AICO Ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4LITHO IN USA.

REEVING AND WIRE ROPE SPECIFICATIONS

The fallowing charts show the wire ropesize and type requiredfor the three hoist winches of the crane. Also
shown are figures depicting the correct method of wire rope reeving from the winches to the hoist blocks.
The wire ropes are anchored to the brake band side of the winch by six-bolt clamps secured to the brake
drum. When anchoring the wire rope check to moke sure that the clamp has the correct parf number as
shown in Figure 35, 36, and 37.

The wire rope should be periodically inspected for signs of wear, broken wires, and corrasion. The drum and
sheaves should also be examined periodically for wear and corrugations. Routine lubrication of the wire
rope is also essential in order to prevent corrosion and minimize friction and wear.

MAIN HOIST
LENGTH OF MAIN HOIST WIRE ROPE RECOMMENDEDFOR:
A. IN TRANSIT OR SHIPYARD DRAFT B. NORMAL OPERATING DRAFT
CG. BOOM POINT ROPE WITH6 CL BOOM POINT ROPE WITH 6
BOOM LENGTH TO WATER LINE LINE REEVING* TO WATERLINE LINE REEVING
FT (m) FT (m) FT (m) FT (M) FT (m)
60 (18.3) 190 (57.9) 1500 (457) 130 (39.6) 1200 (366)
80 (a 4) 210 (64.0) 1650 (503) 150 (45.7) 1300 (396)
100 (30.5) 230 (70.0) 1800 (549) 170 (51.8) 1400 (427)
120 (36.6) 250 (76.2) 1900 (579) 190 (57.9) 1600 (488)
140 (49. 7) 270 (82.3) 2200 (671) 210 (64.0) 1700 (518
Main Hoist Drum Capacity 2100 Ft. (640 m) of 7/8 inch (22.2 mm) Wire Rope.
Wire Ropeis 7/8 inch (22.2 mm) 6 x 26 Warrington-Seale, Right Regular Lay, Extra Improved Plow Steel,
Independent Wire Rope Core, Preformed.t _
*Length of wire rope may be changed far installations using other than 6 Tine reeving on mainhoistblock.

WHIP LINE HOIST

Standard Lengths of Wire Rope

NormallyFurnished
Boom Length Wire Rope Length Wire Ropeis I Inch (25.4 mm},
60 Ft. (18.3 m) 750 Ft. (229 m) 19 x 7 Nonrotating,
80 Ft. (24.4 m) 750Ft. (229 m) Extra Improved Plow Steel,
100 Ft. (30.5 m) 800 Ft. (244 m) Independent Wire Rope Core,
120 Ft. (36.6 m) 800 Ft. (244 m) Preformed.t
140 Ft. (427m) 850 Ft. (259 m)
Whip Line Drum Capacity is 1600 Fi. (488 m) of Tinch (25.4 mm) Non-Rotating Wire Rope

BOOM HOIST SUSPENSION

10-PART CONTINUOUS
Boom Length Rope Length
60 Ft. (18.3 m) 800 Ft. (244 m) Wire Ropeis 1 inch (25.4 mm),
80 Ft. (24.4 m) 950 Ft. (290 m} 6x 26 Warrington-Seale,
100 Ft. (30.5 m) 1150 Ft. (350 m) Right Regular Lay,
120 Ft. (36.6 m) 1350 Ft. (4tt m) Extra !mproved Plow Steel
140 Ft. (42.7 m) 1550 Ft. (472 m) Independent Wire Rope Core, Preformed.+

t Note: A wire rope of equal size, strength, flexibility and crush resistance may be substituted.

Rev. Dec. 1978 Page 69

Samco30 National Supply Company
Division of Armco Ine.
NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435

MAIN HOIST REEVING -™

LOAD SENSING SHEAVE

MAIN HOIST DRUM

ANCHOR ROPE TO BRAKE BAND

SIDE OF DRUM WITH 1610546 CLAMP
NOTE: THE MAIN HOIST IS
THE FRONT ORUM ON CRANE

Figure 35 LT-160047

WHIP HOIST REEVING

LOAD SENSING SHEAVE

WHIP HOIST “=e

ANCHOR ROPE TO BRAKE BAND

SIDE OF DRUM WITH 161252! CLAMP

NOTE: THE WHIP HOIST IS

THE CENTER DRUM ON CRANE

Figure 36 LT-160047

Page 70 Rev. Dec. 1978 _

ARMCO National Supply Company
Devigion of Armea Ine
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-43
LITHO INUSA

BOOM HOIST REEVING

foes SHEAVE BLOCK

oy
V >

ROPE TO PASS OVER

SPACER ROOS

DEAD END

f i :
FIXED GANTRY SHEAVES~ + — Te

‘ |
ANCHOR ROPE TO BRAKE
| s BAND SIDE OF DRUM WITH
[7 tei2s2t CLAMP
NOTE: THE BOOM HOIST IS THE REAR
ORUM ON THE CRANE.

Figure 37 LT-160032

Rev. Dec. 1978 Page 71

ARMCO National Supply Company
Dmision of Armco tne
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

BOOM HOIST BLOCK SUPPORTS

Block supports (Fig. 38) are installed on the boom in order to retard any bouncing motion of the floating
sheave block, and to ease wire rope replacement.

Different boom lengths require that different block supports be used between the boom andfloating block.
The chart below specifies the required block support part number for certain boom lengths.

BOOM HOIST BLOCK SUPPORT

Length
80°
Block Support Length
42 Inches (t.07 m)
100° 20 Inches ( .51 m)
120° 9.75 Inches ( .25 m)

LZ a
em HOIST~
2 ee BLOCK SUPPORTS ,
7,
/if
/)

Figure 38 LT-160031

Page 72 Rev. Dec. 1978

National Suppty Company
Owision of Armco ing
NATIONAL HYDRAULIC PEDESTAL CRANE OS-43

WIRE ROPE MAINTENANCE AND INSPECTION

LUBRICATION

During manufacture new ropes receive adequate lubrication for initial storage and the very early stages of
the rope’s working life, In accordance with the wire rope manufacturer's instructions, the initiol lubrication
must be supplemented at regular intervals,

Hf a well ordered plan of lubrication is not used the rope will deteriorate rapidly as follows:

Corrosion and pitting will reduce the steel area of the rope.

The wires will become brittle from excessive corrosion.

The wires of the rope move relative to each other and are subject to frictional wear. A lack of lubrication
increases the rate of the frictional wear.

Pitting causes internal nicking of the wires reducing their strength.

Ropes not in regular use ore subject to loss of lubrication from weathering.

Lubricating a wire rope is as vital as greasing any other piece of machinery. The wire rope manufacturer
should be consulted on proper lubricants and application techniques. Good lubricants have the following
characteristics:

Corrosion Resistant

Water Repellant

Penetrating Ability

Chemical Neutrality

High Pressure Flow Characteristics

Adhesiveness and Affinity for Steel

Plastic Coating

Temperature Stability

STORAGE

Ropes should be stored in coils or on reels in a clean, dry location indoors. If lengthy storage is required,
prudence dictates the rope be periodically inspected and lubricated as required. The rope must be kept clear
of heat and steam and must never be allowed to rest for extended periods on concrete or ash floors.

Rev. Dec. 1978 Page 73

ARMCO National Supply Company
Dwasion of Ameo ine
NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435

INSPECTION

The wire rope should be inspected for the following:

Kinks or severe twists

Broken wires and nicks

Deformed, worn orflattened wires

Corroded or pitted surfaces

Shortened or lengthened rope lays

The running of a soft cloth (preferably cotton) over the entire length of wire rope will assist in locating nicks
or broken wires as the nicks and breaks will pick up threads.

If any of the following conditions exists the rope should be condemned and replaced.

Six wires broken in one rope lay.

Three wires broken in one stand in one lay.

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

Rope severly kinked, crushed, cut, or unstranded, or any other damageresulting in distortion of rope
structure,

Considerable corrosion in the valieys between strands.

Reduction from nominal rope diameter of more than 1/16”.

Page 74 Rev. Dec. 1978 4

ape National Supply Company
Division of Armco Ine.
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

READING SCHEMATICS

A schematic is a graphic representation of a fluid power or electrical system. Graphic symbols emphasize the
function and methods of operation of components. Graphic symbols are capable of crossing language
barriers and can promote a universal understanding of systems.

The symbols show connections, flow paths, and functions of components represented. They can indicate
conditions occuring during transition from one flow path arrangement to another. Symbols do not indicate
construction, nor do they indicate values, such as pressure, voltage, flow rate, and other component settings.
The symbols do not indicate location of ports, direction of shifting of spools, or positions of actuators on
actual components.

In this manual, the schematics are shown with the electrical power off and the engine kill valve
depressed. For any given situation all connected flow lines and related components should be
simultaneously considered. The symbols on the hydraulic and pneumatic schematics are basically the same
and are read in essentially the same manner. The electrical schematics use a separate set of symbols. The
following basic rules apply to the schematics:

Solid lines indicate flow paths.

Dash lines indicate signal or pilot pressure paths.

Squares represent valve positions

Pressure controlled valves shift due to a pressure difference.

Alternate long and short dash lines indicate component boundaries.

Circles represent miscellaneous components.

Diamonds represent fluid conditioners.

Rev. Dec. 1978 Page 75

anwpe National Supply Company
Division of Armee tne
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
NOTES —™

Page 76 Rev. Dec. 1978

Aug National Supply Company
Division of Armeo inc
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

TROUBLE SHOOTING —-CONTROL PRESSURE CIRCUIT

Adequate contro! pressure (700/750 psi) is necessary for releasing all of the brakes and the boom hoist lock
pawl on the crane. Control pressure is also necessary for shifting the selector valve in order to operate the
main and whip hoists. See Figure 11 for the location of the control pressure pump and relief valve.

If the control pressure gage reads in a pressure range of 100 to 600 psi:

1. The control pressure relief valve is either adjusted too low or it has a small piece of dirt plugging the
relief valve’s poppet orifice. Gently tap the case of the relief valve several times with a smal! metallic
object to dislodge any foreign matter that may be in the valve. Then readjust the relief valve if
necessary.

2. If tapping and readjusting the relief valve does not bring the control pressure up to 700/750 psi, back
out the relief valve pressure adjusting screw two turns and allow control fluid to circulate for one
minute. Then readjust the screw while checking the control pressure gage. If adequate and stable
control pressure cannot be obtained, replace the relief valve.

3. If steps one and two do not correct the low pressure condition, the control pressure pump is probably
worn out and should be replaced.

Hf the control pressure gage reads zero:

1. Remove the control pressure pump and examine for damage to the shaft or drive key. Also check the
drive coupling and sprocket stub shaft for damage. Replace all damaged components.

2. Check the suction line hose to the control pressure pump for a restriction or rupturing. Replace the
hose if an impairment is found. Check the control pressure pump suction filter for a restriction and
replace the element.

TROUBLE SHOOTING — PUMP DRIVING HOUSING

LOW LUBE PRESSURE- The chain, sprockets, and bearings of the pump drive housing are lubricated by means
of a pump mountedto the engine side of the pump drive housing. Lube oi! pressure is monitored by a gage
mounted to the top of the drive housing, and an indicator which alerts the operator in the cab of a low lube
pressure condition. See Figure 13 for the location of the components.

lf the indicator turns red while operating the crane:

1. Immediately check the lube pressure gage at the top of pump drive housing. The gage pressure
should not be below 10 psi at low idle speed. If the gage reads more than 10 psi, check the hose to the
indicator for a restriction or rupture and the indicator for proper operation.

2. If the gage reads between zero and 10 psi, check the pump drive lube oil level and chain spray pipe
for damage. Do not overfill the case to prevent overheating and foaming of the lube oi! or damage to
the drive chain.

3. If the pressure is erratic, check the pump suction line for a restriction or rupture and clean the
lubrication filter.

4. If the gage reads zero, remove the lube oil pump and examine for damage to the shaft or drive key.
Also check the drive coupling and sprocket stud shaft for damage. Replace all damaged components.

Rev. Dec. 1978 Page 77

ARMCO National Supply Company
Division of Armeo Inc
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
PUMP DRIVE HOUSINGIS GAINING FLUID - If the fluid level of the drive rises during crane operation, one or
more of the axial piston pump shaft seals is leaking or the control pressure pump shaft seal is leaking. The
hydraulic tank can be pressurized to a maximum of 5 psi (.3 bar) to locate the leaking seal once the pump
drive housing inspection covers have been removed. See page 99 for procedure to replace an axial piston
pump shaft seal. CAUTION: Do not remove the drive inspection covers with the engine running.

Page 78 Rev. Dec, 1978 _=

ARMCO National Supply Company
VV dussion of Armes ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4 LITHO INUSA

TROUBLE SHOOTING

TROUBLE SHOOTING — MAIN OR WHIP HOIST

PROBLEM POSSIBLE CAUSE CORRECTIVE MEASURE

Brakes will not release Emergency brake set Pull vaive to reset for normal operation.
and wincheswill not valve depressed.
turn,
Low hydraulic fluid Check tank tevel and add fluid
level. if necessary.

Clutch not engaged, Engage clutch and checkclutch adjustment.

or clutch jumps out See page 63.
of engaged position.

Piugged charge pump Disassemble filter, clean rod magnets and

suction line filter. replace elements.

Low or absent control Check control pressurerelief valve, pump

pressure. Control land pump suction filter. See page 77.
pressure should be
700/750 psi (48.3/51.7 bar).

Low air pressure. Check air supply pressure, 95 to 100 psi (6.6 to 6.9 bar)
is required for normal operation.

Inoperative tow air Check operation and adjustment of valve by observing

pressure stop valve, P-5. pressure at vaive port 8. Readjust or replace as is
required. See page 86.

Inoperative hoist ‘Check discharge pressures of valve. If pressures are

control valve, C-4, absent repair or replace valve. See page 85.

Low Charge charge If charge pressure is good [160-300 psi (11-20.7 bar),
pressure brake set check air supply to hoist control vatve, C-4. If air supply
valve, P-7 not shifted. is absent, repair or replace P-7. jf charge pressure is low
[140 psi (9.6 bar) or lower], see hydrostatic drive
trouble shooting section.

Main or whip hoist Hoist selector valve Repair or replace valve.

winch turns regardless spool seized.
of position of hoist
selector in operator's
cab.

Brakewill not release Brake releasing valve When control handle is out of neutral, pressure should
but winch wil! pressure malfunction. be supplied to vatve central piston. lf pressure is present,
up and hoist against repair or replace valve. If pressure is absent, reset
brake lemergency load release valve and check valve signal
tubing for obstructions.

Brake foot pedal valve Check whip hoist brake cylinder pressure tap, page 44,
leaking or misadjusted. while hoisting the whip line. Pressure should be
700/750 psi (48.3/51.7 bar). If low adjust foot pedal
valve as described on page 58.

Hoist brake adjusted Adjust hoist brake. See page 57.

too tight.
Low control pressure. Check control pressurerelief valve adjustment as
Control pressure should be described on page 77.
700/750 psi (48.3/51.7 bar).

Rev. Dec. 1978 Page 79

anwpe National Supply Company
Division at Armco Ine
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

PROBLEM POSSIBLE CAUSE CORRECTIVE MEASURE

Main hoist winch Hoist brake set too tight. Adjust hoist brake. See page 57.
operates properly,
but whip does not, Brake releasing When contro! handle is out of neutral, pressure should
or vice versa valve malfunction. be supplied to valve control piston. If pressure is present,
repair or replace valve. If pressure is absent, check valve
signal tubing for obstructions.

Hoist selector valve Check for restriction in control pressure or drain lines to
Operator, P-16, not valve and remove. With air pressure to the top of the valve,
functioning properly. the whip hoist winch should turn. With air pressure to the
bottom of the valve, the main hoist winch should turn. If
pressure and drain lines are Clear and valve receives air
signats from the hoist selector valve in the operator's cab,
replace or repair the selector valve operator, P-16.

Hydraulic motor See hydrostatic drive trouble shooting section.

malfunction.

Brakes will release, Pump actuating cytinder, Adjust and connect actuating cylinder.
but turn winches will 0C-3, disconnected from
not turn. Pump control lever.

Hoist selector valve With air pressure to the top of the hoist selector valve
maifunction. The spool in operator, the whip hoist winch should tuen, With air
the operator or the hoist pressure to the bottom of the valve, the main hoist winch
selector valve is seized in should turn. Repair or replace the hoist selector valve
the center position. or the hoist selector valve operator.

Pump or motor malfunction See hydrostatic drive trouble shooting section. ae,

Brake will not set with Improperly adjusted hoist Adjust minimum discharge pressure and pick up points
control handle in neutral. control valve, C-4. of valve. See page 85.

Faulty brake releasing valve. Check pressure to brake cylinder. If pressure is present
with control handle in neutral, repair or replace valve.

Brake set too loose. Adjust brake. See page 57.

Worn or oily brake linings. Inspect and replace as necessary.

Neutral difficult to find. Pump actuating cylinder Disconnect cylinder from pump control lever. if pump
Pump groans with out of adjustment returns to neutral, adjust cylinder linkage and replac®. If
possible pressure pump does not return to neutral, see hydrostatic drive
indications of hoist gage trouble shooting section; displacement control valve.
whencontrol handle is
in neutral.

Hoist will not lift Insufficient parts of Check reeving chart in cab to determine correct number of
allowable loads. wire rope reeving. lines necessary to hoist load. Add parts of line if required.

Pump or motor maifunctian. See hydrostatic drive trouble shooting section.

Brake releases late and Low contro! pressure. Adjust control pressure as described on page 41.
load drops slightly when Pressure should be
control handle is moved 700/750 psi (48.3/51.7 bar).
in lower direction.
Improperly adjusted hoist Adjust minimum discharge pressure and pick up points
control valve, C-4. of vaive. See page 85.

Pump actuating cylinder Adjust cylinder to be sure it does not push or pull on —
0-3, improperly adjusted. pump control lever when contro! handle is in neutral.

Page 80 Rev. Dec. 1978

ARMGCO National Supply Company
MZ crsssian ct Armes ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS$-435
LITHO INUSA

PROBLEM POSSIBLE CAUSE CORRECTIVE MEASURE

Winch will power down Main and/or whip hoist line Lower main and/or whip hoist until hoist line follower is
but will not hoist. travel limiter is actuated. hanging from line travet limiter valve box arm.

Valve P-4 is shifted causing Check for air signal to diaphragm of P-4. If a signal is
vaive P-3 to be shifted. present, adjust actuating cams for valves V-5 and V-6 and
check operation of V-5 and V-6. tf no signal is present
checkfor signal to cylinder of valve P-3. !f P-3 has a signal,
repair or replace P-4. If no signal is present at P-3, repair
or replace P-3,

Faulty hoist control Check both discharge pressures of valve. If either pressure
valve, C-4. is absent, repair or replace valve. Minimum and maximum
should vary by 65 psi (4.5 bar). See page 85.

Winchwill turn in hoist Shuttle valve in main or whip See hydrostatic drive trouble shooting section.
direction, but will not motorvalve manifold is
turn in power down shifted and held.
direction.
Brakeset too tight. Adjust brake. See page 57.

Faulty hoist control Check both discharge pressures of valve. if either

valve, C-4. pressure is absent, repair or replace valve. Minimum and
maximum should vary by 65 psi (4.5 bar)

Pump and/or motor See hydrostatic drive trouble shooting section.

maifunction.

Operation of hoist is Orifice mistakenly installed Lift displacement control valve from atop main/whip
extremely sluggish when under pump displacement pump and remove orifice from inner most “O” ring port.
hoist handle is moved control valve.
out of neutral. Hook
continuesrising several
feet and brakes squeal
whenhandle is returned
to neutral.

Main or whip hoist Blocked or severedair line Repair air line.

motor fails to change to hoist high speed valves,
speeds. P-14 or P-15.

Faulty hoist high speed Replace faulty valve.

valve, P-14 or P-15.

Charge pressure supply Install tubing and fittings as shown in the illustrated parts
tubing to hoist high speed list.
valve notinstalled when
motor changed out.

Main or whip hoist Leaking main or whip Repiace motor shaft seal. See hydrostatic drive trouble
shaft assembly (drum) hoist motor shaft seal. shooting section.
gaining fluid.

Rey. Dec. 1978 Page 8}

ARMCO National Supply Company
Owision of Armco Ine
NATIONAL
UTHOINUSA
HYDRAULIC PEDESTAL CRANE OS-435

TROUBLE SHOOTING — BOOM HOIST

PROBLEM POSSIBLE CAUSE CORRECTIVE MEASURE

Brake and lock pawl Closed charge pump Open vaive and install stem locking device.
will not release and suction line valve.
winch will not turn.
Emergencybrake set Pull valve to reset for normal operation.
vale depressed.

Low hydraulic fluid level. Check hydraulic tank level and add fluid if necessary.

Clutch not engaged, or Engage clutch and check clutch adjustment. See Page 63.
clutch jumps out of
engaged position.

Plugged suction tine filter. Disassemble filter, clean rod magnets and replace elements.

inoperative boom hoist Check discharge pressuresof valve. If pressures are absent
contro] valve, C-2. repair or replace valve. See page 85.

Low charge pressure brake if charge pressure is good [160-300 psi(11-20.7 bar)j, check
set valve, P-8, not shifted. air supply to boom hoist contro! valve C-2. If air supply is
absent, repair or replace P-8. if charge pressure is low
[140 psi (or 9.6 bar) or lower], see hydrostatic drive
trouble shooting section.

Winch turns, brake and Upper (lower) boom angle Lower (raise) boom until system is disengaged. Adjust
lock pawl release when limiter system actuated. cams as may be required. See page 65.
powering down but not
when hoisting or vice One of boom angie limiter Check operation of all four valves. Under normal conditions
versa. valves, V-13, V-14, P-1 or V-13 and V-14 should not send pressure to P-1 or P-2 and
P-2, is shifted. P-1 and P-2 should permit free air flow. Replace or repair
any faulty valves.

Fauity boom hoist control Check both discharge pressures of valve. If either pressure
valve, C-2. is absent, repair or replace valve. Minimum and maximum
should vary by 65 psi (4.5 bar). See page 85.

Low or absent control Check control pressurereleif valve, pump and pump
pressure. Control pressure suction filter. See pages 41 and 77.
should be 700/750 psi (48.3/
51.7 bar).

Brake and tock paw! will Faulty boom brake/lock Repair or replace valve.
not release but winch pawl releasing valve, P-13.
will pressure-up and
hoist against brake.

Lock pawl remains Faulty or improperly Replace or adjust valve. See page 42.
release when boom adjusted lock pawi cylinder
brakeis set. flow control valve.

Lock paw] return spring Install spring.

disconnected.

Boom brake and lock Improperly adjusted boom Adjust minimum discharge pressure and pick up points
paw remain released hoist control valve, C-2. points of valve. See page 85.
when control handle
is in neutral Faulty boom brake Repair or replace valve.
releasing valve, P-13.

Page 82 Rev. Dec. 1978 _=

ARMCC National Supply Company
VW owisaonot Armee ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4
LITHO IN USA

PROBLEM POSSIBLE CAUSES CORRECTIVE MEASURE

Boom brake remains Boom brake adjusted Adjust boom brake. See page 57.
engaged but lock too tight.
pawi releases.

Brake and lock paw! will Pump actuating cylinder, Adjust and connect actuating cylinder.
release but winch will OC-2, disconnected from
not hoist or power down. Pump control lever.

Pump and/or motor See hydrostatic drive table shooting section.

malfunction.

Neutral difficult to find. Pump actuating cylinder, Disconnect cylinder from pump control lever. If pump
Pump groans with DC-2, out of adjustment. returns to neutral, adjust and connect cylinder to control!
possible pressure lever. If pump does not return to neutral, see
indications on boom hydrostatic drive trouble shooting section.
gage when control
handle is in neutral. Pump displacement See hydrostatic drive trouble shooting section.
Brake and lock paw! controt valve out of
are set adjustment.

Boom operation slow. Air pressure regulator out Adjust air pressure regulator. If so equipped, check
of adjustment. Control air adjustment of air compressor unloading valve.
Pressure should be
95/100 psi (6.6/6.9 bar).

Boom hoist, shaft Leaking boom hoist Replace motor shaft seal. Se hydrostatic drive trouble
assembly (drum) motor shaft seal. shooting section.
gaining fluid.

_— Rev. Dec. 1978 Page 83 |

ape National Supply Company
Division of Armea inc.
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
TROUBLE SHOOTING — SWING
PROBLEM POSSIBLE CAUSES CORRECTIVE MEASURE

Crane will not swing Closed charge pump Open valve and install stem locking device.
allowable loads suction line valve.

Swing brake valve Pull valve to release brake and provide air to swing
depressed. control valve, C-1.

Low hydraulic fluid level. ‘Check tank fluid level and add fluid if necessary.

Clutch not engaged, or Engage clutch and check clutch adjustments. See page 63.
clutch jumps out of
engaged position.

Plugged suction line filter. Disassembly filter, clean rod magnets and replace elements.

Pump and/or motor See hydrostatic drive trouble shooting section.

malfunction.

Swing brake releases Low hydraulic fluid level. Check tank fluid level and add fiuid if necessary.
but crane will not
pressure-up and swing Pump actuating cylinder Properly connect cylinder to pump control lever.
allowable loads. DC-1, disconnected from
pump control Jever.

Plugged suction line Disassemble filter, clean rod magnets and replace elements.
filter.

Swing gage shuttle valve Disconnect shuttle valve at bottom of swing motor.
on motor faulty. Disassembly valve, clean and inspect. Replaceif ball or
body shows signs of heavy wear.

Pump and/or motor See hydrostatic drive trouble shooting section.

malfunction.

Swing brake will not Low or absent control Check control pressurerelief valve, pump and pump
release but swing drive pressure. Control pressure suction filter. See pages 41 and 77.
will pressure-up and turn should be 700/750 psi
against brake. (48.3/51.7 bar).
Swing brakeset too tight. Adjust brake as described on page 58.

Faulty swing brake Repair or replace valve.

releasing valve.

Neutral difficult to find. Pump actuating cylinder Disconnect cylinder from pump control lever. if pump
Pump groans with brake DC-3, out of adjustment. returns to neutral, adjust cylinder linkage and replace.
set or swings If pump does not return to neutral, see hydrostatic
inadvertently with brake drive trouble shooting section.
released.

Crane swings in one Faulty swing control Check both valve discharge pressures. Minimum and
direction only. valve, C-1. maximum should vary by 65 psi (4.5 bar). If either pressure
is low, repair or replace valve. See page 85. If pressures
are good, see hydraulic drive trouble shooting section.

Pump malfunction See hydraulic drive trouble shooting section.

Swing is jerky with Swing brake is dragging. Adjust swing brake and verify pads do not drag on disk.
abnormally high See page 58.
pressures on swing gage.

Swing brake wil! not Brake adjusted too loose. Adjust brake. See page 58.
property set.
Worn or ail contaminated Replace brake pads.
pads on brake.

Broken brake springs. Replace broken springs.

Swing gear reducer Leaking motor shaft seal. Replace motor shaft seal. See Hydrostatic Drive Trouble
is gaining fluid. Shooting Section.

Page 84 Rev. Dec. 1978

ARMCO National Supply Company
> Sc ol Armes ne
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435LITHO IN U.S.A.

AIR VALVE REPAIR, MAINTENANCE AND OPERATION

HOIST AND SWING CONTROL VALVE (Figures 40, 41 and 42)

OPERATION- With the handle in the “OFF” or neutral position, both control pressure ports, | and 3, are open
to the atmosphere through their respective pilot valves in the control valve.

The handle operates a dual cam. The peripheral surface of the larger section is contoured to provid2 minute
positioning increments to the pressure control portion. The smaller section moves the right and left hand
levers to operate the pilot valves.

Movement of the handle in the first 10° of the 46° travel arc closes the exhaust of the pressure control
portion (no preload setting) and one of the pilot valves. The other pilot valve is operated when the handle is
movedin the opposite direction. Handle movement to or beyond the 10° position unseats the inlet valve in
the control portion of the pilot valve. Controlled pressure from the unseated inlet valve of the pressure
control portion flows through an internal passageto the inlet valve seats of the pilot valves. Depending upon
the quadrant in which the handle is positioned, the controlled pressure will flow through the openedpilot
valve to the “OUT” port, 1 or 3. The pressure at the “OUT” port is proportional to the handle position in the
handle travel arc.

The control valve will automatically compensate for downstream air pressure changes. If the air pressure at
the “OUT” port increases over that called for by the handle position, the diaphragm in the control portion
will deflect downward. This moves the exhaust valve seat away from the inlet and exhaust valve unit and
vents the excess pressure. If the pressure drops below that called for by the handle position, the control
spring will force the diaphragm upward. The exhaust valve seat then movesthe inlet valve of the inlet and
exhaust valve unit from its seat to open the “IN” port to the “OUT” port and restore the pressure called for.

MAINTENANCE - Maintenance periods should be scheduled in accordance with frequency of use and
working environment of the control valve. A repair kit containing seals and other expendable parts is listed
in the OS-435 parts list.

Notice the operating portion of the valve can be removed without disturbing the tubing connections.
Remove the valve from the pipe bracket by loosening studs (1) and lift the unit free.

Completely disassemble the control valve. Wash all metal parts in a nonflammable solvent and ail rubber
parts with soap and water. Rinse each part thoroughly and blow dry with a low pressure air jet. Arrange the
parts on a clean white surface in the order of the exploded view.

Examine each part carefully. All parts of the repair kit should be used when rebuilding the valve. As
reassembly proceeds, lubricate each part. Use no. 107 Lubriplate on metal-to-metal surfaces and Cosmolube
on all rubber parts. Equivalent greases to those recommended can be used.

PILOT VALVE LEVER ADJUSTMENT - Use the adjustment set-up shown in Figure 40 and an inlet pressure of 90
psi (6.21 bar). Turn the adjustment screw (24) clockwise until the control spring (27) is slightly compressed.
Remove the valve protectors (47). Move the control valve handle (7) back and forth on both sides of the
“OFF” position, observing the action of levers 41 and 45. The pilot valves should be fully open after the
handle moves through the first 10° of the travel arc. If the pilot valve levers need adjusting, place the handle
in a maximum increasing pressure position. With a 3/32” hex key wrench, turn the adjusting screw (44) of
the activated lever (either 41 or 45) counterciockwise, just far enough to crack the exhaust valve. The gage
will show a drop in pressure. From this point, turn the adjusting screw clockwise a fuil three (3) turns. This
will open the inlet valve of the pilot valve to its maximum capacity.

Move the handle to the opposite extreme position and repeat the adjustment for the other pilot valve lever.

CAM DOG ADJUSTMENT - The eccentric cam dog pin (38) aligns the cam dog (39) with the rise on cam 15. If
pressure responseis notidentical to handle position in both directions, compensatethis difference by turning
the cam dog pin (38) either clockwise or counterclockwise.

Rev. Dec. 1978 Page 85

ARMCO National Supply Company
Dwision of Armea tne
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435
PRESSURE SETTING ADJUSTMENT - Use adjustment set-up shown in Figure 40 and an inlet pressure of 90 psi
(6.21 bar). Adjusting screw 24 varies the minimum and maximum pressure setting a like amount without
changing the pressure range. Turning the adjusting screw in raises the maximum and minimum pressures.
The minimum pressure should be about 13 psi (.9 bar) and the maximum pressur should be about 80 psi (5.52
bar). If the minimum pressure is set too high, rough operation will result. If the minimum pressure is too low,
the hoist speeds or swing speed will be below the maximum possible.

NOTE: The maximum pressure is the pressure with valve control handle moved 46° and the minimum
pressure is the pressure with the valve control handle moved 10° from the neutral or “OFF”
position. The discharge pressures with the control handle in the neutral or “OFF” position should
be 0 psi.

DIAPHRAGM OPERATED VALVES

OPERATION - The diaphragm operated valves are a normally closed valve and require approximately 5 psi
(.3 bar) to the diaphragm to open the valve.

REPAIRS - A repair kit for the diaphragm operated valvesis listed in the parts list. Instructions for the valve
repairs are included with the kit.

CYLINDER OPERATED VALVES(Single Acting)

OPERATION- The single acting cylinder operated valves can be normally open or normally closed valves.
The valves require approximately 35 psi (2.4 bar) to the piston to shift the valve. The valves are spring
returned.

REPAIR - Replacement seals for the valve spools and cylinder pistons arelisted in the parts list. The valves are
simple in design but should be carefully disassembled, cleaned, lubricated and properly reassembled.

CYLINDER OPERATED VALVES (Double Acting)

OPERATION - The two double acting cylinder operated valves are normally closed valves. The valves require
approximately 125 psi (8.6 bar) hydraulic pressure to be shifted with 90 psi (6.21 bar) pressure on the
opposite side of the piston. In case of loss of air pressure the valves are spring returned.

REPAIR - Replacement seals for the valve spools and cylinder pistons are listed in the parts list. The valves are
simple in design but should be carefully disassembled, cleaned, lubricated and properly reassembled.

LOW AIR PRESSURE SAFETY VALVES (Figure 39)

OPERATION- The low air pressure safety valves are adjustable pressure holding valves that do not yield until
the air supply pressure exceeds the setting. After opening, the valve permits free air flow. When the air
supply pressure drops below the opening pressure setting of the valve, the valve closes and exhausts the air
pressure in the “‘downstream” position of the control system.

PRESSURE SETTING ADJUSTMENT- The pressure setting of the valves is adjusted by loosening the jam nut and
turn the adjustment screw “IN” to increase the setting and “OUT” to decrease the setting. The pressure
setting range of the valves is 0 to 75 psi (0 to 5.2 bar).

NOTE: The decreasing air pressure warning valve (P-6) should be set to yield at 75 psi (5.2 bar). The low
air pressure main/whip stop valve (P-5) should be set to yield at 50 psi (3.4).

REPAIR - Should the valves fail to function properly they should be replaced.

Page 86 Rev. Dec. 1978 _

ARMCO National Supply Company
‘Division of Armeo Inc
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4
LITHO IN USA.

MISCELLANEOUS VALVES

REPAIR - Replacement seals, repair kits and replacement knobsare listed in the parts list. The repair kits
include instruction for rebuilding the valves. Care should always be exercised that the valves are properly
reassembled.

LOW AIR PRESSURE SAFETY VALVES

ADUUSTING SCREW

JAM NUT

] DIAPHRAGM

INLET:

OUTLET

Figure 39 LT-160036

Rev. Dec. 1978 Page 87

ARMCO National Supply Company
Omision of Armco ing
NATIONAL HYDRAULIC PEDESTALCRANE —OS-435
CONTROL VALVE ADJUSTMENTSET-UP

ve HS
in -& VOL. \)
Figure 40 LT-160033

CONTROL VALVE OPERATION

LEGEND:
|, CONTROL
2, SUPPLY
3. CONTROL

I
——2

Figure 41 LT-160034

Page 88 Rev. Dec. 1978 Sud National Supply Company

WY Owsonotameaine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

CONTROL VALVE PARTS

Figure 42 LT-160035

= Rev. Dec. 1978 Page 89

NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435

HOIST AND SWING CONTROL VALVE PART DESCRIPTIONS

Item Item
No. Description No. Description

1, SCREW, 5/16” X %2-1/8” Cap 31. SEAT, Exhaust Valve

2. PIPE BRACKET 32. O-RING
3. STRAINER, Port 33. SPRING, Exhaust Valve
4, GASKET,Port 34, INLET and EXHAUST VALVE UNIT

5. NUT, 14 - 28 35. O-RING

6. YOKE, Handle 36. BODY

7. SHAFT, Handle 37. PIN, Cotter

8. BALL, Handle 38. PIN, Cam Dog

9. NUT, 5/16” - 18 39. DOG, Cam

10. WASHER, Lock 40. PIN, Lever

YW STUD, 5/16” - 18 X 1-1/8” 4). LEVER, Right Valve

12. HOUSING, Cam 42. PIN, Roll

13. NUT, Cap 43. ROLLER

14. SCREW,Set 44, SCREW,Set —
15. CAM 45, LEVER, Left Valve

16. SHAFT, Cam 46. RING, Retaining

17. ARBOR,Spring 47. PROTECTOR, Valve
18. SPRING, Handle 48. RING, Retaining

19, WASHER 49. WASHER

20. SPRING, Handle 50. O-RING

21. ARBOR, Spring 51. GUIDE, Plunger

22. NUT, 5/16” - 18 52. O-RING

23. STUD, 5/16” - 18 X 1-5/16” 53, PLUNGER

24, SCREW, Spline Adjusting 54, SPRING, Exhaust Valve

25. HOUSING,Spring 55. SEAT,Inlet Valve
26. SEAT, Spring 56. O-RING
27. SPRING, Control 57, SPACER, Valve
28. NUT, 9/16” - 18 58. VALVE, tnlet

29. FOLLOWER, Diaphragm 59. SPRING,Inlet Valve

30. DIAPHRAGM 60. RING, Retaining

Page 90 Rev. Dec. 1978 SGuzb Nationat Supply Company

Vv Division of Armeo ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4
LITHO INUSA

HYDROSTATIC DRIVE TROUBLE SHOOTING

The following instructions and fault-logic diagrams should provide a comprehensive guide to trouble
shooting the hydrostatic drives of the OS-435 crane.

A fault-logic diagram is provided for each of the five problems which experience has shown to cover the
majority of problems encountered with hydrostatic drives. The applicable diagram should first be found and
then followed to trouble shoot the hydraulic transmission. The paragraphs below give specific instructions
covering steps in the fault-logic diagrams.

DISPLACEMENT CONTROL VALVE INSPECTION

Disconnect the pump actuating cylinder and remove the mounting bracket and cylinder from the pump.
Remove the valve mounting cap screws and lift the valve away from the pump. A gasket and three O-Rings
are used beneath the valve and the swing pump has an orifice inside the inner most O-Ring. Care must be
exercised to be certain no parts are dropped into the pump case.

The valve linkage (connection to swashplate}, pins and retaining rings should all be closely examined.
Confirm the torsional spring is not broken and the orifice (when used) is not plugged. Inspect the O-Rings for
damage.

The valve is removed form the pump by removing the pin connecting the valve linkage to the swashplate
angle feedback link. Upon replacement of the valve, new O-rings and a new gasket of the proper thickness
should be used. The valve must be carefully lowered to insure proper location of the O-Rings, gasket and
orifice.

DISPLACEMENT CONTROL VALVE MOUNTING

MOUNTING SCREW

CONTROL LEVER

aren PLUG

GASKET- o

9} => == S2—— 0-RINGS

PIN WITH RETAINING RING — ' NN ORIFICE
NO (WHEN USED)

PIN WITH COTTER PIN- PIN WITH RETAINING RINGS

CONTROL LINK
SWASHPLATE——
\ \——-PIN WITH COTTER PIN
\,
\—--- FEEDBACK LINK

Figure 43 LT-160037

Auge National Supply Company Rev. . Dec.CC. 1978

7 Page 91
Divisian ol Armea Ine.
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
DISPLACEMENT CONTROL VALVE ADJUSTMENT

WARNING: The variable pump control valve assembly is adjusted at the factory. At no time should the
control valve be readjusted in the field. If the adjustment screws have been tampered with, use the
following procedure to make the correct control valve adjustment. Refer to Figure 44.

1. Remove the contro! valve assembly from the pump prior to making the adjustments. See ‘Displacement
Control Valve Inspection’.

2. Remove the end plug from the centering spring mechanism. With locknut (Item 1} loose and holding the
centering spring housing (Item 3), turn the spring adjusting screw (Item 2) until the screw is just touching
the centering spring washer; thus taking the free end play out of the centering spring mechanism. This is
best done by exerting a light back and forth force on the control valve spool (Item 6) at the same time the
adjusting screw is being turned down, Care must be taken not to compress the centering spring (item 4)
beyond its installed height. Tighten the locknut (item 1) and recheck the spool (item 6) for end play.

3. Adjust the control valve spool {Item 6) for the neutral position. Remove the 7/16’’-20 boss sea! plugs (Item
5) on either side of the control valve housing (Item 7) in the control valve spool bore location of the
casting to reveal the servo cylinder porting holes (Item 8). Loosen the locknut (Item 9) and adjust the
contro! valve spool by screwing the centering spring housing (ttem 3) in or out so that the open areas
{Reference A) between the spool lands and sides of th porting holes are equal. Tighten the locknut (Item
9), recheck the open areas, and reinstall the two 7/16’’-20 boss seal plugs.

4. Re-install contro! valve on pump. Care should be exercised not to damage the O-Rings under the valve
and to properly position the orifice (If used). Carefully check the operation of the pump after the control
valve adjustment.

DISPLACEMENT CONTROL VALVE ADJUSTMENT

Figure 44 LT-160038

Page 92 Rev. Dec. 1978 -_

ARMCO National Supply Company
MP casionatvonee ne
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435LITHO INUSA

STYSTEM RELIEF VALVE INSPECTION (Figure 48)

Using a new or borrowedrelief valve of the same setting, replace the system reljef valves one at a time,
checking the system operation after each replacement.If the problem ceases,discard the faulty relief valve.

Inspect the valves for the praper setting. The first two digits of the setting are stamped on the end of the
valve. For instance 45 for 4500 psi (310.3 bar), 60 for 6000 psi (413.8 bars), and 15 for 1500 psi (103.4). Both of
the swing motor relief valves are stamped 45. The main and whip hoist motors have a 5000 psi relief valve
on the left side and a 1500 psi relief valve on the right side, when viewed from the valve manifold block
end. The boom hoist motor has a 6000 psi relief valve on the left side and a 1500 psi relief valve on the right
side, when viewed fram the valve manifold block end.

RELIEF VALVE OPERATION

HIGH PRESSURE RELIEF VALVE

SYSTEM PRESSURE

Spo HIGH PRESSURE RELIEF VALVE

Figure 45 LT-160039

SHUTTLE VALVE INSPECTION (Figure 48)

The valve spool must move smoothly in the bore. Inspect far warn, galled or broken parts. The spoo! and
valve manifold block are matched and are not interchangeable.

The swing motor shuttle valve spool has a spring ond washer on each end. The hoist motor shuttle valves are
blocked to shift only when the system has high pressure at motor port “A’’. For this reason the hoist motor
shuttle valve spools, when viewed from the valve manifold block end, have a spring and washer on the
teft-hand end and a spool extension or spacer on the right-hand end.

Sanct Na | Supply © ny Rev.

ev. Dec. . 1978 Page 9 3
Division of Area ine.
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

CHARGE PRESSURE CHECK VALVE INSPECTION (Figure 46)

CHARGE PRESSURE CHECK VALVE

TYPICAL CHARGE PUMP

CHARGE PUMP CHARGE PRESSURE.

RELIEF VALVE,

TYPICAL AXIAL PISTON PUMP—,

a.

Figure 46 LT-160040

Carefully remove the charge pump to expose the cartridge check valves. Inspect the valves for spring load,
proper seating, damaged O-rings and foreign material. When the problem is in one direction only,
interchange the check valves to see if the problem changes sides. A.new gasket should be used when the
charge pump is replaced on the axial piston pump.

CHARGE PRESSURE RELIEF VALVE INSPECTION (Figures 47 and 48)

Inspect for foreign material holding the poppet open, galling or wear on the poppet and seat, a broken
spring of an improper setting.

Page 94 Rev. Dec. 1978

ARMCO National Supply Company
Dwision of Armeo Ine.
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

CHARGE PUMP
— TYPICAL CHARGE PUMP

TK CHARGE PUMP CHARGEPRESSURE RELIEF

VALVE COMPONENTS

py
Ct —POPPET
. SS
) —~ SPRING °
\ S {
- SHINS KO? ©
o D> 2
& car ‘ ~ CHARGE PUMP GASKET
‘
TYPICAL CHARGE PUMP INLET !

TYPICAL AXIAL PISTON PUMP — \

Figure 47 LT-160041

Rev. Dec. 1978 Page 95

a National Supply Company
Division ot Armed Inc.
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435

MOTOR VALVE MANIFOLD ASSEMBLY

SWING SWING
MOTOR MOTOR
PORT
“Ah PORT
Re

(AW |

SWING MOTOR
SHUTTLE VALVE if

TA UZ.
i
Lo yi SWING MOTOR CHARGE
CLG
“y ‘WY ; PRE! SSURE RELIEF VALVE

SWING
MOTOR
CASE

HOIST HOIST
MOTOR MOTOR
PORT PORT

Tn!
HOIST MOTOR
SHUTTLE VALVE

ue HOIST MOTOR CHARGE

PRESSURE RELIEF VALVE

HIGH PRESSURE
RELIEF VALVE

HIGH PRESSURE
RELIEF VALVE

MOTOR
RN | A
MOTOR
PORT PORT

Figure 48 17160015

Page 96 Rev. Dec. 1978

ARMCO National Supply Company
Drvsiort of Armco Ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

CHARGE PUMP INSPECTION (Figures 46 and 47)

Carefully remove the charge pump. The shaft and internal gears must turn smoothly. Futher disassembly of
the charge pump is not recommended. Check the condition of the pump drive clevis and tang.

CHECKING CHARGE PRESSURE

The proper gages for checking charge pressure are provided in the operator’s cab on the right-hand rear
panel. In neutral charge pressure should be 190 to 300 psi (13.1 to 20.7 bar). While powering down charge
pressure should be 180 to 290 psi (17.4 to 20 bar). While hoisting or lowering a load, charae pressure should
be 160 to 280 psi (9.3/19.3 bar). NOTE: PRESSURES SLIGHTLY ABOVE THOSE NOTED ARE NOT UNCOMMON.
THE PRESSURE, HOWEVER, SHOULD NOT EXCEED 400 PSI. (27.6 BAR).

The charge pressure system has two relief valves, one in the charge pump and one at the motor. The charge
pressure relief valve at the motor has a lower pressure setting to provide for system cooling. In neutral and
while powering down, the charge pressure relief valve at the pump is used. While hoisting or lowering a
oad, or swinging the crane, the charge pressure relief valve at the motor is in use.

INTERPRETING CHARGE PRESSURE

NO CHARGEPRESSURE- If there is no charge pressure at any position of the contro] lever, the charge pump is
probably at fault. Most likely the drive shaft has been broken. To confirm the diagnosis, remove the charge
pump and examine for broken parts.

Complete lack of charge pressure could also be due to spring breakage, damage, or dirt in the charge
pressure relief valve located in the charge pump. Examine the relief valve for dirt, wear, and possible
sticking.

FLUCTUATING PRESSURE - If the charge pressure is erratic with control lever in neutral and in the side
position, with pressure level perhapsa little lower than expected, this may indicate cavitation of the charge
pump from low fluid level in the reservoir, collapsed suction hose, or dirty suction filter elements. Check for
these conditions and replace the suction line filter elements.

CHARGE PRESSURE DROPS WHEN CONTROL LEVER IS SHIFTED - If the charge pressure holds steady when the
control lever is in neutral, with about the right expected pressure, then falls rapidly as the control lever is
moved to a side position, this usually indicates that the charge fluid is escaping into the case through
clearances which open up as the control lever tries to cam the pump. The most likely fault is a scored valve
plate, When the valve plate becomesscored fluid pressure can get under it and tendstolift it from intimate
contact with the bearing plate. This allows some of the high pressure loop fluid and some of the charge
pump fluid to escape into the pump or motor case. With this condition the charge pressure may fall very low,
too low to cam the pump swashplate to more than a small angle. If charge pressure falls below 140 psi (9.7
bar), replacement of the damaged pump and motor is necessary.

if charge pressure drops only when trying to power down an empty hook or boom or drops only when
swinging one direction, the shuttle valve in the motor valve manifold is probably shifted and held. A similar
condition, however, will exist if an O-ring underneath the displacement control valve is damaged and
leaking. (See Figures 43 and 48).

NOTE: Charge pressure tends to increase with an increase in engine speed. The lowest acceptable
charge pressure is 140 psi (9.7 bar).

Rev. Dec. 1978 Page 97

Ago National Supply Company
Division of Aemea inc.
 NATIONAL
CITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
CHECKING HIGH PRESSURE

[f the charge pressure seems to respond normally as the control handle, in the operator’s cab, is moved out
of the neutral position, perhaps drooping slightly but not drastically, check the high pressure gage in the
right-hand console in the operator’s cab. For a properly operating system, the pressure in the loop should be
charge pressure when the control handle is in neutral. However, as the control handle is moved to hoist a
load or swing the crane, the pressure should immediately rise to the value required by the load on the
system.

INTERPRETING HIGH PRESSURE

NO HIGH PRESSURE CAN BE DEVELOPED - if there is verylittle or no rise in loop pressure when the control
handle, in the operator’s cab, is moved out of neutral, one of the high pressure relief vaives, in the motor
valve manifold may be seized in the open position or damaged. Since there are two high pressure relief
valves, one for each direction of operation, try moving the control handle (without a suspended laad) into
hoist and powerdown. If pressure can be developed in one direction and not in the other, one ofthe relief
vaive poppets is probably damaged or seized. If pressure cannot be developed in either direction, a relief
valve spool may be seized open. Suspected relief valves should be removed, inspected, cleaned and
replaced if such is required. See figures 45 and 48for pictorial descriptions. NOTE: When replacing a relief
valve be certain the pressure setting of the replacement is correct. See ‘System Relief Valve Inspection”.

FULL HIGH PRESSURE CANNOTBE DEVELOPED - If only partial pressure is obtained on the high pressure gage
when the contro! handle is moved out of neutral, one of three faults may be present. Assuming charge
pressure had been checked and found to be normal, the first fault may be a leaking charge pressure check
valve. One or both check valves which permit the feeding of charge pump fluid into the loop may be
damaged orsticking. If this condition exists, fluid is escaping from one side of the system loop into the
opposite side of the system loop through the charge pump circuit. Symptoms of this fault would be fairly
normal operation of the system when unloaded, but an inability to build up high pressure (therefore torque)
for heavy loads. A system with this fault may also experience overheating. If the system will not develop
pressure in either hoist or powerdown, a leaking check valve is nota likely fault unless, by coincidence, both
check valves are damagedand Jeaking. If the system fails to develop pressure in one direction, inspect these
valves.

The second possible fault is excessively worn piston slippers. Worn slippers cause excessive leakage offluid
into the case, seriously reducing performance of the system. Sypmtoms would be similar to leaky check
valves. A major factory overhaul is recommended for the hydraulic transmission.

The third possible fault is the installation of a relief valve with a pressure setting below the specified
requirement. (See ‘System Relief Valve Inspection’). Replace any relief valves of improper setting.

EXCESSIVE HYDRAULIC SYSTEM NOISE

Cavitation or internal pump or motor damage from contamination are the most common causes of excessive
pump or motor noise. When excessive noise is apparent the following items may be the cause:

1. Dirty Charge Pump Suction Line Filter - causes cavitation of charge pump.

2. Restriction in Charge Pump Suction Line - causes cavitation of charge pump.

3. Improper Hydraulic Fluid - heavy fluids can cause cavitation.

4. Water in the Hydraulic Fluid Forming an Emulsion - can act like a heavy fluid and cause cavitation.

5. Air Entrained in the Hydraulic Fluid - causes cavitation and excessive noise. (See air in hydraulic fluid)

Page 98 Rev. Dec, 1978

anwee National Supply Company
Oiision of Armee ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

AIR IN HYDRAULIC FLUID

Air entrained in the hydraulic fluid can be the cause of excessive noise, low pressures and extensive
damage to hydraulic components. Check all lines and connections, especially those in the charge pump
suction routing, for possible leaks which would permit air to enter the system. Check the fluid level in the
reservoir. A low fluid level will allow air to enter the system through the charge pump suction line.

PUMP AND MOTOR SHAFT SEAL REPLACEMENT (Figure 49)

NOTE: It is recommended that all shaft seal parts be replaced.

. Remove the large retaining ring located on the shaft end of the pump or motor. Remove the side
opposite the tangs from the groove first.

Remove the aluminum housing. It is held in place by the friction of the O-Ring on its outside diameter.
Pry the housing toward the end of the shaft until the O-Ring is free.

Remove the aluminum housing from the shaft. This part is actually an assembly that is being held
together by the friction of an internal O-Ring. It will normally remain assembled until physically
separated.

Behind the aluminum housing is the bronze sealing ring. This ring is also held in place by internal O-Ring
friction. Work this part free and carefully slide over the shaft.

CAUTION: This part is easily damaged and extreme care must be exercised when handling.

All of the shaft seal parts, which are included in the shaft seal kit, have now been removed. It is
recommendedthat this entire shaft seal be replaced.

Prior to assembly, lightly lubricate all parts with clean hydraulic fluid, place one O-Ring in the inside
diameter of the aluminum housing. Place the six (6) springs in the cavities in the aluminum housing.
The shaft spline should be covered with thin, clean plastic to protect the parts from damage bythe shaft
during assembly.

Slide the bronze sealing ring over the shaft and onto the shaft pilot diameter with the O-Ring facing the
motor or pump. Using clean hands, work the ring into place using hand force only.

With clean hands, insert the stationary seal pilot into the aluminum housing, locating the notch in the
stationary seal over the pin in the housing.

. Install the O-Ring on the outside diameter of the aluminum housing then slide it into place against
the bronze sealing ring. Since this is a spring loaded assembly, it may be necessary to push against the
aluminum housing to expose the retaining ring grooves.

10. Install the retaining ring with the beveled side out putting the side opposite the tanks into the groove
first. Be certain the retaining ring has snapped into its groove completely.

Rev. Dec. 1978 Page 99

any National Supply Company
Owimen of Armea Inc
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435

PUMP OR MOTORSHAFT SEAL

— PUMP OR MOTOR

RETAINING RING GROOVE

--"O" RING
BRONZE SEAUNG RING
/- STATIONARY SEAL
@ “O*RING
j (L—-PIN
(7“OLRING

ALUMINUM HOUSING

RETAINING RING
“@
srano—/ @

Figure 49 LT-160042

Page 100 Rev. Dec. 1978 =

anwpe National Supply Company
Devision of Armco Inc
 LITHO IN U.S.A
OS-

Page 101
Rev. Dec. 1978
HYDRAULIC PEDESTAL CRANE

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Division of Armco lnc.
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NATIONAL
 —.
OS-435

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Page 102
LOH ONILVHSd0 W3ALSAS
 LITHO NOUSA.
OS-

Page 103
Rev, Dec. 1978
HYDRAULIC PEDESTAL CRANE

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 —
OS-435

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NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435

PUMP AND MOTORPART

INSTALLATION TORQUE VALUESIN FT.-LBS.

MAIN/WHIP
HOIST SWING & BOOM
LOCATION MOTORS MOTOR PUMP SWING PUMP
VALVE MANIFOLD BLOCK 16 (2.2) }16 (2.2) _ —
2 (29) 21 (2.9)
END CAP 240 (33.2) 67 (9.3) 240 (9.3) 44 (6.2)
290 (40.1) 82 (11.3) 290 (11.3) 54 (7.5)
CHARGE PUMP — — 27 (3.7) 10° (1.4)
37, (51) ] (1.5)
DISPLACEMENT CONTROL VALVE — — 10) (1.4) 10 (1.4)
WW (15) ol G5)
CHARGE PRESSURE — — 125 (17.8)| 30 (4.1)
CHECK VALVES 135 (187) 40 (5.5)
FRONT COVER 67 (9.3) 67 (9.3) 67 (9.3) 45 (6.2)
82 (11.3) 82 (11.3) 82 (11.3) 54 (7.5)

NOTE: Torque values in parentheses are kg-m.

Page 106 Rev. Dec. 1978 =

“8 ARMCO National Supply Company
VV owson of Armee ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4 LITHO INUSA

PUMP AND MOTOR REPLACEMENT

Whenever trouble shooting procedures have determined that the hydrostatic transmission must be replaced
certain precautions and steps should be followed. Generally the pump and motor should be changed out as
a pair. A new pump or motor can become damaged if operated in conjunction with a used unit.

As always, the prime consideration when working on the hydraulic system is to insure no contamination is
introducied into the system. When replacing a pump and/or motor the following basic outline should be
used. The kill valve in the operator’s cab should be depressed prior to opening any hydraulic connections.

1. Remove the damagedunits and replace with the new units.

2. Using the plugs and covers from the new units, cover and plug the ports of the old units. Many old
units are salvageable when removed from service, but can suffer irreparable damage if not properly
protected.

. Replace all filter elements.

If any debris is present in the hoses or tubing, the hoses and tubing should be flushed clean with a
suitable solvent and blown dry.

. Connect all tubing and hoses replacing all related O-Rings.

Using clean hydrulic fluid, hand fill the pump and motor cases.

. Fill the hydraulic tank to the proper operating level.

Double check all hydraulic connections which have been disturbed.

Double check all pump and motor mounting screws.

Double check the adjustment of the pump acutating cylinder.

. Disengage the clutch.

. Start the engine and set at the low idle speed (1000 RPM).

13. Manually engage the clutch briefly six to eight times. This action permits the pumps to receive
lubrication prior to being run continuously.

14. Fully engage the clutch and observe the charge pressure in the operator's cab. The charge pressure
should be 180-200 psi.

15. Observe the level of the fluid in the hydraulic tank and add fluid if necessary.

16. Operate the crane under no load, observing charge pressures.

17, Operate the crane under load, observing charge pressures. Engine RPM should be 1500 anytime a
load is lifted. Charge pressure should be 160-180 psi during operation.

18. Inspect the system for hydraulic leaks and correct any abnormalities.

Samco National Supply Company Rev. Dec. 19 1978

ev. Dec. Page ‘age 107
10
ARMCO
V7 Dsisian ot arco ine
 NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
PUMP AND MOTOR REPAIR

Anyrepoir of the axial piston pumps and motors requiring the removal of the end cap or front cover is not
recommended to be performed in the field. Major repairs should only be attempted by experienced,
qualified and properly equipped personnel. Only minor repairs, such as those discussed in the hydrostatic
drive trouble shooting section, should be performed in the field.

EMERGENCY LOAD LOWERING

In an emergency created by the loss of control pressure, loss of air pressure, loss of diesel power or
malfunction of the hydraulic transmission, a toad can be lowered by the following procedure. WARNING:
THIS PROCEDURE IS NOT FOR USE ON THE BOOM HOIST SYSTEM.

1, Kill the diesel engine.

2. Engage the clutch by hand.

Remove the shuttle valve spool from the hydraulic motorof the hoist which must be lowered. Note the
orientation of the valve spool and replace the plugs in the manifold block.

Remove the hose from the bottom of the brake cylinder of the hoist which must be lowered and
connect a hand operated hydraulic pump to the brake cylinder.

Slowly apply hydraulic pressure to the brake cylinder until the wire rope drum begins to turn. The
speed of the drum should not exceed 30 RPM. The drum can be slowed or stopped by lowering the
pressure to the brake cylinder. CAUTION: Do not over pressure the brake cylinder. Maximum pressure
should not exceed 800 psi (55.2 bar).

Upon completion of the lowering, clean and properly re-install the shuttle valve spool, reconnect the
hose to the brake cylinder and disengage the clutch by hand.

NOTE: Light line loads may not be able to over come the friction forces in the hoist system even when
the brake is fully released.

Page 108 Rev. Dec. 1978 _

XZ dusiontaimeaine
ARMCO National Supply Company
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA

CRANE START-UP PROCEDURE AFTER STORAGE OR SHIPPING

The following procedure is recommended when starting a crane that has been in storage, either after field
use or as shipped from the plant. This procedurewill aid in instructing new operators on the correct method
of starting the crane, and help to assure that essential maintenance points are not overlooked. After
completion of this procedure and when the crane is in normal service, the maintenance check lists found on
pages 0 and 0 should be followed to assure proper care and operation of the crane.

1. Check the air supply regulator to see that it is set in the proper operating range, 95/100 psi.

2. Open the air reservoir drain valve and purge any water or debris that may have accumulated during
storage.

Check the fluid levels in the air line lubricators.

. Open the pump suction line valve beneath hydraulic tank, and insert the channel shaped valve lock over
the valve stem.

. Check the hydraulic tank oil level to see that oil appears in the upper portion of the tank sight glass.

Open the two valves beneath the diesel fuel tank.

Check diesel fuel level.

. Check engine oil and coolant levels, and condition of engine air cleaner.

. Check shaft assembly, pump drive housing, and swing gear box oil levels. See page 13 for
recommended lubricants.

. Manually operate clutch to check its adjustment. Adjust as described on page 63.

. Disengage clutch.

. Check to see that the circuit breaker for the hydraulic tank heater is turned to “ON”, and that the
heater’s thermostat knob (if equipped) is set at 80°F.

13. Turn the engine glow plug and 24 VDC transformer circuit breaker to “ON”.

14, Pull the engine kill valve. The air and power pilot light should come on.

. Pull engine start vaive. Release valve immediately when engine starts.

COLD WEATHER STARTING NOTES:

Cranes Equipped With Caterpillar Engines - If the ambient air temperature is less than +60°F (16°C), it
is recommendedthat the glow plug button be pushed for approximately 30 seconds prior to engine
cranking.

Cranes Equipped with Detroit Diesel Engines* - Hf the ambient-air temperature is in the +35°F (2°C) to
-20°F (-29°C) range, it is recommended that the ether “QuickStart” knob be pulled for approximately
two seconds while cranking engine,

*Note: New cranes shipped from the Gainesville Plant do not have the either cylinder installed in the
“Quick Start’ mechanical valve. The cylinder is mounted directly above the valve, and must be
screwed into the valve prior to operating the system for cold weather start-ups.

16. Check engine gages and allow engine to warm up at low idle speed.

— Rev. Dec. 1978 Page 109

ARMCO National Supply Company
Wow scnctarmesine
NATIONAL
LITHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435
17. Engage clutch and allow hydraulic oil to warm up at low idle speed. Check for leakage in hydraulic
system.

18. Observe main, boom and swing charge pressures to be sure they are in the proper operating range,
160/300 psi.

19. Observe pump drive housing lube oil gage to seeif it is in the proper operating range, 20/40 psi.

20. Observe contro! pressure to see if it is in the proper operating range, 700/750 psi.

21. Check all “brake off’ indicators by pulling the swing brake valve, and by moving the main and boom
handles slightly out of neutral,

22. Check swing, boom, hoist control handles for proper centering when released.

23. Operate the emergencybrake set to assure its operation. On the main, and whip boom hoists the drums
will not rotate and the brakes will not release with the brake set valve depressed.

24, Check the brake adjustments as described on pages 57 and 58.

25. Lubricate crane as described on page 14.

26. Check operation of the line travel limiter system. See page 67.

27, Check the operation of the boom angle limiter system. See page 65.

28. If the crane has wire rope spooled on hoist drums, the wire rope should be thoroughly inspected and
\ubricated before placing crane into service. See page 73.

29. Check operation of load-radius indicating devices installed on crane. See Load Indicating System
instructions.

30, Check the operation of boom lights and beacon lights, if so equipped.

Page 110 Rev. Dec. 1978 —_=

ei ey * ARwpo National Supply Company
Owision of Armea Ine
PARTS LIST
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN U.S.A,

05-435
Z6PATA OFFSHORE COMP aNY
THIS
NATIONAL.
OP ECTE TCATION
= 148
& 345

PREFACE

National Hydraulic Pedestal Cranes are manufactured by National Supply

Company, Division of Armco Inc., at the Gainesville, Texas Plant.

An identification plate is located in the engine compartment. !t provides

such information as Model, Type, Serial Number and Specification Number.

—, NOTE: This Parts List applies only to Cranes with Serial Numbers above
Serial Number G-269.

HOW TO ORDER

To insure receiving the proper material:

A. Use part number and description. Do not use reference numbers.

B. Be sure part number ond description agree; also check footnotes.

C. Give full description of crane, including Model, Type, Specification

Number and Serial Number.

D. Order by numberof pieces and notby sets, unless so stipulated in

parts list

NATIONAL OILWELL
P.O. BOX 4638
HOUSTON, TEXAS 77210-4638
As used herein, any references to National
shall be deemed to mean National Oilwell,

Page i
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
NOTES

Page fie | Reve Oct. J98O. 5 Areas: netone!supe Compeny

 A
7

Die Sancta iaN “Heo Bye DATE as

OWG. yi Da Dea, = $3
DESCRIPTION QTY. 2 aL -22- -
ITEM SIZE PART NUMBER . =
1 DWG MEE a owe 5778
GANTRY AND RELA PARTS: A 1 -
1642400 ssembly, Gantry
ne 2 ITEH SIZE PART NUMBER
.
DESCRIPTION qty.
SPring vocccesecececcececeueceetenenenees
> E
2. 0 1601414 2 BOOM AND RELATED PARTS: (Continued)
3. 0 1601438 PHN coc cece ccccecececeteeeeeceetetsuceenaeeeeee ees Support, Block (120'.Boom) ........... 2
4. - 6501608 Pin, Cotter W/49x1" .ccccecececeene eens eee eeeee eens 4 S.C 1612427
5. ¢ 1601437 PIUNGGD cece nce eeececeecereeeenec ence te teeneeeenees 2 16. 1605664 Pin (F/ Support) ..:....-+ssccscceecseceescceceres 4
4
6. A 01-1612009-801 Beacon, 120V, E.P., Boom & Gantry .......-..s-eee ees 1 17. D 1605735 Bushing (F/Support) ...-.-.ssccescceseeceeseeeeeee
18.0 - G-6501620-S Pin, Cotter (F/ Support) dellieteeseenee peneeeeen 4
Cable, Perille 600V, 1.5 mm, 3 Cond. .........--.5- 135' 1
7.
8.
9
-
7802469-001
7000394-11 Screw, H.H. Cap 5/8"x1-1/4" Gr.5,C.P. (F/Ladder) ... 6 19. A 33-1612008-813 —sInstallation, Boom & Sheave i1]. Lights ......0....
Lock 5/8" C.P. (F/Ladder) ...... 6 20. D 7802469-0 01 Cable, Perilli 600V, 71.5 mm, , 3 Cond. Totes .....0.sse eee 325!
9. - 7619058 Reg. Spring
Washer, H.H. 4 ; seeeesreess
10. - 7000443-11 Screw, Cap 3/4"x2-3/4" Gr.5 C.P. (F/Landing}) ..
Lock a C.P. (F/Landing) ..... ; MISCELLANEOUS PARTS:
i. - 7610066 Washer, Reg. Spring , i
630012 Nut, Hex 3/4" C.P.(F/Landing) .....eee- see e scene “TB7807083
-
7000609-14 Screw, H.H. Cap 1-1/4"x3-3/4" Gr.8 Nkl.PTtd.(F/Pad). 12 2, 0 7801012 Ball Gyrhaalw o TUTE.
13. - 12 3 - 7802210 Wire Rope 7/8" rTeceeescccsererereeersts
Clip, Crosby
a. - 7620098 Washer, Spring Lock 1-1/4" ..-...ce ese cree seer teens
4, - 7802217 Clip, Crosby Wire Rope 1" .
POWER ASSEMBLY AND RELATED PARTS: 5. oO 7817069-135 Rope, Wire 1" 6x26 Boom .....
1 6. 0D 7817220-180 Rope, Wire 7/8" 10x19 Main
1 E 161 2009-100 Assembly, POWEr .....eseere eee reee esse teen rrtee sense
1 7 - 7817078-080 Rope, Wire 1" 19x7 Whip... 2... cee cece eres ee eeee
2. A G-1612754 Bearing, SWING. ......eceece secre cette ee te tent neetee tn 1
72 8. A X16-2302-009 System, Markload Load Weighing
3. OD G-2405045 Screw, Dr. He. Cap 1-1/2"x9" Gr.8 (F/ Bearing) ..... Gage, Pressure .........2csc0ce ssvseeeccsseesnsee 1
Washer, Hdn. 1-1/2" (F/ Bearing) ..-....-+-seeeeeeee 72 9. O X16-1509
4. oO X16-1536-P D X16-1660 Wrench, Brake Adj. ..........cc.cccseeseseeeeeeeees ]
60 10
5. OD G-2405047 Screw, Dr. Hd. Cap 1-3/4"x9" Gr.8 (F/ Bearing) .....
1. D X16-2048 Wrench, HOS€ ........ss1s.sssceccececeeceereeeeee 1
6. D G-1613802-P Washer, Hdn. 1-3/4" (F/ Bearing) ....-..eseeeeeer ees 60 wrench, HOS€ .........ssssssssssreseessesseeseeeess 1
7. 0 X16-1704-1 Shim, .003" (F/ Bearing) 40 12. X16-2049 2
40 13. oC 7815241 PUG ..eeecee ce secssipesipsssse sseseecneseenesees
8. 0B X16-1704-2 Shim, .005" (F/ Bearing) 3200
rng ee
X16-1704-3 Shim, .007" {e Bearing) -
9.
10.
O
D X16-3704-4 Shim, .020" (F/ Bearing 40 NOTE: ALL PRIMARY AND SECONDARY COATINGS TO BE IN ACCORD
CCORDANCE WITH SPEC. PP-108 WITH
nN. oO X16-1704-5 Shim, .015" (F/ Bearing) sees 40 TOP COAT COLOR TO CUSTOMER SPEC.
Flange, Mounting w/ Welding Note Labels ..........- 1
* 12. =A 1612097 A-
1 RIG UP DATA: Prints to be supplied: E-1612400, A-1612009-801, E£-1612009-100,
$@12009- 805 Ring, Collector .....cc cece eee eee e tere ree eeeeeeeees
A-1612885, A-GX16-2193, A-1616025, A-1616019, E-X16-8026, 5121 2009-803, Coxe2318
13. =A
14. =D 1612007-801 Bar, Tie (F/ Collector Ring) .....--++eeeeeeeeeeree 3 B-1u12009-s10
15. A 1614826 Catwalk ..cccccecccccececenecceneseeeeeeeeeenneeeees 1 ILLUSTRATED PARTS LIST PAGES (10-80): 0-24
1613885 Handrail ........-.ee- (7-80):
OPERATOR'S MANUALTD-16001 5-15, 57-59, 63, 65, 66, 69-72
16. A MISCELLANEOUS:
7. «6B X16-1808 Skid, Shipping ....... ~
18. A GX16-2193 Cover, Oi1 Protection i i :
Wire, SST .064" Dia. NOTE: Two (2) sets of above listed rig-
19,0 - 7822095 a. ae one (1) set in crane oeeter sain ting as follows:
20. - 7802362 Connector, W/H C5205x16 (F/ Collector Ring) .....--. 17
z b. Send one (1) set to Crane Producti Group ini Houston office with request that
2. - roooen pcrews aay Cap eee ce, (F/collertorRing) i i
prints beforwarded to NSCO serviceman being dispatched to rig for crane
Reg. Spring oP. -- ollec ing) rints be
asher,
23.
. 7
6300062 Nut, Hex 3/8" C.P, (F/ Tie Bar) v2.0.0... teeceee eee 3
Washer, Snubbing (F/ Tie Bar) .........--- Pie eceee 2
24.0 - 7624019
Washer, Type A Narrow 3/8” C.P. (F/ Tie Bar 2
25. - 7621024 i
wa 3B 1612009- 806 Box Cet.,Junction (cou. Rincp se cs cd
BOOM AND RELATED PARTS: 4
T. C G-1615083 Assembly, Boom Base (OL
2. OD 1615013 Extension, 30! .eccecccecce cee cercceeesereeeeaeennes
Assembly, Point ..........-
» A 1615003
1615015 Extension, sheave ....-.. FOR: Zapata Offshore #55E-15463-102
a8 vrem JURE PART NUMBER pescmiP tion
5. OD G-1620770 Pin, Hi/Lo Throwout — ~ seo'o
‘CUOSEELE MACHINE] ma TEAAL
6. - 6300062 Nut, Hex 3/8" C.P. (F/PIN) ....- sees eee cece ence eeee VENDOR “ARENESS
7. B 1615026 Indicator, Boom Angle .....esseeeceeecee cree eeeeeens OTHERWISE SPESIFICD
FRACTIONS + O13”
8. B 1605629 Indicator, Boom Angle ......- cece er ere eer e re eeeeores + 0" 0"
oe ANGLES
9. B 1616025 Assembly, Boom Saver (120' Boom) co
Tubing, Snyflex 1/4" ....-.eeeeee eee eeee a
OW. 7819106-0 AAMC National Supply Company CRANE COMPLETE, 0S-435 w/ Cat 3408, 120' Boom
We. - 7819107-0 Tubing, Snyflex 3/8" ......ecee cece ener e cet e ce eeces bh
= AZo Baracaot Atenza Stee! Cargoranon 120V AC. API-2C
12. - 7819048 Ty Rap vecccccccceeesenee erence nncceereetaeaencesens & SCALE sa at >
13. #C 1612456 Assembly, Boom Hoist Block ......-secesereeecereres PAPERSEOES S x “erisyee | $e. PART NUMBER
14. OA 1616019 Assembly, Load Weighing - For Markload .......-.+. }
ne SUEMECY NUMBER [SUPEQSEDED oF CHECKED 3° ¢ X16-5148
> jyneace
* Label is form 76-5 quantity 5 required.
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA.

CAB ASSEMBLY

} NOT APPLICABLE
TO THIS ORDER
SEE DRAWING ../@/2009- GOO
saseccnearnenanencneeannmmnsnent IN APPENDIX

SEE PAGES A-I8 AND A-t9

FOR WINDOW GLASS DETAILS
SEE PAGES A-I6 AND &-I7 FOR I
WINDSHIELD WIPER COMPONENTS
17,24, 27,34,38

17,24,27,34,39

Ls’
!
~9,24,25,33
(ON REAR RH. WALL)

SEE PAGE 8-4 FOR

MANIFOLD COMPONENTS

15,35,42,44

SWITCH AND BREAKER BOX

(MOUNTED ON REAR LH. WALL)
SEE PAGE B-I3 FOR COMPONENTS:

LT-160321

Argo National Supply Company Rev. Oct. 1980 Page A-1

Division of Armco
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
CAB ASSEMBLY
Item Part No.
No. No. Description Req'd.

1 G-1613684 ASSEMBLY, Right-Hand Console (See Page A-5)... 000.2. eee 1

2 G1613685 ASSEMBLY, Right-Hand Side Front Panel (See Page A-7) .................-- 1
3 G-1613686 ASSEMBLY,Right-Hand Side Rear Panel (See Page A-8)......-.......020005 1
4 G-1613698 ASSEMBLY, Left-Hand Console (See Page A-3). 0.6.2. 1
5 1617662 ASSEMBLY, Electrical Box (See Poge B-12) 00. eee 1
6 7801151 BUSHING, Conduit, Esco #122-1/2 00. 1
7 7802255 CONNECTOR, Crouse-Hinds *CGB-193, 1/2" x90° 20.0.2. cee eee 1
8 1614622 COVER 06 etree tenes 1
9 1614623 COVER 0 eee eee eee 1
10 G-1613689 DOOR, Sliding... 00 eee 2
lt 1612604 FAN, Defrost... eee eee 1
12 G-7811039 FIXTURE, Dome Light, Requires: ©... 00.02 1
17811009 LAMP, Wesco *305, 24V
13 7807003 HANDLE, Outside Door... eee 1
4 7807008 HANDLE, Inside Door... 00. eee ]
15 1617663 HEATER, Cab (240 Voll) 000 cece cece cect eveeeeteeveeees 1
1617670 HEATER, Cab (120 Volt). eee 1
16 7808025 INSULATION (Order by Square Foot)... 000. ee As Req’d.
17 6300001 NUT, * 10-24 Hex, Cadmium Plated 2000... eee As Req'd
18 6310052 NUT,Flexloc 21FK, 5/16''-24 UNF, Cadmium Plated. .............-..0.-... 4
19 G-1613697 PANEL, Valve (See Page A-14) 0000 eee 1
20 1600657 ASSEMBLY, Brake Pedal (See Page A-13) .. 2020 eee 1
21 1617649 ASSEMBLY, Boom Hoist Foot Pedal (See Page A-12)............--.0202000- ]
22 1617630 PEDESTAL, Lower 2000 ee eee ee 1
23 | 161763) PEDESTAL, Upper... 0 000 eee eee eee 1
24 7817170 RUBBER, Neoprene Sponge, 3/167 x 27 00 eee As Req'd
25 7000106-11 SCREW, Hex Head Cap, 1/4” x 3/4", Grade 5, Cadmium Plated ............. 17
26 7000209-11 SCREW, Hex Head Cap, 3/8" x 1-1/4", Grade 5, Cadmium Plated ............ 4
27 7055091 -01 SCREW, Filister Head Machine, #10-24 x 5/8", Cadmium Plated ............. As Req'd
28 7818329 SEAT ee eect e eee 1
29 1.610749 STRIP, Wear 2.00. ee eee 46”
30 T8I9Q16 TRACK, Upper. eee 1
31 7819017 TRACK, Lower. 0. eee }
32 7500097 VALVE, Foot Pedal Throttle 000.0 ete eee ]
33 G760806i WASHER, 1/4” Barseal 2 ce eee ee VW
34 7619025 WASHER, * 10 Regular Spring Lock, Cadmium Plated. ................ 00505 As Req'd.
35 7619037 WASHER, 5/16” Regular Spring Lock, Cadmium Plated .........2.......-.- 4
36 7822016 WEATHERSTRIP, Door... eee Tce cece ee As Req'd.
37 G-1613660 WELDMENT, Cab... eee eee 1
38 G-1613691 WINDOW, Right-Hand Sliding (Frame and Glass)..........02..-2...- ]
39 1617646 WINDOW,Upper Front (Frame and Glass)... 60... eee 1
40 1617647 WINDOW,Lower Front (Frame and Glass)... 0000. .00 2 ee 1
4) 1617648 WINDOW, Rear Sliding (Frame and Glass)... eee 1
42 6300051 NUT, 5/16" Hex, Cadmium Plated ..... 02.2000. 2002.00 c cc eee 4
43 7813045 NUT, 1/2” Conduit Lock oe eee es 1
44 7000157-11 SCREW, Hex Head Cap, 5/16’’ x 1°", Grade 5, Cadmium Plated .............. 4

NOT APPLICABLE
TO THIS ORDER

SEE DRAWING /@/2 009 - 600

mae wet APPENUIX

Page A-2 Rev. Oct. 1980 - Aree National Supply Company

Dyas ob Armco
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHOIN USA.

LEFT-HAND CONTROL ASSEMBLY (G- 1613698)

ns,

NOT APPLICABLE
TO THIS ORDER

SEE DRAWING ../@/2¢83..

ites» * . . 5 : . L7-160062

Aap National Supply Company Rev. Oct. 1980 Page A-3

NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
LEFT-HAND CONTROL CONSOLE ASSEMBLY (G-1613698)
Item Part No.
No. No. Description Req‘d.

1 1612648 BUSHING 2000 ee eee eee 1

2 1613647 PANEL, Engine Gage .. 2... eee 1
3 1613675 PANEL, Left-Hand Control 1
4 1617614 PANEL, Console Housing 1
5 1617615 LEVER 2
6 1617618 SHAFT... eee 1
7 1617624 HANDLE, Boom Hoist Control . 1
8 1617626 HANDLE, Swing Control }
9 6300081 NUT, 1/2’’ Hex, Cadmium Plated ....... 2
10 6310061 NUT,Flexloc #21 FK-624, 3/8'-24 UNF... 2
VW 6500608 PIN, Cotter, 3/82" x1" 20.0 eee 1
12 7053104-13 SCREW, Pan Head Machine, 1/4’ x 1/2’, Nickle Plated ............ 10
13 7500104 VALVE, Emergency Brake Set and Swing Brake, Includes: .................. 2
4 —7815238 PACKING, O-Ring (Spool Seals)
14 7621016 WASHER, 1/4” Type A Narrow, 0.625" ©.D., Cadmium Plated 1
15 7621044 WASHER, 3/4” Type A Narrow, 1.469’ O.D., Cadmium Plated 3
16 7802110 COLLAR, 3/40 tees 2
7 7802340 CLEVIS 2 eee eee 1
18 7802478 CONNECTOR, Weatherhead #1468 x 4x 4K . 1
19 7804220 ELBOW, Weatherhead #1469 x 4K. eee 2
20 7804223 ELBOW, Weatherhead #1469 x 4x 4K 000. eee 3
21 7806065 GAGE, Oil Pressure (Electrical), Requires: 6.0... ees 1
1 —7811043 BULB, Face Illumination
1 —7817189 RESISTOR
7806021 GAGE, Oil Pressure (Mechanical), Requires:... 0000.00.00. 02000..00.0200- 1
1 —7802477 CONNECTOR, Weatherhead #1468 x 4 K
1 —7802481 CONNECTOR,Parker-Hannifin #66 NTA-4-2
20'—7819106-0 TUBING, 1/4” Synflex
22 7806066 GAGE, Engine Coolant Temperature (Electrical), Requires: ................. 1
1 —7811043 BULB, Face Illumination
1 —7817189 RESISTOR
1601079 GAGE, Engine Coolant Temperature (Mechanical).................-. 1
23 7808024 INDICATOR, Brake Off 2
24 7809015 JOINT, Ball... . 2
25 7810023 KNOB,Ball .. . 1
26 7810024 KNOB, Boll 2. cece eens 1
27 7815018 PIN 2 ee 1
28 7819041 TACHOMETER, G.M.Engine (Electrical), Includes:. Jou... ee 1
1 —7811043 BULB, Face Illumination
7819042 TACHOMETER, Caterpillar Engine (Electrical), Includes........-.00....0000, 1
1 —7811043 BULB, Face illumination
G-7819044 TACHOMETER, G.M. Engine (Mechanical), Requires: 2.0.2... 000... e eee 1
1 —G-7802785 CABLE
7819090 TACHOMETER, Caterpillar Engine (Mechanical), Requires:............0.0..-, 1
1 —G-7802468 CABLE
29 7819106-0 TUBING, 1/4” Synflex. 0000 eee As Req’d.
30 7819111 TEE, Weatherhead #3750 x4... .0000 00000 cc 1
31 7819142 TEE, Parker-Hannifin #271 NTA-4-4 1
32 ZB-0756 BEARING 2.00 eee eee e ee ae 4

SOY APTLICSPLE
Spgs ORDER

SEE DRAWING 1Gl2083_

Page A4 Rev. Oct. 1980 Aig National Supply Company

Division of Armco:
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHOINUSA

SWING CONTROL VALVE LINKAGE

(3,1 43

10,16,17, 18

LT-160064
Item Part No.
No. No. Description L Req'd.

1 G-1613683: ASSEMBLY, Left-Hand Control Console... 220... eee 1

2 1617617 LINK, Connecting ............... : 1
3 6300041 “NUT, 174" Hex, Cadmium Plated .. . 2
4 6300051 NUT, 5/16” Hex, Cadmium Plated 3
5 6310061 NUT, Flexloc #21FK-624, 3/8-24 UNF 220020 eee 1
6 6320063 NUT, Hex Jam, 3/8°-24 UNF, Cadmium Plated................... 2
7 7000109-11...[ SCREW, Hex Head Cag, 1/4” x 1-1/4", Grade 5, Cadmium Plated... . _2
8 70001 57-11 SCREW, Hex Head Cap, 5/16" x 1°", Grade 5, Cadmium Plated ...... . 3
9 7053106-13 SCREW,Pan Head Machine, 1/4" x 3/4", Nickel Plated ..............0....- 10
*10 7500245-001 VALVE, Swing Control. 00 cette eae 1
1 7619033 WASHER, 1/4’’ Regular Spring Lock, Cadmium Plated ....-.... 00.002. 2
12 7619037 WASHER, 5/16'' Regular Spring Lock, Cadmium Plated .................... 3
a3. |. , 7621016 WASHER,1/4"’ Type A Narrow, 0.625" O.D., Cadmium Plated - 12
14 7809015 JOINT, Balf 6 eee bee eee oe ]
Fe) 7817706 ROD, Threaded, 3/8°'-24 UNF x (As Req’‘d. Joc eee 1
ce 16 7802478 CONNECTOR, Weatherhead * 1468 x 4 x 4K (Port #3) . See eee ]
17 7804223 ELBOW, Weatherhead #1469 x 4x 4K (Port #1) 0 eee eee }
18 7819142 TEE, Parker-Hannifin #271 NTA-4-4 (Port #2) 00000. cee eee 1

Tall NOTE: Rebuild Kit may be purchased per part no. 1617297 KIT, 7500245-001 Valve Repair.

‘ Sp sen supe compan

Deneson of Armco
Rev. July 1982) Page a9 -
AAJHO IN USA, AL ~ — we ee
BOOM HOIST CONTROL VALVE LINKAGE

17,14,9,5:

ite 12,17

4, SEE PAGE A-I2 Kod COMPONENTS

18

3
22,2113

7 ' LT-160065

!tem Part No.

No. No. Description Req'd.

y 1607667 PLATE, Foot Pedal Bolting ............. Settee eee eens 1

2 G-1613683 ASSEMBLY, Left-Hand Contro! Console... 00.00 eee 1
3 1617617 LINK, Connecting 2.0000 eee ene eee l-
4 1617649 ASSEMBLY, Boom Hoist Foot Pedal... 200. ee eee 1
5 6300041 NUT, 1/4” Hex, Cadmium Plated 2
6 6300051 NUT, 5/16" Hex, Cadmium Plated 3
7 6310061 NUT,Flexloc #21 FK-624, 3/8-24 UNF ........ beet eee eee 2
8 6320063 NUT, Hex Jam, 3/8'’-24 UNF, Cadmium Plated . beeen ee . 4
9 7000109-11 SCREW, Hex Head Cap,1/4” x 1-1/4", Grade 5, Cadmium Plated Licence eee 2
10 7000157-11 SCREW, Hex Head Cap, 5/16" x 1", Grade 5, Cadmium Plated . an 3
VW 7000304-31 SCREW, Hex HeadCap, 1/2 x 1-1/4'', Grade 5, Cadmium Plated beeeee 2
12 7053106-13 SCREW, Pan Head Machine, 1/4” x 3/4’, Nicke! Plated .................... 10
*13 7500245-001 VALVE, Boom Hoist Control 2... eee 1
14 7619033 WASHER,1/4’' RegularSpring Lock, Cadmium Plated ..................0.0- 2
15 7619037 WASHER,5/16" Regular Spring Lock, Cadmium Plated .................... 3
16 7619050 WASHER,1/2“ RegularSpring Lock, Cadmium Plated ..................0- 2
17 7621016 WASHER,1/4” Type ANarrow,0.625” 0.D, Cadmium Plated ..............: 10°
18 7809015 JOINT, Ball Soe eee beens 2
19 7817706 ROD, Threaded, 3/8” 24 UNFx (As Req’ d. Jo eee 1
20 7817706 ROD,Threaded, 3/6’-24 UNFx (As Req‘d.) . Ceres . 1
2 7802478 CONNECTOR, Weatherhead #1468 x 4 x 4K (Port #3)Sect teens 1
22 7804223 ELBOW, Weatherhead * 1469 x 4 x 4K (Ports *1 and #2) .00......... 2

“NOTE: Rebuild Kit may be purchased per part no. 1617297 KIT, 7500245-001 Valve Repair.

Page” A-10 Rev. Jufy 1982| Simcb Nationst Supply Company

V Duwnor of Armco
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.
MAIN AND WHIP BRAKE PEDAL ASSEMBLY (1600657)*

16

18

LT-160140
Item Part No.
No. No. Description Req'd.

1 1600647 PEDAL, Brake 200... ee teeta ]

2 1600648 BASE eee 1
3 1600649 BODY,Brake Valve... eee 1
4 1600650 PISTON, Valve 1
5 1600651 SPRING,Valve }
6 1600652 PLUNGER, Valve... cee ee 1
7 1600653 END, Brake Rod ©... 6... eee 1
8 1600654 LINK, Pedal/Valve. oo teen tee 2
9 1600656 PIN Co eee 1
10 1606661 SPRING, Pedal... 20.2202 tees 1
VW 2410022-012 PACKING, O-Ring 2.00222 ce eee eee 1
12 6320040 NUT, 1/4'-28 Hex Jam, Cadmium Plated 2.020.000 eee 1
13 6500808 PIN, Cotter, 8° KV eee 2
14 7000160-11 SCREW, Hex Head Cap, 5/16” x 1-3/4”, Grade 5, Cadmium Plated ........... 4
15 |- 7621024 WASHER, 3/8" Type A Narrow, 0.812" O.D., Cadmium Plated............... 2
16 7619037 WASHER, 5/16'' Regular Spring Lock, Cadmium Plated ..00........0.000, 4
17 7800042 PIN, Yoke (Complete with Cotter Pin)... 0.2.0.0. 2
“18 7804168 ELBOW, Weatherhead *C5405x8. 62.20 2
"19 7000304-11 SCREW, Hex Head Cap,1/2” x 1-1/4", Grade 5, Cadmium Plated ........... 2
*20 6300081 NUT, 1/2” Hex, Cadmium Plated ... 2.0.0. 0.0. ee 2
*21 7619050 WASHER,1/2’' Regular Spring Lock, Cadmium Plated ..............-.000-- 2

*NOTE: Items 18, 19, 20 and 21 are not included in assembly part no. 1600657.

ARM Nationst Supply Company Rev. Oct. 1980 Page A-13

‘Owision of Armco
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
AIR VALVE PANEL(G-1614620)
NOT APPLICABLE
TO THIS ORDER

SEE DRAWING/@72007-GO3
tenttinersinemmraenceentN APPENDIX

612,17
(TYPICAL, , UNLESS NOTED}

(7-160323

en
Page A-14 Rev. Oct. 1980 ARM National Supply Company
Deviseon of Armee
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA,

AIR VALVE PANEL (G- 1614620)

Item Part No.
No. No. Description Req'd.

1 1607668 MANIFOLD, Air. eee 1

2 1607659 VALVE, Low Charge Pressure Brake Set, Includes: .....0...0.. 0000.00 eee ee 2
4—7815238 PACKING, O-Ring (SpoolSeal)
1—2410022-220 PACKING, O-Ring (Piston Seal)
3 G1613659 PANEL, Valve Mounting... 0000.0 e ene 1
4 6800031 BUSHING,Standard M.I. Hex, 3/B° x V4 0 eee 4
5 7000105-11 SCREW, Hex Head Cap,1/4” x 5/8", Grade 5, Cadmium Plated ............. 4
6 7000108-11 SCREW, Hex Head Cap, 1/4" x 1°", Grade 5, Cadmium Plated ............... 32
7 7000111-11 SCREW, Hex Head Cap, 1/4” x 1-3/4", Grade 5, Cadmium Plated ............ 2
8 7500017 VALVE, Shuttle 20 eee 7
9 7500115 VALVE, Includes:. 200. eee 3
4—7815238 PACKING, O-Ring (Spool Seal)
*10 7500142 VALVE ee eee eee 4
VW G-7500338 VALVE eee eee 2
12 7619033 WASHER,1/4’' Regular Spring Lock, Cadmium Plated ....0..0.0.....00000005 38
13 7802478 CONNECTOR, Weatherhead #1468 x 4x 4K 2000. eee 17
14 7804117 ELBOW, Weatherhead #C5405x4x4...000.00.00.0 00.0000... 00048. 2
15 7804219 ELBOW, Weatherhead *1469x 6K... eee 1
16 7804223 ELBOW, Weatherhead #1469 x 4x 4K 0600 cee 28
7 7817185 RIVNUT, 1/40 eet e eect teeta 38
18 7819106-0 TUBING,1/4” Synflex. 00.0000 teens As Req'd.
19 7819142 TEE, Parker-Hannifin #271 NTA-4-4.0.000 000 00 ee 7
20 7819145 TEE, Parker-Hannifin #272 NTA-4-4.0 0 eee 8

*NOTE: Rebuild kit may be purchased per part no. 1617299 KIT, 7500142 Valve Repair.

NOT APPLICABLE
JO THIS ORDER

SEE DRAWING L&/2W02-

G03
stastennapessuesmecomeecesseeem ene IN APPENDIX

oh

Samco NationalSupply Company Rev. Oct. 1980 Page A-15

NATIC
NATIONAL ESTAL CRANE OS-435
FRONT WINDSHIELD WIPER

1,2,3 4 5,6 7,8

l2

(7-160231
\tern Part No.
No. No. Description Req'd.

1 6300001 NUT, #10-24 Hex, Cadmium Plated 2002 ee 2

2 7053092-13 SCREW, Pan Head Machine, #10 x 3/4", Nickel Plated ...............2000- 2
3 7619025 WASHER, Regular Spring Lock, #10, Cadmium Plated ................00005 2
4 7051079-01 SCREW,Round Head Machine, *8-32 x 3/4", Cadmium Plated ............. 2
5 G-7806023-002 DRIVER, WiperArm 0.000 eee eee }
6 G-7818350-002 SHAFT, Medium . 2.0.00 cee eee }
7 G-7800023-003 GASKET, Wiper Mounting... 00.0000. tenes 1
8 G-7800023-005 SPACER, Wiper Arm Mounting .... 2... 000.000 000 cece eee 1
9 G-7800023-004 NUT, WiperArm . 000 ce eee 1
10 G7815244.002 PLATE... cece eee eet ence etna . ’
VW 7802477 CONNECTOR, Weatherhead #1468 x 4K 0.0. 2
12 G-7812050-002 VALVE, Wiper Motor. 00 eee }
13 6817001 NIPPLE, Standard Pipe, 1/87 XU ees 1
14 G-7812050-001 MOTOR, WiperAir, 85° Sweep . 0.0.2.2 6 eee 1
15 7819106-0 TUBING,1/4” Synflex 0 eee ae As Req'd.
16 7804220 ELBOW,Weatherhead *1469x 4K... 000. eee eee 1
7 G-7800023-001 ARM, 21-1/2” 1
18 _&7801 173 . BLADE, 220 ee ce eter eee eee 1

| Page A-16 Rev, Oct. 1980 ARMCO National Supply Company

 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA.

COLLECTOR RING AND ROTORSEAL(G-1613658)

NOT APPLICABLE
TO THIS ORDER

SEE DRAWING /@/200Q9-2§

IN APPENDIX

: L7-160156
~ Item Part No.
No. No. Description Req'd.

1 G1613657 ADAPTER, Collector Ring. 2.0.2. ce tenes }

2 X16-1339 FLANGE, Airline ............ fee 1
3 2400066-15 ASSEMBLY, Hose, Consisting of: 1
21-5/8’'—6100036 HOSE, Aeroquip *2651-16
2—7805083 FITTING, Aeroquip #4411-16S
4 7801162 BUSHING, Conduit, Esco #124-1 cc cee eee ]
5 7802412 CONDULET, Crouse-Hinds *1B-39 with Cover... 0000... bee 1
6 7802362 CONNECTOR, Weatherhead *C5205- \o— See e eee e beeen teens 1
7 6806004 COUPLING, 1/2" Standard Pipe 00... eee 1
8 7806053 GASKET,Esco * GASK-1943-10 eee ]
9 6817056 NIPPLE, Standard Pipe, 1/2 x6" 066s l
10 6B17044-G NIPPLE, Standard Pipe, 1/2’’ x Close, Galvanized ......0.0..00.0..000..0000- 1
li 6300041 NUT, 1/4’ Hex, Cadmium Plated 2.000.000... eee 4
12 6874008 PLUG,1’ Standard Square Head Pipe... 6.2. eee t
13 6884024 REDUCER, Standard Pipe, 1"° x 1/27 eee 1
14 7817031 RING,Collector (Electrical Slip-Ring Assembly)... 2.00020. 00eeeee 1
15 7817084 ROTORSEAL 20 eee eee 1
16 7000111-11 SCREW, Hex Head Cap, 1/4” x 1-3/4’, Grade 5, Cadmium Plated ............ 4
17 « 7619033 WASHER,1/4’ Regular Spring Lack, Cadmium Plated ...........0.6.0...05 4
: *18 2410022-222 PACKING, ORing 001 eee 1
, 719 7066208 SCREW, Hex Socket Head Cap, 3/8°° x 1 0 eee 4
_ _ "20 7612014 WASHER, 3/8" High Collar Spring Lock... 0.000020... eee eee 4
| 21 700021 2-11 SCREW, Hex Head Cap, 3/8” x 2", Grade 5, Cadmium Plated.beeen cena 4
) 22 781904) WASHER, 3/8” Regular Spring Lock, Cadmium Plated .......0.....2....... 4

. “NOTE: Items 18, 19 and 20 are not included with Item 15, Part No. 7817084 ROTORSEAL

Aap NationalSupply Company Rev. Oct. 1980 Page B-1

NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
MISCELLANEOUSAIR PIPING—LARGE AIR RECEIVER

COUPLING IN TOP OF COLLECTOR

RING AND ROTORSEAL ASSEMBLY
3 SEE PAGE B-I| FOR COMPONENTS

IL 28 |
98
a

C)
a=en ®° 4,14,21,29
So GAGE poe

SranTeR
AIR MOTOR
ai
shy, 8 26 «22 «(2 27 TO VALVE ON
BACK OF CAB
Lo x 6|
v [aieoro
ae
4 TO _STARTE!
\ | 23

I
| \
wl
al
a
=| \ 19 f / 15,20,30,31
° 25
GI
|
{ 3

\\. yet
“WS

- . mee a , . (7-160159

Page B-2 Rev. Oct. 1980 camco National Supply Company

‘Dension of Ar
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHOINUSA.

MISCELLANEOUSAIR PIPING—-CAB REAR WALL

Item Part No.
No. No. Description Reg‘d.

1 6800062-G BUSHING,Stondard M.j. Hex, 3/4’’ x 1/2’", Galvanized ..... 20.00.00 0-0..000-- 5
2 G-6800069-G BUSHING, Standard M.I. Hex, 3/4’ x 1/8, Galvanized ......000.....02.00. 1
3 G-6800083-G BUSHING,Standard M.1. Hex, 1°’ x 1/2’, Galvanized... 2.0.0... 1
4 7802296 CONNECTOR, Weatherhead C5205 x 4x4 00.0 6
5 7802306 CONNECTOR, Weatherhead #7205 x4 2000. ce 2
6 7802388 CONNECTOR, Weatherhead #1468 x 6K 20.000 1
7 7802477 CONNECTOR, Weatherhead #1468 x 4K 000. ee 2
8 7802478 CONNECTOR, Weatherhead #1468 x 4x 4K 2000.00. 36
9 7802480 CONNECTOR, Weatherhead *1468x6x 8K 2000.0 cee eee ?
10 7803030 DRYER eee ent eee 1
VW 7804139 ELBOW, Weatherhead #7405 x 4x4 20-0002 eee 2
12 7804219 ELBOW, Weatherhead #1469 x 6K. 0 06... ee 2
13 7804223 ELBOW, Weatherhead #1469 x 4x 4K 0000 ce eee 1
14 7804227 ELBOW, Weatherhead #1469 x6x8K o. 000002 eee 3
18 7806060 GAGE, 0-200 PSI, Air. 000 eee eee 1
16 7807057 HORN, Air... eee 1
17 7811069 LUBRICATOR, 1/2'' Norgren 1
18 6817044-G NIPPLE, Standard Pipe, 1/2’ x Close, Galvanized ........................-. 1
19 6820057 NIPPLE, Extra Strong Pipe, 1/2" x Close... eee 3
20 6300041 NUT, 1/4" Hex, Cadmium Plated 000. eee 3
2) 6300051 NUT, 5/16" Hex, Cadmium Plated 2.00.00 eee eee 2
22 6300062 NUT, 3/8’ Hex, Cadmium Plated 20.0.2 4
23 6875002 PLUG,1/4’ Standard Countersunk Pipe... ees 4
24 6875004 PLUG, 1/2" Standard Countersunk Pipe ... 0200000 ee 2
25 7817169 RECEIVER, Air 02. ee eee eee eee 1
26 7000108-11 SCREW, Hex Head Cap,1/4’ x 1", Grade 5, Cadmium Plated ............... 3
27 7000157-11 SCREW, Hex Head Cap, 5/16 x 1’, Grade 5, Cadmium Plated .............. 2
28 7000208-11 SCREW, Hex Head Cap,3/8” x 1’, Grade 5, Cadmium Plaied............... 4
29 7819142 TEE, Parker-Hannifin #271] NTA-4-4 26000 3
30 7819143 TEE, Weatherhead #1471 x 6K 20 1
31 7819106-0 TUBING, 1/4’ Synflex. 00 eee As Req'd.
32 7819107-0 TUBING, 3/8" Snyflex 00 ete eens As Req’a.
33 7500088 VALVE, 1/2'' Screwed Angle Glabe 20.00. 2
34 7500143 VALVE, Cylinder Operated ©0000 eens }
35 7500149 VALVE, 1/2" Safety Relief... ec eee ee 1
36 G-7500346 VALVE, 1/2” Check 000 tenes 1
37 7619033 WASHER, 1/4’ Regular Spring Lock, Cadmium Plated .......0.......0...05. 3
38 7619037 WASHER, 5/16'' Regular Spring Lock, Cadmium Plated .................00. 2
39 7619041 WASHER,3/8” Regular Spring Lock, Codmium Plated ..............0..005- 4
40 6829001 ELBOW, Standard MI. Street, 1/8'°x 90° 2 eee 1

Anueo National Supply Company Rev. Oct. 1980 Page B-5

Deagion of Anmso.
NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435
MISCELLANEOUS ELECTRICAL EQUIPMENT AND CONDUIT FOR
CRANES WITH CATERPILLAR ENGINES (120 and 240 VOLT)

NOT APPLICABLE
TO THIS ORDER

SEE DRAWING L@/Z007-800

__.IN APPENDIX
-—_I?
37
* 29,3053! EXISTING BRACKET {
ON ENGINE —-TO SWITCH & BREAKER BOX
rr re) | ASSEMBLY, SEE PAGE; B13
y
TRANSFORMER | | Fl
FOR COMPONENTS
'
pf —__ - -___-.i
COUPLINGS WELDED 1
I +10 eectRicaL Box
| IN CAB FLOOR
| ASSEMBLY, SEE PAGE B-12
| FOR COMPONENTS
3,17,36 23,26 28 1

a
kK '9
¥TO GLOW
PLUGS 7 JACKET WATER 24
HEATER
i) 3,19,36
O
1,29,30,31

23,26
9,24
'e ce 3, 20 20,36
HYDRAULIC~
TANK HEATER >. 7 —
1,29,30,31 7 22,32
oN res 3 ra
“ 13,25
4
7 2,19
2,19
5
10,25,31,38 8
= =
a OS 22,32,34
28 —
COUPLING WELDED ~/
1N LEFT HAND SIDE PATE

77 18

SEE PAGE 8-( FOR

COLLECTORRING

Vow : SM gas ye . : : . =

£T-160054

Page B-6 Rev, Oct. 1980. ARMCO National Suppty Company

wy Omran of Armen
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

MISCELLANEOUS ELECTRICAL EQUIPMENT AND CONDUIT

FOR CRANES WITH CATERPILLAR ENGINES (120 and 240 VOLT)
) Item Part No.
No. No. Description Req'd.

1 1617859 BRACKET... ee ete eee 2

2 G-6800083-G BUSHING, Hex Pipe, 1” x 1/2‘, Galvanized... 20... 4
3 7801151 BUSHING, Conduit, Esco #122-1/2" eee ee 4
4 7802352 CLAMP, Hydra-Zorh #200050... eens 3
5 7802142 CONDUIT, 1 Rigid Aluminum . 000006 eae As Req'd.
6 7802145 CONDUIT, 1/2” Rigid Aluminum «0.0... ete ee As Req'd.
7 7802404 CONDUIT,1/2” Flexible Liquid Tight... 0. eee As Req'd.
8 G-7802434 CONDUIT,1°’ Flexible Liquid Tight 00.0.2 As Req'd.
9 1617664 CONDULET, Drilled, #1-19, With Cover... 000. eee 2
10 1617666 CONDULET, Drilled, #T-39, With Cover... 0.0.00 cece eee 1
iW 7802149 CONDULET, Crouse-Hinds *T-19, With Cover 0000.00 ee 2
12 7802154 CONDULET, Crouse-Hinds *LR-39, With Cover... ee eee ]
13 7802155 CONDULET, Crouse-Hinds #T-39, With Cover 2.00... ee 3
14 7802411 CONDULET, Crouse-Hinds #LB-39, With Cover 00.002. 1
15 G-7802466 CLAMP, Hydra-Zorb #200100... cette ]
16 7802235 CONNECTOR, Crouse-Hinds *CGB-194 000 eee 1
17 7802236 CONNECTOR, Crouse-Hinds *CGB-192 2000... eee 4
18 7802385 CONNECTOR, Esco #5234, 1°’ x Straight. eee 4
19 7802400 CONNECTOR, Esco #5232, 1/2’ x Straight... 0.00. ee 10
20 7802418 CONNECTOR, Esco *5252, 1/2 x 90° 0c eee 2
2) G-7802488 CONNECTOR, Esco #5254, 1° x90° ee 2
22 7805119 FITTING, Receptacle 0002. cece tee 2
23 7805157 FIXTURE, Wesco #V12009, Vapor TightLight ..........-......000000 00005 2
24 7806051 GASKET, Esco *GASK-1941-1/27 cette eens 4
25 7806053 GASKET, Esco *GASK-1943-17 ee é
26 7811001 LAMP, Wesco 150 AVRS 130 V (For 120 V. Cranes) 0.0.0.0. eee eee 2
d 7811008 LAMP, Wesco 100 AVRS 230 V (For 240 V. Cranes} 0.0.0.2. eee ee 2
° 27 6817044-G NIPPLE, Standard Pipe, 1/2'' x Close, Galvanized .........0.000. 0.00 eee eee ]
28 6817073-G NIPPLE, Standard Pipe, 1’ x Close, Galvanized ............-....--... 2
29 6300041 NUT, 1/4° Hex, Cadmium Plated 00.6002 eee 8
30 7000105-11 SCREW, Hex Head Cap,1/4” x 5/8", Grade 5, Cadmium Plated ............. 8
31 7619033 WASHER, 1/4’ Regular Spring Lock, Cadmium Plated ©0000... 00 eee ee 10
32 G-7817004 RECEPTACLE, Hubbell #5262 Duplex (For 120 V. Cranes) .........0....2200. 2
G-7817183 RECEPTACLE, Hubbell #5662 Duplex (For 240 V. Cranes) ......0..02...000-. 2
33 6874004 PLUG,1/2’ Standard Square Head Pipe... 6... eee 1
1 34 7802177 COVER, Outlet 2 eens 2
: 35 7819026 TRANSFORMER 2 eee eee 1
; 36 7813045 NUT, 1/2’ Conduit Lock .....0...... cee 4
| 37 7802405 CONNECTOR,Esco *4Q50 FM eee eres 1
| 38 7000102-11 SCREW, Hex Head Cap, 1/4" x 3/8" Grode 5, Cadmium Plated 2

de er eh

SEE DRAWNG Z@ZZ2COP-BOO

vecutmrunneveneneniN APPENDIX |:

Samco National Supply Company Rev. Oct. 1980 Page B-7

Dinsron of Armes
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
MISCELLANEOUS ELECTRICAL EQUIPMENT AND CONDUIT
FOR CRANES WITH G.M. ENGINES (120 VOLTS) ae
NOT APPLICABLE
YO THIS ORDER

ReNG WQWe
fetta tmmeeeed APPENDIX
lr
37

10 SWITCH & BREAKER BOX

MOUNTEDONENGINE CONCABFLOOR (
| FORCOMPONENTS
! a) ELECTRICAL BOX
| ASSEMBLY. SEE PAGE B-12
i i<—s COMPONENTS
24,27 4

20

7 24,27

{ HYDRAULIC=— x
{ TANK HEATER
1, 30,32,33 | 7
1 23, 31,34
{

rg
o
8

0,26,33,38 r
23, 31,34
15,26 29 7
COUPLING WELDED: we 4
IN LEFT HAND SIDE PLATI “
ea
ee 36

SEE PAGE B-] FOR

COLLECTOR RING

LT-160053

Page B-8 Rev. Oct. 1980 Arg Nations!Supply Company

 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA.
MISCELLANEOUS ELECTRICAL EQUIPMENT AND CONDUIT
—_ FOR CRANES WITH G.M. ENGINES (120 VOLTS)
tem Part No.
\ No. No. Description Req'd.

1 1617859 BRACKET. 00 tee e eee J

2 G-6800083-G BUSHING,Hex Pipe, 1" x 1/2'’, Galvanized... 00.00.0000. 4
3 7801151 BUSHING,Conduit, Esco #122-1/2" 00 cee 5
4 7802352 CLAMP, Hydra-Zorb #200050... 6.2 3
5 G7802466 CLAMP, Hydra-Zorb #200100... 26. 1
6 7802142 CONDUIT, 1’ Rigid Aluminum 2.000000. teens As Req‘d.
7 7802145 CONDUIT, 1/2 Rigid Aluminum o6 0.0. cee As Req'd.
8 7802404 CONDUIT,1/2’ Flexible Liquid Tight... 2.0... eee eee As Req‘d.
9 G-7802434 CONDUIT, 1”’ Flexible Liquid Tight ©. 00... eee As Req'd.
10 1617664 CONDULET,Drilled #1-19, With Cover... 200... 00 eee es 2
VW 1617666 CONDULET,Drilled #1-39, With Cover 2.02. eee 1
12 7802149 CONDULET, Crouse-Hinds #T-19, With Cover . 6000... eee 2
13 7802154 CONDULET, Crouse-Hinds *LR-39, With Cover .......00000 000.00 eee eee ]
14 7802155 CONDULET,Crouse-Hinds #T-39, With Cover 000000002 eee 3
15 7802411 CONDULET, Crouse-Hinds *LB-39, With Cover ..0.0. 0000000000000 eee eee ]
16 7802235 CONNECTOR, Crouse-Hinds *CGB-194 2.000.000 eee 3
17 7802236 CONNECTOR, Crouse-Hinds *CGB-192 2220.0 3
18 G7802491 CONNECTOR,Crouse-Hinds *CGE-194.. 020.00 eee 4
19 7802385 CONNECTOR, Esco #5234, 1°’ x Straight... eee 4
20 7802400 CONNECTOR, Esco *5232, 1/2’ x Straight 26.0. ee es 7
21 7802418 CONNECTOR, Esco #5252, 1/27 x 90° 0 eee 2
22 G7802488 CONNECTOR, Esco #5254, 1 x90 eee ee 2
23 7805119 FITTING, Receptacle 0.22. cc eens 2
24 7805157 FIXTURE, Wesco #V12009, Vapor Tight Light... 0. ..00000.0......0000 000 2
~~ 25 7806051 GASKET, Esco *GASK-1941-1/2 0 ett eee 4
26 7806053 GASKET,Esco *GASK-1943-177 00 eee 6
} 27 7811001 LAMP, Wesco * 150 A/RS130V 200... eee 2
28 6817044-G NIPPLE, Standard Pipe, 1/2’ x Close, Galvanized ......0.00.-...000 2202 1
29 6817073-G NIPPLE, Standard Pipe, 1°’ x Close, Galvanized .0......0.0 000000 e eee 2
30 6300041 NUT, 1/4” Hex, Cadmium Plated... 0... eee 4
31 G-7817004 RECEPTACLE, Hubbell #5262 Duplex (120 Volt)... 2.2... eee 2
32 7000105-11 SCREW, Hex Head Cap, 1/4" x 5/8’', Grade 5, Cadmium Plated ............. 4
33 7619033 WASHER, 1/4” Regular Spring Lock, Cadmium Plated ..........00..2--..000. 6
34 7802177 COVER, Outlet 00 eee eee 2
35 7813045 NUT, 1/2 Conduit Lock 2.000020 5
36 6874004 PLUG,1/2" Standard Solid Square Head Pipe .........2.0..0.0. 002 1
37 7802405 CONNECTOR, Esco *4Q5OFM 000. eect ee eens 1
338 7000102-11 SCREW, Hex Head Cap, 1/4” x 3/8’, Grade 5, Cadmium Plated ............. 2

NOT APPLICAPLE
TO THIS ORDER

—
SEE DRAWING AQWE__
dceusttte tees oot APPENDIX

Sapo tations! Supply Company Rev. Oct. 1980 Page B-9

NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
MISCELLANEOUS ELECTRICAL EQUIPMENT AND CONDUIT
FOR CRANES WITH G.M. ENGINES (240 VOLT)

NOT APPLICABLA
TO THIS ORDER

SEE DRAWING LVWE

IN ARPENDIA 18

)
j--—-TO SWITCH & BREAKER BOX
COUPLINGS WELDED | ASSEMBLY. SEE PAGE 8-13,
PRESSURE SWITCHES MOUNTED -—8
ON ENGINE 1N CAB FLOOR | FOR COMPONENTS.
29 dk. | zt TO ELECTRICAL BOX
co > 26,30 ON \ ASSEMBLY. SEE PAGE 8-12
' FOR COMPONENTS
| 4—3,23,34 A f
SP
elu
aie
32 4
J 1 20
ke 13,27
b— 317,34 ie 31
sense 45
2i
08OGG BET

or i

2 oN
HYDRAULIC { \ |e
TANK HEATER \ oj 7
3,21,34

24,25,36

11,28,38,40

SEE PAGE B-I

FOR COLLECTOR RING
betgtt Caren

.1-160052

Page ~B-10 Rev. Oct. 1980 ARMCO

NJ
National Supply Company
Orson ot Armee
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INU.SA.
MISCELLANEOUSELECTRICAL EQUIPMENT AND CONDUIT
FOR CRANES WITH G.M. ENGINES (240 VOLTS)
-—, Item Part No.
) No. No. Description Req'd.

1 1617859 BRACKET. een ete tet eee tees 1

2 G-6800083-G BUSHING,HexPipe, 1’ x 1/2’, Galvanized... 0.260 4
3 7801151 BUSHING, Conduit, Esco #122-1/27 00 eee 5
4 7802352 CLAMP, Hydra-Zorb #200050... cece eee eee 3
5 G-7802466 CLAMP,Hydra-Zorb 200100... tenes 1
6 7802142 CONDUIT, 1 Rigid Aluminum . 2000 eee As Req'd.
7 7802145 CONDUIT, 1/2" Rigid Aluminum ©2022. 0c eee As Req'd.
8 7802404 CONDUIT, 1/2” Flexible Liquid Tight... 0.00. eee As Req'd.
9 G-7802434 CONDUIT, 1’' Flexible Liquid Tight . 2... 00... As Req'd.
10 1617664 CONDULET,Drilled #1-19, With Cover .....0..00 0.000000 cee cee eee 1
VW 1617666 CONDULET, Drilled #7-39, With Cover 000 ce eee 1
12 7802148 CONDULET, Crouse-Hinds *LR-19, With Cover... 000.00 }
13 7802149 CONDULET,Crouse-Hinds #7-19, With Cover 2.000060 02 cc 3
14 7802154 CONDULET, Crouse-Hinds *LR-39, With Cover... 2... eee eee 1
15 7802155 CONDULET,Crouse-Hinds *T-39, With Cover... 00020. 0 2-2 ee eee 3
16 7802411 CONDULET, Crouse-Hinds *LB-39, With Cover 2.00.00. 0 200.20. ee 1
17 7802235 CONNECTOR, Crouse-Hinds *CGB-194 200.0 eee 3
18 7802236 CONNECTOR, Crouse-Hinds *CGB-192 22... ee 3
19 7802385 CONNECTOR, Esco #5234, 1°’ x Straight... 0.62. eee 4
20 7802400 CONNECTOR, Esco #5232, 1/2 x Straight ©... ee eee 7
21 7802418 CONNECTOR, Esco #5252, 1/2" x 908 eee ee 2
22 G-7802488 CONNECTOR, Esco *5254,1° x909 eee 2
23 G-7802491 CONNECTOR, Crouse-Hinds *CGE-194. 000 eee 4
24 7802177 COVER, Outlet 200.0 eee eens 2
— 25 7805119 FITTING, Receptacle 2
26 7805157 FIXTURE, Wesco #12009 Vapor Tight Light... 0.00 eee ee 2
] 27 7806051 GASKET, Esco *GASK-1941-1/2" 5
. 28 7806053 GASKET, Esco *GASK-19438-1 cece ee eee 6
29 7806045 GROMMET «oc eect eee 2
30 7811008 LAMP, Wesco * 100 AVRS 230V ©6662 2
31 6817044-G NIPPLE, Standard Pipe, 1/2" x Close, Galvanized... ...0..00.... 0002. c eee 2
32 6817073-G NIPPLE, Standard Pipe, 1‘' x Close, Galvanized ............02-.....2-2000. 2
33 6300041 NUT, 1/4" Hex, Cadmium Plated 2.00.60 4
34 7813045 NUT, 1/2 Conduit lock .. 0020.0 eee 6
35 6874004 PLUG, 1/2 Standard Square Head Pipe... eee }
36 G7817183 RECEPTACLE, Hubbell #5662 Duplex (240 Volt} 0. eee ee 2
37 7060105-11 SCREW, Hex Head Cap, 1/4” x 5/8’, Grade 5, Cadmium Plated ............. 4
38 7619033 WASHER, 1/4°' Regular Spring Lock, Cadmium Plated ...............2..0.. 6
39 7802405 CONNECTOR, Esco *4Q5O FM 0002 eee ee 1
40 7000102-11 SCREW, Hex Head Cap, 1/4” x 3/8’, Grade 5, Cadmium Plated ...000........ 2

NOT APPLICABLE
TO THIS ORDOB

SEE DRAWING _LQWE

lott atten APPENDIX i
™ ane a ay _ an ab . ~ nS

Space NationalSuppty Company Rev. Oct. 1980 Page B-1i

NATIONAL
LITHO IN USA.

ELECTRICAL BOX ASSEMBLY

—

21
"o CAPPLICAPLE} /
oC THIS ORDS 0 0

SEE peawing LG/Z00F-806 °

yo
cotttisiilh APPENDIX
a
oo 6

2 » 2B ‘
=

Mie
if

oe Asa irae

5 = “is
i 7 o Onn os.26.27

3,5,25 LI 36,25 SHOWN

4 L¥-160128

Item Part No.

No. No. Description Req'd.

1 7801053 BLOCK, Barrier ............... 1

2 1617668 BOX, Electric... 02.0. eee 1
3 7801151 BUSHING,Conduit, Esco #122-1/2’ 4
4 7802404 CONDUIT, 1/2" Flexible Liquid Tight... 0.0000 ec cece cece sevens As Req'd.
5 7802235 CONNECTOR,Crouse-Hinds *CGB-194 2002022. .eeeetee 1
6 7802400 CONNECTOR, Esco #5232, 1/2" x Straight 0.2.0... 2.0 eee 3
7 7804223 ELBOW, Weatherhead #1469 x 4x 4K 0000 eee eee J
8 7805034 FUSE, 5Amp. . 00.00 eee eens 1
9 7806045 ]
10 7807028 1
VW 7813037 LIGHT, Pilot, Includes: 60. eee eee 1
1—7801128 BULB,Pilot Light
12 6300004 NUT,#6-32 Hex, Brass 6c eter ett ees 2
13 6300041 NUT, 1/4’ Hex, Cadmium Plated 2.0.0.0 eee 8
14 2407222 PLATE, Identification (Not Shown). 0.000000 ee eee ee 1
15 7817023 RECTIFIER, 25 Amp... eee eee 1
16 7000109-11 SCREW, Hex Head Cap, 1/4” x 1-1/4", Grade 5, Cadmium Plated ............ 4
17 7051066-01 SCREW, Round Head Machine, *6-32 x 1/2’, Cadmium Plated .............. 2
18 7818157 STRIP, Identification 1
19 7801142 SWITCH, Push Button 1
20 7818215 }
21 7819037 1
22 7619017 2
23 7619033 WASHER, 1/4” Regular Spring Lock, Cadmium Plated ..................... 8
24 7822070 WIRE, #14-2, Type SOV 0 cent eee As Req'd.
25 7813645 NUT, 1/2" Conduit lock 200 ete ete 4
26 7000108-11 SCREW, Hex Head Cap, 1/4" x 1", Grade 5, Cadmium Plated ............... 4
27 G7608061 WASHER,1/4" Barseal 2... ee teens 8

Page B-12 Rev. Oct. 1980 Spmeb National Supply Company

V Division of Armoo
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

SWITCH AND BREAKER BOX ASSEMBLY

NOT ‘APPLICABLH
13

TO THIS ORDER
B/0
SEE DRAWING J@/Z@0P-
_IN APPENDIX

3.4.5.6

16,217
24,25
N= 16,21,28,25

COUPLING IN Cag FLOOR

U7-160324
tem Part No.
No. No. Description Req'd.

1 G-7801095 BOX, Switch, Crouse-Hinds *FS-33 . Lee }

2 7801108 BOX, Breaker, Square-D #Q08-16RB (With Door) Petes 1
3 7801098 BREAKER, Circuit, 15 Amp. Tandem (2 Spaces Required) .............2-.... As Req'd.
4 7801103 BREAKER, Circuit, 30 Amp. Single (2 Spaces Required)...........-....2.0.-- As Req'd.
5 7801117 BREAKER, Circuit, 20 Amp. Tandem (2 Spaces Required) .........-.......5. As Req'd.
6 7801119 BREAKER,Circuit, 30 Amp. Tandem (2 Spaces Required) ................... As Req'd.
7 7801151 BUSHING,Conduit, Esco #122-1/2 eee 2
8 7801162 BUSHING, 1" Conduit. 00 tee eee 1
9 7802142 CONDUIT,Rigid, 1’°x 26” Long .... ]
10 7802404 CONDUIT, 1/2” Liquid Tight ...2.007 As Req'd.
a 7802235 CONNECTOR, Crouse-Hinds *CGB-194 200... ene 1
12 7802418 CONNECTOR, Esco #5252, 1/2 x 909 eee 1
13. G-7802435 COVER, Crouse-Hinds #$-323 000.0 eects 1
14 G-7807062 HUB, Square-D #B-100 000 neces 1
15 6817073-G NIPPLE, Standard Pipe,1°’ x Close, Galvanized Lee eee ete eee i
16 6300041 NUT, 1/4’ Hex, Cadmium Plated 2002.2 eee 5
V7 7813052 NUT, 1° Conduit lock 0 eee 1
18 2407220 PLATE, Left-Side Breaker Identification... 06... eee 1
19 G-2407247 PLATE, Light Switch Identification 0 eee 1
20 G-2407259 PLATE, Right-Side Breaker Identification... 2.0.02... eee 1
“21y | 7000108-11 SCREW, Hex Head Cap, 1/4” x 1", Grade 5, Cadmium Plated 2... 5°
22 7818163 STRAP, 1/2" Conduit... 2.0. eee 2
23 7818298 SWITCH, Toggle 20.2 ee eens 3
24 G-7608061 WASHER, 1/4” Barseal 6.2 tee 5
25 7619033 WASHER, 1/4’ Regular Spring Lock, Cadmium Plated .........0........0.. 5
26 7819049 TYRAP 2 ete eee 2
27 7822070 WIRE, #14-2, Type SO-1. 2.0.62 ee As Req'd
28 7813045 NUT, 1/2" Conduitbock 2.0020 eee ee 2

Aamcd National Supply Company Rev, Oct. 1980 Page B-I3

Bunsion of Armco:
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA.

CATERPILLAR ENGINE
7)

17 12,19 35 6
‘6 4
23
10, 14,21

15
a
KILL CYLINDER 5

10, 14, 21

9,13, 18, 20

10,14, 2t

i 38,39

29,30

29, 30
epi oe Lo 24 22 24
fetta Poe ES . ‘ 8,11, 19
ITEMS 26,27,28 AND 36 ARE NOT SHOWN

LT-1601 10

anuipo National Supply Company Rev. Oct. 1980 Page C-l

NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435
CATERPILLAR ENGINE
Item Part No.
No. No. Description Req‘d.

1) G1613933 ENGINE, Caterpillar 3408 PCTA |. . 1

2 G-1613937 SUPPORT, Muffler... ..0..0.0.. 1
3 G-1613938 CONNECTOR, Flexible Exhaust. . 1
4 G1613939 FLANGE, Muffler Upper ....... : 1
5 G-7812035 MUFFLER. 2. ee 1
6 7817195 RAINCAP 200 eee 1
7 7817170 RUBBER, Neoprene, 3/16" x 2’ Wide x 6'-0"' Long 1
8 6200041 NUT, 1/4’ Hex, Cadmium Plated 200.00 eee 4
9 6300062 NUT, 3/8’ Hex, Cadmium Plated ... 8
190 6300121 NUT, 3/4” Hex, Cadmium Plated 00. ees 24
nN 7000109-11 SCREW, Hex Head Cap, 1/4" x 1-1/4°", Grade 5, Cadmium Plated ............ 4
12 7000112-11 SCREW, Hex Head Cap, 1/4" x 2’’, Grade 5, Cadmium Plated 2
13 7000208-11 SCREW, Hex Head Cap,3/8” x 1’, Grade 5, Cadmium Plated 8
14 7000440-11 SCREW, Hex Head Cap, 3/4" x 2’, Grade 5, Cadmium Plated... 0.0.0.0 .000. 24
15 6320042 NUT,1/4”" Hex Jam, Cadmium Plated }
16 G-1613942 BUTTON 1
17 G-1613941 ADAPTER, Kill Cylinder . . 1
18 G-7608063 WASHER,3/8” Bar-Seal 8
19 7619033 WASHER, 1/4‘ Regular Spring Lock, Cadmium Plated .. . 6
20 7619041 WASHER, 3/8’' Regular Spring Lock, Cadmium Plated 8
21 7619066 WASHER, 3/4’’ Regular Spring Lock, Cadmium Plated 24
22 7802194 CYLINDER, Clutch Actuation ....0. 200.0, 0.00000 1
23 G-7802439 CYLINDER, Engine Kill . 2.22.00. eee eee ]
24 7802478 CONNECTOR, Weatherhead #1468 x 4x 4K 00. eee 2
25 7804223 ELBOW, Weatherhead #1469 x 4 x 4K 4
*26 7818038 SENDER, Tachometer, Dixson #201A 1
*27 7818046 SENDER, Temperature, Stewart Warner *362-AH. 00.2 eee ]
*28 7818047 SENDER,Oil Pressure, Steward Warner *353-Z ..........0...... 1
29 7000481-11 SCREW, Hex Head Cap,7/8" x 2'', Grade 5, Cadmium Plated 8
30 7619074 WASHER, 7/8'' Regular Spring Lock, Cadmium Plated 8
31 7819106-0 TUBING,1/4” Synflex.. 0000002 As Req'd.
32 7804220 ELBOW, Weatherhead #1469 x 4K. . )
33 7805175 FITTING, Aeroquip *412-20-24S. .. 1
34 6100037 HOSE, Aeroquip #2651-24.............. 5
35 7802477 CONNECTOR, Weatherhead #1468 x 4K ... 1
36 7807013 HEATER, Circulation (For 240 V Cranes) 2000... eee 1
7807016 HEATER, Circulation (For 120 V Cranes) 2.0... 06k eee 1
37 6300081 8
38 7060307-11 8
39 7619050 8

“NOTE: Sender is required only on engines equipped with electrical gages.

NOT APPLICABLE
TO THIS ORDER

SEE DRAWING /@LPIGO|

conmisinaernenrwemendtN APPENDIX ,

Page C-2 Rev. Oct. 1980 Samco National Supply Company

Vv Diasionof @rmce:
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHOINUSA.
G.M. ENGINE
~~

) NOT APPLICABLE
TO THIS ORDER

30 15,16, 18 23 28
34 10
3 _t
a
8, 14,21 35 9
29 ST
il, 19
KILL CYLINDER

814,21
7, 13,17, 20

NS Pec
=.
2,26, 27
— _ KILL CYLINDER
: SEE ABOVE
} FOR COMPONENTS
. 5 \

oO
7
Lame

' ° 5

(|
\| loT[o } {.
tL flojje L_| —~

“a aegiyteatst
ai a3
Pe
25 24 \a
22 6, 12,19
ITEMS 3!,32 AND 33 ARE NOT SHOWN
ade Ge ERMA aD gate et

U1-160155

Seu Rev. Oct. 1980 Page C-3

NATIC
NATIONAL HYDRAULIC PEDESTAL CRANE —-OS-435
G.M. ENGINE
Item Part No.
No. No. Description Req'd.

1 1612941 ENGINE, G.M.12V-71 0 00 eee renee 1

2 1612932 SUPPORT, Muffler. ..0...... 2
3 1612934 FLANGE, Muffler Upper 2
4 G-1613944 BRACKET,Kill Cylinder 1
5 787170 RUBBER, Neoprene, 3/16” x 2’’ Wide x 48” Long .......000. 0.0000 ae 2
6 6300041 NUT, 1/4" Hex, Cadmium Plated . 0.0200. eee 4
7 6300062 NUT,3/8’’ Hex, Cadmium Plated .........0.00.0 02.000. 16
8 6300103 NUT, 5/8” Hex, Cadmium Plated .. 20.6.0. eee 32
9 6310043 NUT,Flexloc #21FC-428, 1/4°-28 UNF .....0 2.00.00. ee ]
10 6320041 NUT, Hex, Jam, 1/4’°-28 UNF, Cadmium Plated... 00 .0.000020002 002002 eee 1
at 7000108-11 SCREW, Hex Head Cap, 1/4" x 1", Grade 5, Cadmium Plated ............... 2
12 7000109-11 SCREW, Hex Heed Cap, 1/4" x 1-1/4", Grade 5, Cadmium Plated ............ 4
13 7000208-11 SCREW, Hex Head Cap, 3/8” x 1’, Grade 5, Cadmium Plated ............... 16
14 7000397-11 SCREW, Hex Head Cap, 5/8 x 2'', Grade 5, Cadmium Plated ............... 32
15 7053092-13 SCREW, Pon Head Machine * 10-24 x 3/4", Nickel Plated ..0.....00000..... 1
16 7400443 TUBING,Stainless Steel, 1/4’’ O.D. x 035’ Wall x 5/16" Long... ...0-....... 1
17 G-7608063 WASHER, 3/8 BarSeal 900. ee eee 16
18 7619025 WASHER, #10 Regular Spring Lock, Cadmium Plated. ..........0..-.005 1
19 7619033 WASHER,1/4’’ Regular Spring Lock, Cadmium Plated .........0.........4. 6
20 7619041 WASHER, 3/8’ Regular Spring Lock, Cadmium Plated ............0 ......-- 16
21 7619058 WASHER, 5/8” Regular Spring Lock, Cadmium Plated .............-..... 32
22 7802194 CYLINDER, Clutch Actuation 2000000 tte 1
23 G-7802440 CYUNDER, Engine Kill 0 ee eee 1
24 7802478 CONNECTOR, Weatherhead #1468 x 4x 4K 0002. eee 2
*25 7804223 ELBOW, Weatherhead #1469 x 4x 4K 0 eee tees 5
26 7808026 INSULATION, 1500°F, 4° Pipe .0 0 eee 2
27 7809026 JACKET, Cut Roll Aluminum... 6200 ees 2
28 7809014 JOINT, Ball 0 eee eee 1
29 7812031 MUFFLER 2
30 7817017 RAINCAP .........:Pe ee net eee tee eee eee ee 2
731 | 7818038 SENDER, Tachometer, Dixson #201A ...0..000.00 000 cece eee 1
$32 7818046 SENDER, Temperture, Stewart Warner *362-AH 00. ee 1
133 7818047 SENDER, Oil Pressure, Steward Warner *353-Z.. 2... 02.220 cee 1
34 7819106-0 TUBING,1/4” Synflex 0.0000 eee As Req'd.
35 7804220 CONNECTOR, Weatherhead #1469 x AK 00 eee 1

*NOTE: Elbows on Air Starter and Throtile Actuator are not shown (One elbow each).
+NOTE: Sender is required only on engines equipped with electrical gages.

NOT APPLICABLE
JO, THIS ORDER

_t
Page C-4 Rev. Oct. 1980 Semct National Supply Company
ARMCO
AJ) Seesonor ace
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN U.S.A.

HOIST SELECTOR VALVE SUBPLATE AND HOLDING VALVE ASSEMBLY (1607205)

1,2 (shim 2993" Loose }

19

: i]
(8

. @
1.2 (sum 289" Loose ) 5 / @ ~~

17-160079
tem Part No.
No. No. Description Req'd.

1 1600214 SHIM, 0.005" nnn eee eee 2

2 1600215 SHIM, 0.0077 200 cece cee eee 2
3 1600223 FLANGE, Valve... cette 2.
4 1600269 SPOOL, Check Valve... 0.00. ete eee 1
5 1601277 HOUSING,Spring 0.0 cee ne 1
6 3602297 CAGE, Check Valve .. 600 eee J
7 1607206 SUBPLATE 20. eect ene eee 1
8 1612239 SLEEVE 2222 1
9 1612240 SPRING cent cece ee 1
10 1612241 CAP, Check Valve 1
oy apAl$l 3265 | WASHER, Spring 1
12 [1710324 ‘| DISC, Valver fe. t-
i3 1710326 SPRING 20 eee 1
14 171033) SEAT ete eee tenes 1
15 2410022-220 PACKING, ORing 200000 teens 1
16 2410022-222 PACKING, ORing 2000. eee eens 3
17 6875004 PLUG, Standard Countersunk, 1/27. 200 cee eee 2
18 7006260-08 SCREW, Hex Socket Head Cap, 7/16’ x 2’, Cadmium Plated. ............... 8
19 763 2016-C WASHER,7/16" High Collar Spring Lock, Cadmium Plated ..............-.- 8
20 7815051 PLUG, Weatherhead #7230 x4 000 ce ee ees 1

ARM m National Supply Company { Rev. Oct. 1980 Page D-19

of Armeo
NATIONAL
LITHO IN USA. E OS 5

HOIST SELECTOR VALVE (G-1614251)1 a

NOT ‘APPLICABLE
TO THIS ORDER

SEE DRAWING ZAP

cesteenetnenmeeeeasesIN APPENDIX ,

L1-160148

Item Part —_— No.

No. No. Description Req'd.

1 1614243 BLOCK, Valve Operating Mounting ........ 0.006. .c cece eee cece eee 1
2 2410022-014 PACKING, O-Ring... 00. eee 10
3 2410022-016 PACKING, O-Ring 220. cee 2
4 2410022-210 PACKING, O-Ring «60. cect tetneene 3
5 2410022-223 PACKING, O-Ring . 20.0.0 tte teens 4
6 G2410022-230 PACKING,O-Ring . 0.2.00 cece tees 2
7 7006116 SCREW, Hex Socket Head Cap, 1/4 x3 0 eee 4
*B G-7500341 VALVE, Hoist Selector (Includes tems 3, 4, 5 and 6 and 5 of lem 2).. 1
9-1 >7815051.- PLUG, Weatherhead #7230 x4 20.000... 02 cee ee ‘ eye
T10 7804223 ELBOW, Weatherhead #1469 x4x 4K 000000 eee 2
ti 7000443-11 SCREW, Hex Head Cap,3/4" x 2-3/4’, Grade 5, Cadmium Plated ............ 6
Ti2 7619066 WASHER, 3/4’ Regular Spring Lock, Cadmium Plated ..................... 6 —
13 7642010 WASHER,1/4" Hi-Collar, Spring Lock . 2.6.2... eee 4

NOTE: titems 10, 11 and 12 are not included in Assembly Part No. G-1614251
*The smal! Directional Control Valve included in Part No. G-7500341 may be purchased separately per Part No,
G-7500342 Valve. |

Page D-20 Rev, Oct. 1980 Ac National Supply Company

Deacon ut Ar
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHOINUSA.

SWING GEAR REDUCER ASSEMBLY WITH FUNK BRAKE (G-1614300)

) NOT APPLICABLE
TO THIS ORDER

LT-160057

Rev. Oct. 1980 Page F-1

doug National Supply Company
Ghvision of Armco
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
SWING GEAR REDUCER ASSEMBLY WITH FUNK BRAKE (G- 1614300)
item Part No.
No. No. Description Req’d.

] ZB-3937 BEARING 206 e en 2

2 7801106 BRAKE, Swing (See Note #1) 2
3 G 1614302 CARRIER, Swing Pinion Shaft Bearing... 2.2.0... 2... 2
4 7802088 CLAMP, Gates #10 00 cnet teens 4
5 G-1614307 COVER, Swing ©2200. ete eee neces 1
6 7803012 DRIVE, Three Stage Reduction «000... eee eens 2
7 6829002 ELBOW, Standard Ml. Street, 1/4 x90° 00000 eee eee 1
8 7813028 NIPPLE 20 ee eee nee eee 4
9 7000306-11 SCREW, Hex Head Cap, 1/2” x 1-3/4'', Grade 5, Cadmium Plated ............ 8
10 G1614304 GEAR, Swing Pinion ©2000 2
1 6100039 HOSE, Gates #4230-0135, 30" Long... 0.0.00... eee 2
12 G-7812046 MOTOR, Hydraulic Swing... cee eee 2
13 6817011 NIPPLE, Standard Pipe, 1/4 x40 cece eens 1
14 6300121 NUT, 3/4" Hex, Cadmium Plated 2.0.00... 00000000000 cee eee 4
1§ 2410022-250 PACKING,O-Ring 20.0. eee eee eee 6
16 6511216 PIN, Dowell, 3/4° x 2° eect eee 4
W7 1617306 PLATE, End Cover 0.0. ene eens 2
18 6873008 PLUG,1°’ Standard Cored Square Head. 56... eee ]
19 6875001 PLUG, 1/8" Standard Countersunk ..0.000000000000 00 0c ce eee 2
20 G-1614305 RETAINER, Dowell Pin... 0.00.00. 0 20 e eee 2
2) G-1614311 RING, Pinion Bearing Back-Up 6.200 eee 2
22 G6910073 RING, Retaining .. 0... 2
23 2401590 SCREW, HexDrilled Head Cap, 3/4’' x 2-3/4'’, Grade 5, Cadmium Plated ..... . 16
24 2405032 SCREW, Hex Drilled Head Cap, 5/8" x I8UNF x 2’, Grade 5, Cadmium Plated . 8
25 7000208-11 SCREW, Hex Head Cap, 3/8” x 1°", Grade 5, Cadmium Plated ............... 6
26 7000305-11 SCREW, Hex Head Cap, 1/2” x 1-1/2", Grade 5, Cadmium Plated ............ 8
27 7000397-11 SCREW, Hex Head Cap, 5/8” x 2’’, Grade 5, Cadmium Plated ............... 8
28 7000442-11 SCREW, Hex Head Cap, 3/4” x 2-1/2", Grade 5, Cadmium Plated ............ 4
29 7006307-08 SCREW, Hex Socket Head Cap, 1/2‘ x 2'°, Cadmium Plated................. 8
30 7006526-08 SCREW, Hex Socket Head Cap, 1°’ x 3°, Cadmium Plated .................. 14
31 G-1614306 SEAL, Swing Pinion 2.00. eee 2
32 Y$-5500-D SEAL cee eee eee ee ee 2
33 G-1614303 SHAFT, Swing Pinion. 20000. eee cece eens 2
34 G-1614312 SHIELD, Dual Pinion 20. cece eet eee 1
35 G-1614301 SUPPORT, Swing Reducer... 02.06.02. eee 2
36 7612018-C WASHER, 1/2” Hi-Collar Spring Lock, Cadmium Plated .................... 8
37 G-7612026-C WASHER, 1°’ Hi-Collar Spring Lock, Cadmium Plated.........0.......000.5 14
38 7619041 WASHER,3/8"' Regular Spring Lock, Cadmium Plated. 00.00.00... 6
39 7619050 WASHER, 1/2’ Regular Spring Lock, Cadmium Plated ..................... 16
40 7619058 WASHER,5/8” Regular Spring Lock, Cadmium Plated ...0......0......0005. 16
4) 7619066 WASHER, 3/4’’ Regular Spring tock, Cadmium Plated ............2.2...... 20
42 7621024 WASHER, 3/8" Type A Narrow,0.81" O.D., Cadmium Plated................ 4
43 1612933 WASHER «wenn nee 8

NOTE #1: For replacement brake see page F-8 and order items. NOT APPLICABLE
TO THIS ORDER

Page F-2 Rev. Oct. 1980 wo

ARMCO National Supply Company
Vv Dragon ot Aman
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA.

SWING GEAR DRIVE (7803012)

ltem Part No.
No. No. Description Req'd.

1 ¥617311-001 HOUSING, Output... ... 1

2 161731 1-002 CAGE, Planetary....... 1
3 G-1617311-003 GEAR, Planet ......... 3
4 161731 1-004 SHAFT, Planet Gear .... 3
5 161731 1-005 PLATE, Output Shaft ...... 1
6 161731 1-006 PLATE, Planet Gear Shaft . 3
7 1617311-007 SHAFT, Output 2.002 tenes J
8 161731 1-008 SHIM, Group. eens 1
9 161731 1-009 GASKET ]
10 161731 1-010 RETAINER, Seal. cee eens 1
HW 1617311-011 HOUSING,Input 00 eee 1
12 1617311-012 GEAR, Driven Ist Stage 1
13 1617311-013 SHAFT, 2nd Stage... ee cee eee 1
14 1617311-014 GEAR, Driven 2nd Stage... 20. eee 1
15 G-1617311-015 GEAR, Sun 1
16 G-1617311-016 PACKING, O-Ring 2
7 161731 1-017 GEAR, Ring... eee eee nee 1
18 1617311-018 STUD... 3
19 1617311019 SPACER, Bearing . 3
20 1617311-020 PLATE, Cover .... 1
21 G-16t7311-021 GASKET ..0.0.... 1
22 161731 1-022 SHAFT, Input... . . 1
23 161731 1-023 PLUG ... 22. eee 1
24 1617311024 WASHER... 2.2.02. - ]
25 G-1617311-025 ASSEMBLY, Bearing .. 3
26 G-1617311-026 BEARING 20000 eee 1
27 YS-5008 SEAL eet ee eee ee 1
28 ZC-2364 BEARING .. 1
29 2C-2400 BEARING ........... ]
30 ZC-2401 BEARING 3
31 ZT-4300 BEARING 1
32 ZT-5010 BEARING 1
33 2410022-250 PACKING, O-Ring 2.002. eee 2
34 5506304-00F BOLT,Place, 7/16 — 20x 1" 3
35 5506406 BOLT, Place, 1/2’ — 20 x 1-1/4" 6
*36 §506426-00F BOLT, Place, 1/2” — 20x 3-3/4" 0 eee 2
*37 §506430-00F BOLT, Place, 1/2'° — 20x 4-1/4"... 0.00.0. 7
38 6310080 NUT, Flexloc *20FC820, 1/2’ — 20 UNF... . 12
39 6571214 PIN, Spring Slot Steel Standard, 3/16” x 7/8". . 3
**40 6573224 PIN, Spring Slot Steel Standard, 1/2” x 1-1/2’". 2
4) 6874002 PLUG, Standard Solid Square Head, 1/4... . 1
42; G-6910071 RING, Retaining... 2.2.06 eee 2
43 G6910072 RING, Retaining. 000 cee 3
44 7900303-11 SCREW, Hex Head Cap, 1/2” x 1", Grade 5, Cadmium Plated............... 4
45 7007 158-08 SCREW, Hex Socket Flat Head Cap, 5/16” x 1-1/4", Cadmium Plated......... 8
46 7815054 PLUG, Magnetic Drain, 1/2°° NPT 20. eee 2

NOTE: *Measure Bolt to determine propersize.

po. { **Not shown.

Arg National Supply Compeny Rev. Oct. 1980 Page F-7

Denson ef Ameo:
 NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
SWING BRAKE ASSEMBLY — FUNK BRAKE (7801106)*

NOT APPLICABLE
TO THIS

LT-160055
Item Part __ No.
No. No, Description . Req'd.

*] G-1617310-001 WASHER © eee 2

*2 G-1617310-002 PLATE-CLUTCH, Drive .... 0.0... ees 1
"3 G-1617310-003 PLATE,Clutch 6.0. ee 10
*4 G1617310-004 PLATE, Separator 2.00 ee 10
*5 G7918611 SEAL, Piston 0. eee eee eee 2
*6 YS-1761 SEAL, Shaft. ee eee 1
7 G1617310-005 SPRING 00 eee 5
8 1617310-006 HOUSING,Input ........-. 1
gee de Ff. 1617310007 |, HOUSING, Ouiput \
“> 10 1617310-008 SHAFT.....00...000...002. 0 1
1 1617310-009 PISTON, Brake ........... 1
12 7000210-11 SCREW, Hex Head Cap, 3/8" x 1-1/2", Grade 5, Cadmium Plated... .. 2
13 7006210-08 SCREW, Hex Socket Head Cap, 3/8” x 1-1/2", Grade 5, Cadmium Plated. ..... 4
14 7815051 PLUG, Weatherhead *7230x 4..........-. 2.00. ce eee 1
15 6572416 PIN, Spring Slot Steel Standard, 3/8 x 100.6 eee 5

*NOTE: Items 1 through 6 inclusive are recommended replacementparts for brake reconditioning.

Page F-8 Rev. Oct. 1980 Arg Nations! Supply Company

Denson et Armco,
NATIONAL HYDRAULIC
Y PEDESTAL CRANE OS-435
-

GANTRY SHEAVE ASSEMBLY

LT-160113
Item Part No.
No. No. Description Req'd.

1 2404082 KEY, 5/8 x 1" x 2-1/2" Long q |

2 1612406 KEEPER 8
3 1615716 SHEAVE 5 |
4 1615714 WASHER,Thrust 10
5 1612407 SHAFT 0. eee eee 1
6 1612408 CAP eet eee 2
7 1612409 WASHER, Shim 20020 eee 8
8 1612410 SPACER erent teen eee 16
9 1612411 SPACER... ene etter e ees 6
10 1612432 SHAFT 0 eee cet 1
VW 1612425 CAP .......... bee ee : 1
12 2400060 SCREW, Drilled Head Cap, 3/4’ x 1-3/4” 2
13 <}.% 2161-2409: s* WASHER, Shim ees oe ae hee ~3
14 ZB-3751 BEARING,Roller with Inner Race .... 5
15 7805052 FITTING, Grease, 1/87 NPT 202 ee eee 5
16 6875001 PLUG, Standard Countersunk, 1/87. 00. eee 4
7 7000475-11 SCREW, Hex Head Cap, 3/4” x 11-1/2"", Grade 5, Cadmium Plated ........... 8
1& 6300121 NUT,3/4” Hex, Cadmium Plated ........02. 0000202 eee 8
19 7619066 WASHER,3/4”' Regular Spring Lock, Cadmium Plated ................0000. 8
20 2405016 SCREW, Drilled Head Cap, 3/4" x 2", Grade 5 2... 4
21 7822095 WIRE, Annealed Stainless Steel, 0.064" Dia. 6.00.00... 0 eee ee As Reqd.

ARMCD Nations! Supply Company Rev. Oct. 1980 Page G-3

Dison of Armco
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435
TWO SHEAVE BLOCK ASSEMBLY {1612429 RH.

aw NOT APPLICABLE
TO THIS ORDER

i Bo
4eB
SEE. DRAWING 1GIAt
a ~ AN APPENDIM
- panpaanarvacnmnasncrananaensaat
I

tT-160114
Item Part : No.
No. No. Description Req'd.

1 1612421 BLOCK, Right Hand... 2.000 cee eee eee 1

1612440 BLOCK, Left Hand... 2... cette eee ]
2 1615716 SHEAVE ..........- 2
3 1615714 WASHER,Thrust . . . 4
4 1612424 SHAFT... cence teens 1
5 1612425 a 1
6 1612409 WASHER,Shim . 0.0. ee eee eee 3
, 7 ZB-3751 «1: -| .: BEARING,Roller with Inner Race 006.2 ec hee eee ne ee eee se 2
8 2400060 SCREW,Drilled Head Cap, 3/4" x 1-3/4"", Grade 5.2. eee 2
9 7805052 FITTING, Grease, 1/8 NPT 20.0 ee eee eee 2
10 1612438 PIN eect een tn en nt ert e teens 1 _
Vy 6502440-S PIN, Cotter, 3/8” x 5°, Stainless Steel 000 cee ene 1
i2 1612435 PIN eee tenet n eee 1
13 6501624 PIN, Cotter, 1/4’’ x 3” 1
14 1612437 BUSHING ... 20.2.2. 1
5 7822095 WIRE, AnnealedStainless Steel, 0.064" Dia... ees As Req'd.

Page G-4 Rev. Oct. 1980 a i” , Nationa Supply Company

NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA,

BOOM SAVER GROUP

NOT APPLICABLR
TO THIS ORDER

©
9
Saar
\
iF
Ow
SEE pRAWING (@/@O2 5.
IN APPENDIX
= © SON
22 "
te ‘4 =
\ tanetatantsnmannsctacimanspancanannnane!

MANIFOLO IN RIGHTHAND SIDE OF CAB

yoy
voy
2 Voy
voy
an
bob
uw +s
rv] uv) ya
<a +4
@
-
a iy
aot
20

eB i
a3 i
gp 14,2
15
(6

<a]

14

LT-160129

Arup atorsSurry Comoany Rev. Oct. 1980 Page G-13

NATIONAL T CRANE
HYDRAULIC PEDESTAL -4
OS-435
BOOM SAVER GROUP
Item Part No.
No. No. Description Req'd.

“1 1615056-001 ASSEMBLY, Whip Travel Limiter... 000 eee 1

*2 1615056-002 ASSEMBLY, Main Travel Limiter 2.00002 eee 1
3 G-2400061-32 ASSEMBLY, Hose, Consisting of: 0.20.02. eee 2
66’’—6100034 HOSE, Aeroquip *2651-4
27805081 FITTING, Aeroquip #4411-4S
4 1615879 FOLLOWER, Line-Complete With 2—1292141 INSERTS. ............--...20. 2
5 1615845 STRIKER. ete enter ee 1
6 6310082 NUT, Flexloc #50 FAF-813, 1/2"-ISUNC 0. 8
7 7000304-11 SCREW, Hex Head Cap, 1/2” x 1-1/4", Grade 5, Cadmium Plated ............ 8
8 7500017 VALVE, 1/4 Shuttle 20 eee 1
9 7802296 CONNECTOR, Weatherhead *C5205 x 4x4 20.000... .0 0. ee 2
10 7802388 CONNECTOR, Weatherhead #1468 x 6K 2.00.00 0 002 coe ee eee 1
1 7802478 CONNECTOR, Weatherhead #1468 x 4x4 200. eee 2
12 7802436 CHAIN, Proof Coil, 1/4" x 12'-0"' Long, Galvanized .. 2.0.0... eee eee 1
13 7802436 CHAIN, Proof Coil, 1/4”’ x 8-0" Long, Galvanized...........0.......2..000. 1
14 7804117 ELBOW, Weatherhead *C5405 x 4x40... 000 eee 2
15 7804219 ELBOW, Weatherhead #1469 x 6K... tenes 1
16 7804223 ELBOW, Weatherhead #1469 x 4x 4K 0000000000000. ccc cee eee 2
17 7813073 NIPPLE, 1/4’ x 1-1/2", Brass 200 eee eee 1
18 7818330 SHACKLE, Crosby G-213-1/47 0 eres 4
19 7819106-0 TUBING, 1/4" Synflex. 0 eee As Req'd.
20 7819107-0 TUBING,3/8’ Synflex. 00. cee As Req'd.
21 7819050 TY-RAP 00 ene eee 20
22 7819146 TEE, Weatherhead #1472 x OK 00 cect eens ]
23 7802217 CLIP, Crosby #G-429, 1°’ Wire Rope, Galvanized ......,....0...0000202055 1

*NOTE: Parts numbered 1615056-001 and 1615056-002 are identical except for lever position.

NOT APPLICABLS
TO THIS ORDER

SEE DRAWING 24/4025.

IN APPENDIX

Rev. Oct. 1980 —

Page G-14 ARMCO National Supply Company
Desion of Armco.
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LINE TRAVEL LIMITER BOX ASSEMBLY (1615056)

NOT APPLICABLH
TO THIS ORDER)

ffs crcwya L 13725

weenAPPENDIX

LT-160056

Rev. Oct. 1980 Page G-15

ARM 5 National Supply Company
Divsien of Armen
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LINE TRAVEL LIMITER BOX ASSEMBLY (1615056)
Item Part No.
No No. Description Req'd.

1 1615872 HOUSING 2 eee }

2 1615873 COVER 20 tte 1
3 1615874 ARM, Spring . 006 eee eee 1
4 1615875 SPRING 20 teeter teens 1
5 1615876 CAM eee nee ete t eee ae 1
6 1615877 LEVER 2 eee eee 1
7 1615878 SHAFT eee eee ]
8 ZB-0756 BEARING 2.000 ete eee 2
9 2401390 KEY, 1/4" Squore x 15/16" bong... eee 2
10 5504016 BOLT, Closed Eye 0002 tt ete eens }
YW 6300041 NUT, 1/4’ Hex, Cadmium Ploied 60002 eee 2
12 6300062 NUT, 3/8" Hex, Cadmium Plated ...0 0000000 eee 1
13 6300081 NUT, 1/2” Hex, Cadmium Plated 20002 eee 4
14 6310053 NUT,Flexloc #21FA-518, 5/160 0 etree 1
15 6817007 NIPPLE, Standard Pipe, 1/4” x Close 0. ees 1
16 7000108-11 SCREW, Hex Head Cap,1/4’’ x 1"', Grade 5, Cadmium Plated ............... 2
17 7000209-11 SCREW, Hex Head Cap, 3/8"’ x 1-1/4", Grade 5, Cadmium Plated ............ 1
18 7000211-11 SCREW, Hex Head Cap, 3/8”’ x 1-3/4'", Grade 5, Cadmium Plated ............ 1
19 7000303-11 SCREW, Hex Head Cap, 1/2" x 1", Grade §, Cadmium Plated 0.0220 020000.. 4
20 7027 102-30 SCREW, Hex Socket Head Cup Point Set, 1/4’ x 3/8’, Stainless Steel... .... }
21 7500147 VALVE, Check Exhaust }
22 7500322 VALVE. eee 1
23 7600046 WASHER, 3/4” W Type A, 2.0 0.0. 20. eee 1
24 7619033 WASHER, 1/4’ Regular Spring Lock, Cadmium Plated .........-...-...0-0. 2
25 7619041 WASHER, 3/8"' Regular Spring Lock, Cadmium Plated .................-0.. 2
26 7619050 WASHER, 1/2'’ Regular Spring Lock, Cadmium Plated ..................0.. 4
27 7802110 COLLAR 26 tee ete 1
28 7804223 ELBOW, Weatherhead *1469 x 4x 4K 00 eee 4
29 7817170 RUBBER, Neoprene Sponge, 3/16" x 27x 18" Long... 0022.2 eee 1
30 7819106-0 TUBING, 1/4’ Synflex, 24’ Long 0.00... cee 1

NOT ‘APPLICABLE
TO THIS ORDER

SEE DRAWING 4@45-

72S"
IN APPENDIX

Page G-16 Rev. Oct. 1980 Samoan NetlonalSupply Company

Vv
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

BOOM AND GANTRY SAFETY BEACONS

NOT APPLICABLE
TQ THIS ORDER

SEE DRAWING J@/Z009-60/

AN APPENDIX

\ BREAKER BOX ON
ne 8 LEFT WALL OF
\ NS | 2 CAB
s ie Rl 47 5 \
\ uk a t: \—13, 14,15

NN 8 nee

N. (cout
\ WELDED IN RIGHT
\ HAND SIDE OF
S OF CAB

‘ +. “SEE DETAIL ABOVE

t1-160117

item Part No.

No. No. Description Req‘d.

; od G-7811024-1 BEACON, Red Flashing (120 VAC), Includes: .. 2.00.00... ee eee tees 2
| 1—G-7801124 BULB, Xenon Flash
i G-7811024-2 BEACON, Red Flashing (240 VAC), Includes: ©... 0.00. 2
1—G-7801124 BULB, Xenon Flash
2 6817044-G NIPPLE, Standard Pipe, 1/2'’ X Close, Galvanized... 2. 00......-..00.0.0005 2
3 6884024 REDUCER, Standard M.I. Pipe, 1 x 1/2 eee 2
4 6817081 NIPPLE, Standard Pipe, 1° x6" tee 1
5 1612444 BRACKET, Mounting .. 6... 1
6 7802415 CONNECTOR, Crouse-Hinds *CGB-394............ beeen . | 1
7 G-7802491 CONNECTOR, Crouse-Hinds *CGE-194.......... Lae bees an 1
. 8 7802235 .. . CONNECTOR, Crouse-Hinds #CGB194. 2 eee 2
9 7802279 CONNECTOR, Crouse-Hinds *CGB-294.00 000000000 ccc cee : J
10 7807065 HUB, Conduit, Appleton *HUB-75 ...... eee ee eee ee 1 1
‘1 7802149 CONDULET, Crouse-Hinds *T-19, With Cover . L. . Doce eee E ]
| 12 G-7822125 WIRE,Anixter DDS-4,#14-2 0000. eee As Req'd.
1 13 6300001 NUT, #10-24 Hex, Cadmium Plated ............. Lett tenes é
14 G-7053092-13 SCREW, Pan Head, *10-24 x wa", Nickel Plated .........00-...0-..2.0005 6
15 7802206 CLIP, 3/8" Tube. ete eee 6
16 7806051 GASKET, ESCO *GASK 1941-120 cen 1

anuaco Nations! Supply Company Rev. Oct. 1980 Page G-21

Deamon of Armco:
 qn
NATIONAL
LITHO IN U.S.A,
HYDRAULIC PEDESTAL CRANE ~“QS-435
BOOM LIGHT GROUP (MERCURY VAPOR)

NOT APPLYICABLY
TO THIS ORDER

SEE DRAWING LGLZ008-B/3

JN APPENDIX

1,16,19,22

INSIDE OF CRANE
L7.160322

Page G-22 Rev. Oct. 1980 ‘ ure National Supply Company

re OA 8 Arc
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN U.S.A.

BOOMLIGHT GROUP (MERCURY VAPOR)

Item Port No.
No. No. Description Req'd.

1 7801025 BALLAST, Mercury VaporLight (60 Hertz Only)... 000. ee 3

2 G-6800083-G BUSHING,Standard M.!, Hex, 1’ x 1/2", Galvanized... 22.202 1
3 7802404 CONDUIT, Flexible Liquid-Tite, 2" 20 ene As Req'd.
4 7802155 CONDULET,Esco #T-39, With Cover... 0000. ee 1
§ G-7802500 CONDULET,Esco *X-39, With Cover 0. eee 2
& G7802235 CONNECTOR, Croyse-Hinds *CGB-194, 1/2 0 eee 6
7 7802400 CONNECTOR, Esco #5232, 1/2" x Straight ©0060 eee 1
8 7802418 CONNECTOR, Esco #5252, 12 x909 eee ]
9 G-7802492 CONNECTOR, Crouse-Hinds *CGE-395, 1x 90° 0. ee 1
10 G-7802494 CONNECTOR, Crouse-Hinds *CGB-395, 1‘ x Straight... 0.0.02. eee 2
1} 7805158 FIXTURE, Mercury Vapor Light ©... 000.20 eee 3
12 7806053 GASKET, Esco *GASK 1943-1 centers 3
13 1615825 HANGER, Boom Light... eee 2
14 7811011 LAMP, Mercury Vapor... eee 3
15 6817149 NIPPLE, Standard Pipe, 1°" x 5-1/2" 0 eee 2
16 6300081 NUT, 1/2°° Hex, Cadmium Plated ..0 0.0.0 nes 12
17 6300103 NUT, 5/8’ Hex, Cadmium Plated .. 0.0.00. eee 3
18 7813052 NUT, V Conduit lock 2 ences 6
19 7000303-11 SCREW, Hex Head Cap,1/2” x 1", Grade 5, Cadmium Plated ...........-... 12
20 7000396-11 SCREW, Hex Head Cap, 5/8” x 1-3/4’", Grade 5, Cadmium Plated ............ 3
21 7819050 TYRAP 0 eee eee 40
22 7619050 WASHER, 1/2’ Regular Spring Lock, Cadmium Plated ..................... 12
23 7619058 WASHER, 5/8" Regular Spring Lock, Cadmium Plated ..................... 3
24 7822070 WIRE, #14-2, Type SO-T eee eee As Req'd.

NOT APPLICABLE
iO THIS ORDER

8/3
SEE DRAWING [O12 008-
_____IN APPENDIX

ARMGO Nattone! Supply Company Rev. Oct. 1980 Page G-23

Deasion of A:meo
NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE ' OS-435
BOOM AND GANTRY SAFETY BEACONS — EXPLOSION PROOF

NOT .‘APPLIC!ABLE
+O THIS ORDER

SEE DRAWING OME

BREAKER BOX ON
a of LEFT WALL OF
2 CABS

~
A

\ | coupuins
WELDED IN RIGHT
‘ HAND SIDE OF
OF CAB

yl
~ 7.160367

ltem Part No.

No. No. Description Req'd.

1 G-7805162-1 BEACON, Red Flashing (120 V), Includes: 0.202... eee 2

1—G-7801124 BULB, Xenon Flash
G-7805162-2 BEACON, Red Flashing (240 V), Includes: ........TT eee ee 2
1—G-7801124 BULB, Xenon Flash
2 6817044-G NIPPLE, Standard Pipe, 1/2’ x Close, Galvanized 0.0.2... ee eee 1
3 G-1618631 BRACKET,Fixture 2000 tenet teens 2
4 6817081 NIPPLE, Standard Pipe, 1° K 6" cece ]
5 1612444 BRACKET, Mounting .. 2.002 eee 1
6 7802401 CONNECTOR, Crouse-Hinds #CGBS-2013 .. 0.2. ee eee 2
7 G-7802491 CONNECTOR,Crouse-Hinds ACGE-194 2.00. ee eee 1
8 7802235 CONNECTOR,Crouse-Hinds #CGB-194. 222. eee 2
9 7802279 CONNECTOR, Crouse-Hinds #CGB-294 2.00 eee 1
10 7807065 HUB, Conduit, Appleton HHUB-75. 000 cece ene 1
1 7802149 CONDULET, Crouse-Hinds #1-19, With Cover 2.0.00. 0. ee eee 1
12 G-7822125 WIRE, Anixter DSS-4, #14-2. 0000 eee As Req'd.
13 6300001 NUT, #10-24 Hex, Cadmium Plated . 20.0.0... cee 6
14 G-7053092-13 SCREW, Pon Head, #10-24 x 3/4’, Nickel Plated .............0...... 0.000. 6 —
15 7802206 CLIP, 3/8" Tube. cette 6
16 7806051 GASKET, Esco #Gask 1941-1/2% 0 cette ee 1
17. 70001 10-11 SCREW, Hex Head Cap, 1/4” x 1-1/2", Grade 5, Cadmium Plated ............ 8
18 7619033 WASHER,1/4’ Regular Spring Lock, Cadmium Plated ...............0-02005 8
19 6300041 NUT, 1/4‘ Hex, Cadmium Plated 20.00. ene eee 8

Page G-24 Rev. Oct. 1980 SRMCO National Supply Company

Vv Lawson of Armes
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435 LITHO INUSA.

BOOMLIGHT GROUP — EXPLOSION PROOF (MERCURY VAPOR)

NOT APFLICA3LS
TO GHIS CORDES

SEE DRAWING LOY

IN APPEN

—_. >9} 6 . 6
NEY
ar
\ » 6
FRONT OF CRANE

bt | L

i i
H 1
I

|
1

COUPLINGS WELDED
IN FRONT RIGHT HAND WALL
OF CRANE.! |
| 1!
1 1
rf oy
it
1
P|
1 1
1oadot
1 I |
1
1 |
it
1
ty
ii
i

tf
| I '
ri
thor
|
1

24 $a
poi
hort
yi 4
phd
i 1

I | !|
1

rid
boy ol
rl |
ii
' !
ri!
wee Jii!'
fe sl tot

t-----
I
8 aI

INSIDE OF CRANE
LT-140368

ARMCO Kanone!
NJ bacon cA Supply
neo Company Rev. Oct, 1980 Page G-25
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
BOOMLIGHT GROUP — EXPLOSION PROOF (MERCURY VAPOR)
Item Part No.
No. No. Description Req'd.

1 7801025 BALLAST, Mercury Vapor Light 00.020. o eee 3

2 G-6800083-G BUSHING, Standard M.1. Hex, 1° x 1/2”, Galvanized... 00.00. ee 1
3 7802404 CONDUIT,Flexible Liquid-Tight, 1/2" 00 ec eee eee eee As Req‘d.
4 7802155 CONDULET, Esco #7-39, With Cover 2.0... eee 1
5 G-7802500 CONDULET, Esco #X-39, With Cover 00. 2
6 7802235 CONNECTOR, Crouse-Hinds #CGB-194, 1/2'’ x Straight . 2.6... 6
7 7802400 CONNECTOR, Esco #5232, 1/2'' x Straight 2... eee eee 1
8 7802418 CONNECTOR,Esco #5252, 1/2 x90° 200 tee 1
9 G-7802492 CONNECTOR, Crouse-Hinds #CGE-395, 1x 90° 26 eee 1
10 G-7802494 CONNECTOR, Crouse-Hinds #CGB-395, 1’ x Straight.........00.--..-.00-. 2
1 7805159 FIXTURE, Mercury Vapor Light ... 0.0.0.0. 0000000 eee ees 3
12 7806053 GASKET, Esco #Gask 1943-19 tenes 3
13 1615825 HANGER, Boom Light 000 eect eres 2
14 7811011 LAMP, Mercury Vapor... 202s 3
15 6817149 NIPPLE, Standard Pipe, 1° x 5-1/2" eee 2
16 6300081 NUT, 1/2’’ Hex, Cadmium Plated... 200.022. 0 2 eee 12
7 6300103 NUT, 5/8’ Hex, Cadmium Plated «200.000. cee 3
18 7813052 NUT, 1° Conduit Lock 6.00 6
Wy 7000303-11 SCREW, Hex Head Cap, 1/2" x 1", Grade 5, Cadmium Plated ............... 12
20 7000396-11 SCREW, Hex Heod Cap, 5/8’’ x 1-3/4", Grade 5, Cadmium Plated ............ 3
21 7819050 TYRAP ce eee cette eee 40
22 7619050 WASHER,1/2’ Regular Spring Lock, Cadmium Plated ........2.....0-..05. 12
23 7619058 WASHER, 5/8" Regular Spring Lock, Cadmium Plated ..............2...00. 3
24 7802422 WIRE, Anixter VN-TC #2A-1403 200 eee ee As Req'd.
25 7802401 CONNECTOR, Crouse-Hinds #CGBS-2013 06026. 3

HOT~ APPLICAT
APE LA A
LO THs ORDER My

Pave G-26 Rev. Oct. 1980 Squcb Nationst supply Company

Vv Lemon oF Army
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INU SA.

SHORT CATWALK (1612880)

NOT APPLICABLE
© ‘rO THIS ORDER

a
L
ws SEE DRAWING...“We.
acarael ceueuneetN APPENDIX
14

°
al
g

LT-160137

Samco National Suppty Compony Rev. Oct. 1980 Page H-l

VY onsin of area
NATIONAL
LITHO IN U.S.A.

SHORT CATWALK (1612880)

Item Part No.
No. No. Description Req'd.

] 1612881 POST, Front Support... ce eee 1

2 1612882 POST, Center Support ©. eee 1
3 1612883 POST, Rear Support... eee eee 1
4 1612884 GATE 20 cence cece e eens 1
5 1612885 FLOOR 200 cee ee ete 1
6 7810021 KNOB one ett teen eee nee 5
7 1612886 BAR, Gate... eee cette eee 1
8 1612888 KEEPER, Gote 00.6. e eens 2
9 3115000 PLATE, DiamondFloor, 3/16" x 4°" x 25" Long .. 6.0.6. .6 eee 1
10 3115000 PLATE, DiamondFloor, 3/16" x 4x 24" Long ......00.0 00000200000 eee eee 1
11 6701241 PIPE, N.S.D. T-632 Sch. 40, 1-1/2" x 25-5/B" Long... 0... eee 2
12 6701241 PIPE, N.S.D. T-632 Sch. 40, 1-1/2" x 6’-2-5/8" Long... 6. eee 2
13 6701241 PIPE, N.S.D. T-632 Sch. 40, 1-1/2" x 24-5/8” Long... - 00.0. eee 2
14 7804072 ELBOW 20 ene ee nent e eens 4
15 7819072 TEE ce ee eee eee 4
16 7804073 ELBOW 0.0 ce ete nent e eee 1
17 7819073 6 1
18 7805095 FITTING, Eye 22.2 eee 2
WW 7000440-11 SCREW, Hex Head Cap,3/4’ x 2", Grade 5, Cadmium Ploted .........-..... 9
20 7619066 WASHER,3/4’ Regular Spring Lock, Cadmium Plated ..............00.002, 9
21 700031 4-31 SCREW, Hex Head Cap,1/2’ x 3-1/2", Stainless Steel ......0...022...0..0.,. 1
22 7600032 WASHER, 1/2’ N. Type A, 1,062” O.D. 000. eee 2
23 6310081 NUT, Flexloc #30FA813, 1/2°-13UNC 000. cee ee 1

NOT APPLICABLE
TO THIS ORDER

SEE DRAWING .ALQVE

_IN APPENDIX

|
Page H-2 Rev. Oct. 1980 ARMCO National Supply Company
MJ desion ot armea
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN U.S.A.

_ LONG CATWALK (1613870)

NOT APPLICABLE g 8&8

TO THIS ORDER

see cnswine .<@l#@Ze.

ARueo National Supply Company Rev. Oct. 1980 Page H-3

NATIC
NATIONAL HYDRAULIC PEDESTAL CRANE —OS-435
LONG CATWALK (1613870)
oe
Tttem Part No.
No. No. Description Req'd.

t 1613871 SUPPORT... ee ete eee J

2 1613872 SUPPORT 00 eee ene eee 7
3 1613873 SUPPORT... 02 eet teen eee eee 1
4 1613874 SUPPORT. 000 cee eee 1
5 1613876 CT| 1
6 1613877 FLOOR 2 ce ee eee eens 1
7 1613878 FLOOR 2c eee bene eee 2
8 1613879 FLOOR 00 nett eee e tenes 2
9 1613882 FLOOR 00 ene eee ene 1
10 1613883 FLOOR 2200 ent eet ee ee 2
u 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2" x 26" 0 eee 2
12 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2’ x 36-1/2" 6000. ee ee 2
13 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2" x 15'-6" 000. eee ee 1
14 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2". x 15/10" 20.0. ec eee 1
16 6701237 PIPE, Standard Galvanized Sch, 40, 1-1/2 x V7'-6-1/2 eee 1
16 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2" x 17-10-1/2" 20 eee 1
17 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2" x 18'-10-1/2" .. ]
18 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2" x 19'-2-1/2" |. . 1
19 7802274 CROSSOVER «000 eee eee ae 8
20 7804072 ELBOW 200 cet eben e rene 8
2) 7804073 ELBOW 20 ee teeter ee 1
22 7805095 FITTING, Eye eee eee eee 2
23 7810021 KNOB 00 eee eee 2
24 7819072 a 10
25 7819074 02 <a S 7
26 6300081 NUT, 1/2" Hex, Cadmium Plated 27
27 6300121 NUT, 3/4” Hex, Cadmium Plated 24
28 7000304-1 1 SCREW, Hex Head Cap, 1/2” x 1-1/4’', Grade 5, Cadmium Plated ............ 1
29 7000306-11 SCREW, Hex Head Cap, 1/2" x 1-3/4'’, Grade 5, Cadmium Plated ............ 26
30 7000440-11 SCREW, Hex Head Cap, 3/4" x 2’, Grade 5, Cadmium Plated ............... 30
31 7619050 WASHER,1/2’ Regular Spring Lock, Cadmium Plated ..............-...0., 27
32 7619066 WASHER,3/4’ Regular Spring Lock, Cadmium Plated ..............-...005 30

NOT APPLICABLE
@O THIS ORDER
SEE DRAWING .4@/4826
MetinsaissiiscrismmmmnlN APPENDIX

Page H4 Rev. Oct. 1980 ARMCO National Supply Company

Vv Deasion of Armco.
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INU.S.A.

UPPER HANDRAIL (1612896)

NOT APPLICABLE
TO THIS ORDER

SEE DRAWING L@/3B8

5
Craveisee *~y
Maat.N APPENDIX

WS te} ps)

@ vo 2 9 =

~—
© a 2 2

LT-160134

anwpe National Supply Company

Rev, Oct. 1980 Page H-5
Oreaion ot Armee
LITHO IN U.S.A.

UPPER HANDRAIL (1612896)

Item Part No.
No. No. Description Req‘d.

] 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2" x 20-1/20 0 eee 2

2 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2" x 41 0 ee ee 5
3 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2 x43 0 ce cee 5
4 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2" x55" eee 2
5 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2" x 1276" ce 2
6 6701237 PIPE, Standard Galvanized Sch. 40, 1-1/2 x 13-0" 06 eee 4
7 7802274 CROSSOVER 000 ee ete eee 12
8 7804072 ELBOW 2000 ee ete e eee eens 6
9 7804073 ELBOW 20 ee eee ene 2
10 7805107 FLANGE, With: 20200000 nent eee nee 6
2--6300081 NUT, 1/2’ Hex, Cadmium Plated
2—7000306-11 SCREW, Hex Head Cap, 1/2” x 1-3/4", Cad. Plated
2—7619050 WASHER, 1/2’ Regular Spring Lock, Cadmium Plated
2—G-7608067 WASHER,1/2” Barseal
V1 7805107 FLANGE, With: 00002 ee ee eee e eee ee 4
2—-630008} NUT, 1/2’ Hex, Cadmium Plated
2—-7000304-11 SCREW, Hex Head Cap, 1/2’ x 1-1/4", Cad. Plated
2—7619050 WASHER, 1/2’’ Regular Spring Lock, Cadmium Plated
2—-G-7608067 WASHER, 1/2” Barsea!
12 7810021 KNOB 20 eee tenet eee 6
13 7819072 TEE ne eee e tect e eee 2
14 7819073 6 SS 2

NOT APPLICABLE
TQ THIS ORDER

SEE DRAWING .CO/9 BES

nomenN APPENDIX

Page H-4 Rev, Oct. 1980 Aug National Supply Company

Dwaaon of Armco
 ff

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Cc . ~ PROPRIETARY INFORMATION
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This document contains National Supply Co.,
Division of ArmcoInc. proprietary and confiden-
oO tial information. It Is loaned for limited purposes
‘onty and remains the ‘of Armco.It may
not be reproduced in ‘of in part without the
~ writen consent of Armco, must not be
disclosed to persons not having need of such
disclosure consistently with the purpose of the
loan. The document is to be returned to Armco.
:* Upon request and in all events upon completion of
the use for which it was loaned.

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@) ~ 7619033
= |7000106-11
WASHER, REG, SPG. LOCK, $/4” CAD. PLTD.
SCREW, H.H. CAP, 1/4» 3/6" CAD. PLTD.
4l
1s
-| 7000108-11 SCREW, H.H. CAP, 1/4”= 1" CAD. PLTD. 28
~[ 6300041; NUT, HEX. 1/6" CAD. PLTD. 4)
-| G-7608067_| WASHER, BARSEAL, 1/2" 20
- 7619050 WASHER, REG. SPG. LOK../2" CAD. PLTO. 20
(ASV APY SOYAT)
-} 7819073: TEE, KEE KLAMP # 21-8 to
RRAZALAZ/ -| 7839072! TEE, KEE KLAMP # 10-8 4
{| 7900306-11_ SCREW, HH. CAR, 1/2" = 1-3/6" CAD, PLTO. 42
-{ 7000304-11 SCREW, H.H. CAP, 1/2"x 1-76" CAD. PLTD, 8
~ 6701237 PIPE, STO. GALV, PE. SCH. 40, 1-472" 13'-1" 6
~ 6701237 PIPE, STD. GALV. PE. SCH.40, 1-1/2"s 12-6" 2
- 6701237 PIPE, STO. GALV. PE. SCH.40, 1-1/2" 53-2” 3
= 6701237 PIPE, STD. GALV. PE. SCH.40, 1-1/2"% 43” 5
~} 9701237 PIPE, STD. GALV, PE. SCH.40, 1-1/2"41" 4
- 6701237 PIPE, STD. GALV. RE. SCH. 60, t-1/2"»20" 3
- 6300081 NUT, HEX. 42" CAD. PLTD. 20
-| 7aroo21 KNOB, KEE KLAMP # 77-8 16
~ 7805107 FLANGE, KEE KLAMP ## 62-8 10
- 7604073 ELBOW, KEE KLAMP # 20-8 L2

1613885

ty A
1s]-] 7806072 “L-taow, KEE KLAMP 441-8 2
| - 780227% CROSSOVER, KEE KLAMP 445-8 3%
[13/0] 1607004-758 CORNER, TOE BOARD 4
alizicl teigaect2 soann, TOE 1
alit|c} 1619884-11 BOARD, TOE 1
4(10/C{ 1613884-10 BOARO. TOE 4
4/9 {0} 1613866-9 BOARD. TOE 1
(22)3)a5Py 13 PLaces a) Bic} 1613884-8 BOARD, TOE 1
NOTES: al7 {ce} 1613804-7 BOARD, TOE 1
(3) 1a REFERENCE ONLY. alé ic} 1613886-6 ROARD, TOE 2
Gwar in COVER 2.8 SHIPPED SEPERATE. a{s[c[ 1613884-5 BOARD , TOE 1
(7) GS (2-HOLES] 5 Seal UNDER TOE BOARDS & al 4 [D] 1613884-4 BOARD, TOE 1
SHB" DIA. as FLANGES WITH SILASTIC 4l3 lc] t13804-3 BOARD, TOE 2
28-HOLES Oe SEE NOTE #5 SPRAY HOLE WITH COLO al 2ic} 1613886-2 SOARD, TOE 2
SEE NOTES 485 rr GALVANIZE. alr te) weisea,—1 BOARO TOE 1
§. SEAL UNDER TOE S0ARDS [_[ “TPaRT NUMBER seocernen on
B
aS WITH SILASTIC.
Pi> SECTION A-A . Sr a
So
tenesTe RAIL UPPER HAND:
0S-435
The7A1 erneda Lewes ee
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pay resooes rreer za al e-19996 | S210, E0Ge 7
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bor welal sessora ower z
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def esoces Wut, Fltriot ee yen Atte = fo P6623FO ALIOSG, CLSTEM é
o aif] 2fesers | varer, Saae 34 jel 7473930 Pumt® Bonar ser37T t
IOle Ot TQ Fe Crtee 35 Slo) 6r2n77 2 AAG KOS?
anja] 7677539 GRACKET 3] 7 (ol e-7a1s E57 7 Swan \
: {adla} s6r7ae2 sane, Jai se 16/2926 sumed, Toe" seeg aes
lei|-| <zee0es Al abt And Her Fb 6A 7 F ata, Va™ Cant tH
| lel-[ 7aoegr? evo +f lever 7
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i DOCUMENTO ILEGIVEL, ORIGINAL lesleta-essar [sour of Z jit rrd35o 1 aa37, Teeee Poa RE 7
i ENCONTRA-SE NA TI/UNBC. aol «eases coven
____. a z!
7 P merece _ Pues
a See fees oer. oar 2122, Ta _.
[ar] 288908, Swivkt, wekO, Coa
'
 Jicisez6
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.
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|
DOCUMENTOILEGIVEL, ORIGINAL
i ENCONTRA-SENA TI/UNBC.

b
: a2|—] 6300121 NUT, HEX. 34” CAD. PL. 1 {ea
i ai]- yooos3e-H [SCREW- Hero Car axl Gad CP -3[24
1 KOl- 6300041 NUT-Her Ya" CP W/o
: a : 30[- 7019033 |WASHER-Seame Loew va" OP feo
: a Set sal- Te19 006 WASHER: Sreme Lock M4 CP ~1 [30
| Le 37|-| tooo1ob-n ScRew- Hex Ho Car “SKI Ge S OP wt fe
i 2 iMel- 7oo0aqgo-11_ SCREW-HexHoCar Mk?) Ges CP -ale
: 35]
t 34)
| lagl-| @3000a1 uuT-Hex v2 CP N424
i s2|- _roogace-l! SCREW-Hex HoCar “x i%GeS OP 1 124
Bi[-} 7612050 WASHER -Srama Loew V2" CP 1 (82
7 Cy = 7QOCORO3-11| SCREW Hee Ho Cae Walt Ge S CP wt [28
‘ z. bol ~f ero1237 PIPE Sto Ga, RE. Sen 40 SM"x O20" s.o[ 5
: @ ZQ-| g01z37 PIPE Sro.Gauw, PE, Sen 4O 12"xO-42" 9.5] i4
i 27]-[ e702 47 PIPE, SvoGaww, Pe, Sen AO VTS" 3.4] 3.
i 2oj- ro1237 PIPE, SroGav. PE Sena Ax O- 4h” 7.813
= 2sf-] @IO1Z37 PIPE, Sto.Gaw. Re. Seno Mee o 30%" [aa] 3
24] - @TON2*T PIPE Sto Ga, FE, Sous Wx We 3” 44u >
L i {| 23f-] @701237 PIPE, Srte.Gaw. Pe Senso 1210732 %"_ 17.31 4
: 22
za @TO2AT PIPE, Ste Gary. PE. Sen 40 Wale" 3 9" S8i 5
(0) Mi TOP i oFI7 gTIE. TMD of = [01237 PIPE, Sro.Gaw. PE Sendo tx 16'-0" fas] 3
TYP 23-PLCS. i 1} -[ @r01237 PIPE, Ste. Gay. BE. Sen dO 1 xO-23 78 [54] ©
rs GtOI231 PIPE, Sro. Gaus. PE Sen dO ale 8-22" BAM S
G +} _ PROPERTARY RHOBAATION hl SS) SUPPORT Raw KEE WLAMP *TO-B& 1815
Tit document comaim Maen Supoly Co, fo = 7BI901S TEE-CeossoviR KEE KLAMP 840-8 1.8] 2
FP Srmmcleee
Sah and fomnen theeeeices
propesty of Armco. hry [s[-| 7e8a8 SWIVEL" Bovuer WU-RAIL = 30-0 20) 12
i exereproaucedwholeorn wenbont re 114 © TBO22T4 CEOSSOVER KEE KiaAMmP 845-8 41.2145
Siacloved Wo pemans mtneeens LM FasSOTS Yee, KEE KLAMP * 16-6 43
(14) ee ne ScereSan ugencomeletanss 14 TEORNOT FLANGE KEE KLAMP 462-8 2.2) 14
@ ‘hecho wa are af OBS1S SUPPORT, Catwaun siz
ADDED -/2-9-az [2 7610021 KNOB, KEE KLIMP _#34-8 3/23
- Sle] woaaie SUPPORT, Catwarn B., Faouy sa) 1
4 V aie WoOCBBI9 | GATE, Carwaun 45] 4
TWA 161483) FLOOR, Carwauw tu. Etouy Ger. a4 §
\ Pe 1614829 FLOOR, Catwapay LM. sont 206) 1
4 3
i ale (614835, FLQOR, Corwen EW Bene 201 2.
i Ze] woeecs ELGOR Carwarn R.W-Lp. Beer Conner 193) 2
. zis e0BBO4 FLOOR, Canara RL. Cre, 247 2
i Us 108803, FLOOR, Catwarn E.H. Feomt eal
waremray El wo I nencetion fost. mee

i a me, “ ee f=} : aaa a: Natianad

: a WETGH TT COO ooo te te
| / ~— tes al Bs Cre TEL TORS “CATWALK FCP T nto
/ S Tesae aoNtaS 08-435 (L0:
\
rere aligae26
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A ]Avecy AvsastmcutNerg 10 [5-1-0 Nowe 44

BUWAS 2 REGQ'D,. IEF 1G- 9-82) 82-35 Te

Te rE we wane re :
camarn 7

Sear “lLoaute

ian
“Paste Gasman”
KA te
Tare Au Oren Use Brace Srastic Unoer
Weso Ce tren io
f Hores Swot 6 t

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ah
DOCUMENTOILEGIVEL, ORIGINAL]
ENCONTRA-SE NA TVUNBC.
( ~fLoctite 7
Fone Gasner” G- 1615 92S

fs
\r
ID fe] GIB Sprme i
1et- asia Roo, Twmeaceo a"-lo + Biz” Le. z
GOCE ]-
lQ|~[
Taisoie
7802345
Puy c-c. #CP-U3
Cugvis, C.0. 4% AC-225 it
I

BOIS |- 719041 Washer, Rec. Seu. Locn %a" Cao. Pr. 4

14/- 1619033 WasneR, Ree. Gp.. Locn Va" Cao. F- Zz
Adjust Herne For Ain Frow From PorA” Is [- Joooesz Wasuer, A" N. Tree A 1.067" 0,D. 1
A ¥ To Pornt'0” In Positi3Oly Suown, AND
Ain Flow Brockes Fi
Wraan Crevia (lene
wm Port "A~
yo Porto
IZ]
Th
-|
=
G-W600327
6-1000320-30F,
VAwe
Sezew, HH. Cap 42720 UNE RS” SOT
t
1
é & Dimension A Ie O. iO} - TOoolO8-N -Sceew, HH. Care Va"! Ge. S Can. FAL. z
dj -| B77 006 Plus, Sto. Cant Bbmass Soum Sa. Wo. %" 2
Bl -]| $500606 Ping Corre War" x Me" {
72 |] 6320081 Nut, Hex dam %2%ZO Can. R. 1
& GI- GBOoOGt Nurs, Hex %p" Cao. FL. 4
S}-| 6300041 Nurs Hex 4" Can. A. "2
4 {Cl} G-1616972! Plate, Toe }
B[C G-IGiS97O Plate, Bottom '
ZC GAGISSI9 HovsinG I
1 {O| Ge1is917 Guice I
wAQh 1 HUMSER
Sit I DeLC AIP TOM

=
a8
waremar
AqMEO National Supply Division Goon Saver Assemmy, 05-45

vinOow wamonese ALLOOARLE MACHINE FAACTIONS = > iar enacaae

perornVe eae] Bic-1as baer

TOLERANCES UNLESS
OTMEmmIsE se ECE cues
ry wyuats
Tiiseusce
1GISORKeL
 | /61929/
} Pav.

PI~ [AA [ro] ~ [ReO9 4

S{nfapwelrel~ 7a)
J ‘
S| PART NO. DESCRIPTION:
c 1644792 BLOCK, SOLENOID M6.

7804220 ELBOW W/H # /4% 9x4K

24100%-012| O- KING t
1818360 SCREW HEX. SOC. Hil CP*10-24x3”
BD] 7500362 VALVE, FOUR WAY, THREE POSITION
G Te12008| WASH EZ,#10 HI COLLAR SPR LK

NOTE “T" port

DIRECTIONAL CONTROL :
VALVE COMES WITH 4- 5.
'O" RINGS, SAME 4S ITEM %.

, ' tae
é 05-4995. w/Al2 CONTROLS fe OSC RIP TION cumo DATE cm.
OS-215
TemtAL = ae
APO Meaney Compeny VALVEREXROTH SELECTOR
RCE cea os PEMes) [PS-o) Raed |a,
- __ 4
Gaingovile, Texas 76240

SURFACE as preave NONE ASSEMBLY NUMBER enecxeo C3

 4 mpgpnmmesef re
™

RUN IN RW CABLE TRAY

TA
om iG .
Aj

BOOM LENGTH OF CABLE

LENGTH (7802469-001) REQ'D.
N 60° 63s 80" 145°
‘ t Bo" 4s 120 205
90° 95° 140 235
100° tos" 160" 265
120° 125° 200 325°
i \ ‘ : 130° 135 220 355’
SHEAVE ILLUMINATION ‘ i 140° 145" 240 3a5
. . f. 7 S >
. ‘, BOOM LIGHTS ARE TO SWING. ELECTRICAL i iso 15S 260 ANS wed
: ‘ CABLE TO BE INSTALLED TO ALLOW - ”
2h, , FULL RANGE OF SWING. —_ gz 0 23 0
out 3 o e355
. 853% See>] S308
\ O<E2} Sorts 8225
\ ' “of S23] so02/ 8537
—~—— \i A, ij
ea3
ssa fa
s3 28
385°] af
—_—— -- o> 9 x
on 9
oe IZ~ ~ So
— a
oe ee i

Qs BOOM LIGHTS —
no . MOLDED PACKING
} i WASHER
, GLAND NUT
BRASS TERMINAL TUBE CABLE TRAY DOCUMENTOILEGIVEL, ORIGINAL
ITEM 13 . ENCONTRA-SE NA TI/UNBC.

22) - 6300041 NUT, HEX Ya" CAD. PLT. 2f2 [4

2tl- 7ez10l16 WASHER, TYPE A Ya CAD. PLTD. 2fal¢e
20] = {7619033 WASHER , REG. SPG, LOCK % CAD PLTO. jelz{4
to - TOODOB-tt SCREW, W.H.CAP 14°X5" CAD. PLTD. 2]2ie

1612008-813
BALLASTS : NX } -
cq cna cof ‘s
i Dot it it S
r r J 1 184 - [7619094 TERMINAL, API-AMP 31902 eliza
, J!
vos I n | 17 [0 |7815242-002 [PLUG, PIPE BRASS 3% 2 fa
: 7815199-002 |PACKING, MOLDED CABLE Ve” ‘lala
j 70 Boom LIGHTS 7 6800062 -8 BUSHING, PARKER PTA-B 3%Xz" ti2}3
14 [D | 7801234-003 |BOX, JUNCTION WATERTIGHT _ ‘fee
13 [0 [7819662-002 [TUBE, MALE TERMINAL Vo i]z{a
\ 12 [+ | T802555 CABLE, ANIITER TSS 4 19-2 o}so70|
oe ot? ji [= 17815242-003 [PLUG, PIPE BRASS 2iel¢
1o|- | 7a19048 TY RAP 10} 10l20)
9 |-l7902512-006 [CONNECTOR, BULKHEAD HEYCO 3219 tle{s
8 806042-008 GLAND, HAWKE TYPE 501/453-0%- 34NPT z[4[e
7 7802469-001 [CABLE, PIRELLI 600/1000V 1.5% 3 COND
@ |=) 7000396-a8 SCAEW, HM. CAP Vg x 134 CAD. PLTD. ‘Tafa
3 |- [7619050 WASHER, REG. SPG LOCK Ye CAD. PLTD. ifefa
. 4 |- '@300103 NUT, HEX ¥%@ CAD. PLTD tfafs
wenneee 3/-frenod LAMP, 400W MERCURY VAPOR ifafa
COMOUCTONS (TH SEPARATE INSULATION), TO SHEAVE ILLUMINATION 2 |- | 7805159 FIXTURE, LIGHT EWE)
TYPICAL GLANO CABLE INSTALLATION SHEAYE BOOM LIGHTS tlc LtBtSPTS
LAE prersg74 HANGER ~jafe
P ITEM & ILLUMINATION Llatm
} 5po]9
[Sa I cam nero Ie
BOOM M1 BASE
BASE waTeRL
Siege neon SapstyweCompan
Deeon wt mee Come
toneay_ttee Tene
INSTALLATION, BOOM
SHEAVE ILLUMINATION, 05-435)
APPENDIX
 con +t vm ne eee a Sn - 4

ae “SURES? WETO_o esee TI rer aaa ae wn ~ -

oF "WAV GNAL OS-435 +0) TAL CRAnL

3 ; _ API LOAD RATINGS* ;
GypasTe pe BB. * 420 FT. (36.6 m) BOOM
(7 PARTS LINE MAXIMUM) ,
rs
: Py Y yt

1 tou,
: [ MAIN BOIST BAXIMUM LIFTING CAPASITIES WHIP HOIST MAXIMUM LIFTIRG GCAFACiCS | 1
+MIN. LINE PARTS RATED LOAD ie
RADIUS BOOM RATED LOADS LOW HIGH BOOM LOW SPZED HiGH SFE yo
it {m} ANGLE tbs tkgs) SPEED.::SPEED ‘ANGLE Its (kos} tbs & i
30 9.1) 78° 119400 (54 150) i Bette fi
35 19.7} 76° 419 400 (54 150) 18 190 § 210 139706 san i}
w 22) 73° sig4o0 (54 15q)} 7 8 {8 210) 3 (5 430)
{| 45 (93.7) 7o° |1ta700 (50 210) 7
j $0 (95.2) 682 | 98430 (44 640) 6 |
1, 55 (46.8) 65° 1 85399 (40.990) 6 i
+ 60 ‘Wale 1 Borsa (35 390) 5 . ou

f os
a) | tz Sy2 133 090) 5 ik
1 8° 66 860 {20 220} 4 :
75 1 61620 (27 950} 4 ie
i Ed | $7023 (25 860)} 4 bE
cS | §2S550 (24 620} 4 i
34 | 89350 (22 380} 2 SN, . _ 24 kat i
oh | 45420 (20810}} 3 HEAV BLUE AB® TON) 1530 (758 kg, 4
{C0 (30.5) | 38° | 43 22: (19 660} 3 3 2 SHEAVE BLOCK(49 TON} - 1100 tb - {598 kg} i
105 (42.6) i 33° | 40.590 (18 410} 9 3 1 SHEAVE BLOCK (20 TON} _- 700 fb - {318 kaj :
110 (32.5) 29° | 38200 [17 320) 3 3 OVERHAUL BALL (WHIP) ~ 480tb = (248 kg) :
115 (35.1) 23° | 36.020 (16 230) 3 3 WEIGET OF WISE POPE
HO (36.6) 16° | 34020 115 430) 2 3 . SIGRT OF WARE ROPE . /
i #25 (38.1) 6° | 31580 {14 320) 2 3 MAIN HOIST - 1.46 Ibs - {2.18 kg/mm}
7 | WHIP HOIST - 1.89 ‘bt ~ {2.81 kg/m} .
| "ESE Low SPKED WIRE ROPE USED TO HANOLE EACH RATED LOAD MUST BE 7/8 IN. (22 mm) DIA. ‘
| ny 10x19 EFPS AR ITS UF WiTH A MINIMUM BREAKING STRENG”H CF 79 6COLBS.
| wy IOAUTION! ‘ : (35 700 kgs) FOR THE MAIN HOIST AND (IN. (25 mm) DIA. 6x26 WAC EIPS WiTH A iS
1 Zs ! ! LN MINIMUM BREAKING STRENGTH OF 103 409 LBS. (45 900 kgs] FOR THE SOCLI
I THE OPERATION OF THE CAANE DURING PERIODS CF HISK ND VE-DC'TY'S HOIST.
is DANGEROUS. DAMAGE MAY GCCUS FROM KIGH Sot TRANE V2 ROPE USED ON THE WIP HOIST MUST BE 11N. (25SIA. 19x7 IWRC IPS i
|| STRUSTURE DR SUSPENDED LO*CS BEING
WITH TRE CRANE GR OTHER STAUCTURES.
TOSSED AINUT ANT COLLIDING oe a anita) SWING. STREMSTH GE RE an See
gi ee WITH A BINIMUN! BSEAKING STHENGTH CF 84 400 iF Y

© LOAD RATINGS AME IN CONPLIANCE WITH API SPECIFICATICH 20 “‘OFF- 4 oe EQUAL SIZE. StI 7 > « ‘
SHORE CRANES" IN EFFECT AT THE TIME OF CRANE DESIGN. Fay Be SUBSTEeeeyo> STRENGTH, FLEXISILITY AND CRLSH RESISTANCE |
+ MINIMUM LINE PARTS' !S BASED ON SAT= WORKING LOAD CF TRE WIRE
ROPE AND WINCK CAPABILIT’. CAPACITY CF HCOK AND BLOCK MUST ALSO paaras0-011
24072
a BE COKSIDERED.
ieekAa
SEAMN Le - 2: PRES NIE RECEP
 LNATIONA DRILLING
MACHINERY
PEDESTAL
‘CRANES
FACT SHEET
NATIONAL OS-435 hydraulic pedestal crane
qa
te gste e104
123701 (202
oT'- 2 ee 58 my 28: {Gare OPENING
(2 184) 1473p it rea3
|
58
Set
a
\ seni727) CRANE WEIGHTS
: a! BOOM LENGTH TOTAL CRANE WEIGHT™
6118.3 90500 Lp. (41050 KG.)
ao” {24.4 M) 94 200 18 (42 729 KG.)
100" 130 5M) 97 300 L844 135 KG)
120° (366M) [100 900 18 (45 768 KG).
130° (39 6M) (102 600 18 46 526 KG)
4 4z7 Mi [104 300 8 147 HO KG?
APPROXIMATE GROSS OPERATING WEIGHT WITH
STD. CATWALK, ADD 1500 LO 18906.) FOR LONG
2" 305 RW CATWALK
r a

BASE _LOAOING
TOTAL MAX WEIGHT OF CRANE, BOOM AND LOAD (FI
1S 277 800 LB [126 000 KG. 14 STATIC CONDITION}
/IOLINES REEVING MAX. MOMENT {Mal IS 5400 000 FT~L8
~e 4746 420 8-6.) AT € OF ROTATION [STATIC CONDITION }
NORMAL MAX OPERATING TORSION (Mb) IS
475 000 FT.-LB. 168 693 M.-KG.) AT § OF ROTATION
WEIGHT OF MOUNTING FLANGE IS 9050 LB
214105 KG.)
3s-of —
(o.674y

—
co OPTIONAL LINE TENSION
90't24.4) THRY 12011366) SENSING SHEAVES FOR

|
ONLY, LENGTH VARIES WITH: LOAD WEIGHING SYSTEM
BOOM LENGTH
ef

t
‘Cowie a€ ARING
MOUNTING SURFACE
TE_Lrvoon
SUGGESTED access aND ag"
SERVICE CATHAL. Nery DIMENSIONS ENCLOSED BY PARENTHESES ¢ }
“> PERSONNEL ACCESS INTC ' ARE IN METERS,
<— Pepestal SUGGESTED MAX, 800M REST
& ROTATION VERTICAL STATIC REACTION + 22 000 L@
'9979KG)
LT-160421

ROTATING FRAME BRAKES

The main frame is of all-weided, deep beam construction, utilizing low temperature Thehoist brakes are external band-type with single point adjustment; spring set and
steels at critical stress points. The machinery compartment is completely enclosedto hydraulicaily released
altord sheltered access to machinery. Entrance to the compartment is from an
external walkway. The swing brakesara disc type, spring set and hydraulically released.
MAIN AND FASTLINE HOIST CAB

Both have two-stage planetary reduction systems completely enclosed within an cil- The cab is heavy gage steel, rubber cushion mounted, and extends forward of the
tight case to fubricate gears and bearings during drum rotation. Power controiled frame to give the operator excellent visibility in all directions. The futl height, self-
load towering is standard latching, hinged door swings to the rear. Cab interior includes adjustable seat and full
instrument pane} with controls positioned for ease of operation.
One variable displacement, axial piston pumo powers individual reversible motors on
each drum, BOOM

BOOM HOIST A 60-foottattice type, pin connected, tubular steel boom Incorporating nigh strength
low alloy steels with an 8-footoftset sheave extension is standard. The open throat
The boom hoist is a two-stage planetary reduction system enclosed within an oil-tight boom pointhasfive sheaves, with one sheavein the offset extension. Ail sheaves are
case to lubricate gears and bearings during drum rotation. Power controiled load rolter bearing mounted The wide boom foot spread altows forthe list conditions that
lowering and automatic safety lock pawl are provided. are present in off shore apptications. 20-foot, 30-foot, and 40-foot extension sections
are available. Boom lengthsto 180 ft. are available.
The reversible axial piston motar, an the winch,is powered by a variable displace-
mentaxial piston pump. GANTRY
SWING The high gantry arrangement aftords greater capacity at shallow boom angles.
Rotation of the crane is by a dual system, incorporating tworeversible axial piston HYDRAULIC SYSTEM
motor driven three-stage reduction drives, with anti-friction bearings and gil-tight
cases, Each drive is equipped with totally enclosed, spring actuated, hydraulically The closed loop,“hydrostatic transmission” hydraulic system provides simultaneous
released brake on the gear reducerinput shaft. individual speed controlof the three primary functions, swing, boom andhoist, while
allowing the engine to aperate at peakefficiency. Hydraulic fluid is filtered by a
SWING BEARING suctionline filter and high pressure filters in each loop. Thermostaticaity controlled,
return fine, air cooling is provided to maintain optimum fluid temperature.
The swing bearing is a forged alloy stee!, shear ball bearing, with the ball races.
hardened and ground. The gear teeth are an integral part of the outer race. The bear-
ing is suitable for low temperature service.

MANUFACTURER RESERVESTHE RIGHT TO CHANGE SPECIFICATIONS AND/OR DESIGN WITHOUT NOTICE.

April 1981
 PEDESTAL
ary y Yu National Supply Company
ARMCO
V

HOIST DRUMS
DRUM PITCH LAYER LINE SPEED ROPE
DIA. OF LOW SPEED HIGH SPEED CAPACITY
DRUM WIRE ROPE in (mm) ROPE ft/min (mimin)| ft/min (mimin) ft (m)
Main 7/8” 6 x 26 IWRC EIPS 19.9 (505) 1st 218 ( 66) 264 { 80) 210 { 64)
Hoist Breaking Strength 22.9 (582) 3rd 252 ( 77) 305 ( 93) 670 (204)
79600 Ib (36 100 kg) 30.4 (772) 8th 334 (102) 405 (123) 2 100 (640)
1°19 x 7 IWRC EIPS 20.0 (508) 1st 220 ( 67) 266 ( 81) 180 ( 55)
Whip Line Non-Rotating 23.5 (597) 3rd 258 ( 79) 312 ( 95) 590 (180)
Hoist Breaking Strength 26.8 (681) 5th 295 ( 90) 356 (108) 1070 (326)
84 400 ib (38 250 kg)
1° 6 x 26 IWRC EIPS 20.0 (608) ‘st 220 ( 67) _ — 83 (25)
Boom 10 Parts Reeving 23.5 (597) 3rd 258 (79) _ - 272 ( 83)
Hoist Breaking Strength 28.8 (730) 6th 315 ( 96) —_ — 590 (180)
103 400 Ib (46 900 kg) —

MAIN HOIST
PARTS MAXIMUM RATED LOAD* **HOOK SPEED MAX HOOK
OF LOW SPEED HIGH SPEED LOW SPEED HIGH SPEED TRAVEL
LINE Ibs (kg) ibs (kg) ftimin (m/min) ftimin (m/min) ft (m}
1 17 060 ( 7 738) 412 000 { 5 400) 252 (77) 305 (93) 2 090 (637
2 34 110 (15 472) 25 500 (11 550) 126 (38) 152 {46) 1045 (319)
3 51170 (23 211) 38 500 (17 450) 84 (26) 102 (31) 695 (212)
4 68 230 (30 949) 51 100 (23 150) 63 (19) 76 (23) 520 (159)
5 85 290 (38 733) 63 500 {28 800) 50 (15) 60 (18) 415 (127)
6 102 340 (46 421) 75 700 (34 300) 42 (13) 50 (15) 350 (107)
7 119400 (54 160) 86 700 (39 200) 36 (11) 43 (13} 300 ( 91)
8 136 460 (61 898) 98 300 (44 550) 31 (10) 37 (11) 260 ( 80}
9 153 510 (69 632) 109 800 {49 800) 28 ( 9) 34 (10) 230 ( 70)
10 170570 (77371) 121200 (84 900) 25 { 8) 30 ( 9) 210 ( 64
**Based on 3rd layer. *Based on 8th layer.

WHIP LINE HOIST PENDANTLINES

Max. Load *(Low Speed) 18 100 Ib (8 200 kg) Two — 2-1/4" 6 x 19 IWRC EIPS
Max. Load *(High Speed) 13.970 Ib (6 330 kg) Galvanized Lines
Hook Speed (Low)** 258 ftimin (79 mimin) Breaking Strength Each
Hook Speed (High)** 312 ft/min (Q5 mimin) | 444600 Ib (201 650 kg)
Max. Hook Travel 1040ft (317 m)
**Based on 3rd layer. *Based on Sth layer.

[ SWING SPEED l 1.7 RPM ] | LUFFING TIME [_~70 sec. (0° to 80°) ‘|
POWER
BOOM LENGTHS
MAKE MODEL TYPE CYL. RATED BRAKE H.P. Basi soft (83
CAT [3408 DITA] Diesel 8 365 @ 1800 RPM a - son ( 5 m)
am. 12v-71 Diesel 12 406 @ 1800 RPM Mtensions sort (OI
Electric Motor 60 HZ. A.C. 300 @ 1800 RPM 40 ft (12.2 m)
Fuel Tank Capacity 130 Gallons (492Liters) Peon Point 8 ft (24 m)
*Electrical Requirements — 8.5 kw (Incl. 1.5 kw for Lighting) xtension
- an World Headquarters
Starting — 24 v dc or 90 psi air 1455 West Loop South
*Not applicable for electric motor. Houston, Texas 77027
713-906-5111
NOMINAL RATING: 170 570 Ibs.(77 371 kg) Cc) National
(100 ft Boom At A Working Radius Of 30ft) ARMCO Supply
Company
 CRANE NOMENCLATURE

SHEAVE EXTENSION

LOAD SHEAVES

TURN SHEAVES WITH

LOAD WEIGHING OPTION

PENDANT LINES

FLOATING BOOM
HOIST BLOCKS

BOOM HOIST LINES

BLOCK
SUPPORTS:

GANTRY
LANDING > MAIN LINE:

GANTRY SHEAVES

GANTRY
LADOER
GUARD
}-Loap BLOCK

BOOM
BACKSTOPS

BOOM BASE

OPERATOR'S CAB

MACHINERY COMPARTMENT SWING BEARING

LT-160045
NATI
LTHOIN USA
ONAL HYDRAULIC PEDESTAL CRANE OS-435

STANDARDS OF DESIGN AND CONSTRUCTION

The following items were designed to be in compliance with American Petroleum Institute specification 2C ‘‘Offshore
c .
Cranes’:

Crane rating
TOM ONFMRWN

Structural competence by stress analysis

Structural competence by non-destructive testing
Wire rope
Sheaves
Winch drums
Boom, main, and whip hoist mechanisms
Swing mechanism
Controls
Cab
All miscellaneous equipment ——

The following components were designed according to the listed standard, many of which are required by API-2C:

BOOM DESIGN — a) Effective length factors from British Standard 2573 Part|, ‘Specification for permissible stresses
in cranes and design rules.”
b) Impact factors are from API-2C or from customer requirements.
c) Basic safety factors and design equations are from the American Institute of Steel Construction
(AISC) Manual.

GANTRY DESIGN — AISC

FRAME — AISC
LOAD SHAFTS _ AISC
LOAD PINS — AISC

GEARING DESIGN -— American Gear Manufactures Association (AGMA)

WELDING — American Welding Society (AWS). Also meets American Bureau of Shipping (ABS) and Det Norske Veritas
(DNV) welding requirements.

HYDRAULIC AND PNEUMATIC PRESSURE SYSTEMS — National Fluid Power Association (NFPA)

ELECTRICAL SYSTEMS -— National Electric Code (NEC), or other design codes required by the customer.

AMBIENT DESIGN TEMPERATURE — 14°F (— 10°C). ,

The OS-435 standard crane design has been accepted by the following certification agencies:

American Bureau of Shipping (ABS)

WawNnr>

Det Norske Veritas (DNV)

Lloyd's Register of Shipbuilding
Norwegian Maritime Directorate (NMD)
United States Coast Guard (USCG)

nae National Supply Company

Orers.08 of heme
NATIONAL
THO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

CRANE STRUCTURAL MATERIALS SPECIFICATIONS

STANDARD MATERIAL NATIONAL SUPPLY YIELD STRENGTH, MIN.

STRUCTURAL COMPONENT SPECIFICATION COMPANYSPECIFICATION PSI (N/MM?)
Boom Chords ULS. Steel 1663 100,000 (689)
T-1 Type A
Boom Lacing ASTM A-519, 1-647 30,000 (207)
GR. 1025 HR
Boom Section End Fittings and AIS] A-8630 C-676 95,000 (655)
Point Casting
Gantry Front and Rear Legs ASTM A-633 M662 50,000 (345}
Grade D
Gantry Lacing Pipe — ASTM A-53 — 30,000 (207)
Grade A
Main Frame Structural Plates, ASTM A-633 M662 50,000 (345)
Channels, and Bottom Ring Grade D
Swing Bearing Material AISI 4340 _ 100,000 (689)
Main and Whip Load Shafts AISI A-4145 H B-115 100,000 (689)
H-675
Gantry Load Shaft AIS! A-4145 H B-115 100,000 (689)
H-129
Boom Base Pins AISLE A-4145 H B115 100,000 (689)
H-675
Boom Section Connecting Pins ASTM A-564 _ 125,000 (861)
Grade 630
Cond. 1075
Gantry Connection Pins AISI A-4145 H B115 100,000 (689)
H.675
Mounting Flange — ASTM 4-350 M668 36,000 (248)
Forged Portion LF-2
Mounting Flange — ASTM A633 M662 50,000 (345)
Structural Plates Grade D

MATERIAL CONTROL — All structural materials are traceable by heat numbers on the material, which in turn corresponds
to a mill test certificate stating the actual physical and chemical properties of that particular batch (heat) of steel.

— Rev.
agro National Supply Compeny
Owner of Armco,
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

INTRODUCTION
The OS-435 crane incorporates all the standard crane functions and utilizes a lattice type, wire line supported
boom and high gantry permitting the reaching out with heavy loads and the use of long booms.

Here, however, is where the similarities end. The OS-435 is a pneumatically controlled hydraulic unit. Each
hoist drum is powered by its own hydraulic motor powered by a variable displacement pump. This motor
drives through a two stage planetary gear reduction that is completely enclosed within the drum.

The fluid flow to and from each motor is controlled so that the speed of any function (hoist, lower, swing)
depends only on the engine speed and how far the control handle is moved from the neutral position. This
provides the ultimate in smooth contro! and ease of operation.

The swing is a completely independent hydraulic circuit. It utilizes a variable displacement pump driving two
fixed displacement motors. These motors drive the swing pinions through twa totally enclosed three stage
gear reducers.

This modern hydraulic approach_greatly simplifies maintenance. Rather than one large complex piece of
machinery, the hydraulic unit utilizes relatively small, completely independent modules. The modules can
be easily removed for repair or replacement.

The OS-435 has only one friction clutch to adjust; this is the throw-out clutch between the prime mover and
hydraulic pumps. All heavy braking is done hydraulically. The friction brakes are used only to hold the load
while the control handles are in neutral. This provides for long brake life and rare need for brake
adjustment.

The brakes and boom hoist lock pawl are spring set and pressure released. All hoist brakes release
automatically when the control handles are moved out of the neutral position. All the hoist brakes and boom
hoist lock paw! set automatically when the hoist control handles are returned to the neutral position. T’
swing brakes are manually released.

A hydraulic drive provides for a more compact design. It also permits a more complete isolation of the
operator’s cab for more efficient sound and temperature control.

The main frame is of welded steel construction utilizing high strength steels in critical locations. Its deep
beam design gives maximum rigidity with minimum weight.

Ouch Rev. July ! Page 1

ARMCO National Supply Company ev. July 1980 age
VV owstvon of Armes inc
NATIONAL
LITHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

SAFE OPERATING PRACTICES

1. Know the weight of the load you are lifting.

2. Do not exceed the crane’s load chart.

3. Check the weight of unfamiliar loads if within 10% of the load chart capacity.

4. Attach the load properly to the hook with slings or chains and balance the load.

5. Do not wrap the hoist rope around the load.

6. Before hoisting, check the wire rope for kinking or twisting.

7. Bring the hook over loads in such a manner as to prevent swing.

8. If there is a stack rope condition, it should be determined that the rope is properly seated on the drum
and in the sheaves.

9. Move loads smoothly, without sudden acceleration or deceleration.

10. Do not allow personnel to ride the load or hook.

11. Avoid carrying loads over people.

12. Test the brakes each time a load approaching the rated load is handled.

13. Do not leave the crane unattended while a load is suspended.

14. The operator should respond to signals only from the appointed signal man, but should obey a stop
signal at any time no matter who gives it.

15. Never allow fewer than three full wraps of wire rape on any drum.

16. Do not refuel crane with engine running.

17. A carbon dioxide, dry chemical, or equivalent fire extinguisher must be kept in the operator’s cab or
vicinity of the crane.

INSPECTION

A sample inspection check list has been provided in order to acquaint an operator with the proper inspection
of NATIONALpedestal cranes. The inspection procedure has been divided into three general groups based
upon intervals at which inspection should be performed. The three inspection intervals are: daily, weekly,
and monthly. These intervals are recommendedfor normal operation, but may be adjusted to the customer's
operating conditions.

If adjustments or repairs are found to be necessary from an inspection, the inspector should promptly notify
the proper personnel to assure problem correction. The crane operator of the next shift should also be
notified of the defect if the problem has not been corrected prior to the shift change.

Inspection records should be signed and dated bythe inspector, and kept available for future reference as
recommended by the American Petroleum Institute.

Page 2 Rev. July 1980

ARMCO National Supply Company
Division al Armco ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS.435
LITHO INUSA

INSPECTION CHECK LIST — DAILY

CRANE SERIAL NUMBER DATE INSPECTED.

NO. GF CRANE OPERATING HOURS INSPECTED @Y.

CONDITION
“Correction
DAILY PROCEDURE jO.K. - Required COMMENTS

. CHECK FOR AND ELIMINATE SPILLAGE OF

FLAMMABLE MATERIALS SUCH AS FUEL & OIL.
Service engine, checking water and oil levels,
and air cleaner.
Check engine fuel tank level. ——~
~Jole fale

Check hydraulic oi! tank level.

Lubricate boom foat bushings.

Check operation of horn.

Start engine and allow to warm up at idle speed.
Check engine gages.
8. Gheck clutch operation.
9. Engage clutch and allow hydraulic off to warm up
at idle speed.
19. Observe charge pressures to see if they are in
proper operating range, 160/300 psi (11/20.7 bar).
1. Observe control pressure to seeif it is in the
proper operating range, 700/750 psi (48.3/51.7 bar).

12, Observethe triple pump drive iube oil gage to see

if it is in the proper operating range, 20/60 psi
{1.4/4.1 bar) at 1860 RPM.

13, Check swing, boom, and hoist contro! handles far

adjustment and for proper centering when released.

14. Check air regulator to seeif it is in the proper

operating range, 95/100 psi (6.6/6.9 bar).
15. Drain moisture from air receivers.
16. Check all “brake-off" indicators.
AT. Operate emergency brake set to assure its
operation,

18. Visually inspect all running wire rope and check

ali drums for proper spooling.
19. Checkfor leakage or deterioration of components:
in hydraulic and pneumatic systems.

20. Observe condition of pump suction tine filter at

engine speed of 1800 RPM.
21. Check boom pins and ganiry leg pins for missing
or dislocated cotter pins.
22. Check condition of high pressure in-line filters
by depressing red button on filter while powering
down at full speed. If button pops out, replace
element.
*When a checkmark has been placed under the “correction required column for a certain procedure, corrective work
must be performed. After correction of the defect, the date andinitials of the person making the correction are to be
placedin the o.k. column of the procedure in question.

— Rev. Dec, 1978 Page 3

ARMCO National Supply Company
AZ btn of mea te
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
INSPECTION CHECK LIST — WEEKLY AND MONTHLY -

CRANE SERIAL NUMBER DATE INSPECTED

NO. OF CRANE OPERATING HOURS. INSPECTED BY.

CONDITION
*Correction
WEEKLY PROCEDURE O.K. Required COMMENTS

¢. Lubricate crane per instructions in operator's

manual.

2. Check oil levels of all shaft assemblies, swing

gear housings, and the triple pump drive.

3. Check line travel limiter system for proper operation

4. Check boom angle limiter system for proper

adjustment (adjustment must be set to prohibit
boom angles greater than 80° and lower than 0°).

5. Check boom hoist lock pawt for correct engage-

ment and disengagement with ratchet wheel teeth.

6. Check brakes for adjustment and excessive wear

of lining, loose or missing components and
contamination by iubricants.

7. Checkelectrical apparatus such as lights and

switches for malfunction or signs of deterioration.

8. Check air tine lubricator oi! levels.

9. Check clutch adjustment.

CONDITION (
*Correction .
MONTHLY PROCEDURE O.K. Required COMMENTS

1. Thoroughly inspect all wire rope and pendant lines

for deterioration such as: reduction of rope dia. ;
broken and worn outside wires; corroded and
cracked end connections and severe kinking,
crushing and unstranding of wires.

2. Check hooksfor cracks, deformation and damage

to safety latches.

3. inspect boom for deformed, cracked, corroded or

missing members.

4. Inspect gantry for deformed, cracked, corroded or

missing members.

5. Inspect main frame for deformed, cracked, or

corroded members.

6. Checkfor loose bolts on hydraulic pumps and

motors, swing bearing, gantry, swing gear
reducers, and shaft assemblies.

7. inspect sheavesfor cracks, excessive wear,

and they they operate freely.

8. Inspectall load, angle and weight indicating

systems overtheir full range for significant
inaccuracies.

9g. Check for work, cracked, distorted, or dislocated (

boom pins, wire rope rollers, and swing bearing
gear teeth.
“When a checkmark has been piaced underthe “correction required” column for a certaln procedure, corrective work
must be performed. After correction of the defect, the date andinitlals of the persons making the correction are to
be placed in the o.k. column of the procedure In question,

Page 4 Rev. July 1980

ARMCO National Suppty Company
Ormnion of Armeca ine
NATIONAL HYDRAULIC PEDESTAL CRANE O$-435
LITHO IN U.S.A.

OPERATOR'S CAB
[wp

—— 39, LOCATED ON LEFT

REAR WALL OF CAS

43

Ao

36

Figure 1 LT-160319
Engine Tachometer 22. Control Air Pressure Regulator
NOWRON>

Boom Hoist Pressure Gage 23. Whip Hoist “Brake Off” Indicator
Swing Pressure Gage 24. Main Hoist ‘Brake Off” Indicator
Main Hoist Pressure Gage 25. Boom Hoist “Brake Off” Indicator
Engine Water Temperature Gage 26. Swing “Broke Off”Indicator
Engine Oil Pressure Gage 27. Emergency Brake Set Valve
Triple Pump Drive Low Lube 28. Swing Brake Control Valve
Pressure Indicator . Emergency Load Release Valve
Low Hydraulic Tank Fluid 30. Main/Whip Hoist Selector Control Valve
~

Level Indicator 31. Engine Start Valve

. Air Supply Low Pressure Indicator 32. Engine Kill Valve
10. Control Air Pressure Gage 33. Low Boom Limit Override Valve
VW. Control Pressure Gage 34, Horn Valve
12, Swing Charge Pressure Gage 35. Clutch Control Valve
13. Boom Charge Pressure Gage 36. Cab Heater Power Switch
14. Main/Whip Charge Pressure Gage 37. Cab Heater Thermostat Switch
15. Boom Hoist Control Pedal 38. Boom, Beacon and Frame Light Switches
16. Foot Brake Pedal 39. Electrical Circuit Breaker Cabinet
17, Foot Throttle Pedal 40. Electrical Component Box
18. Swing Control Handle 4l. Main and Whip Hoist (Hook) High Speed
19, Boom Hoist Control Handle Selector Valve
20. Main/Whip Hoist Control Handle 42. Main and Whip Hoist High Speed Indicator
21. HandThrottle Control 43. Gage Transformer

Rev. July 1980 Page 5

anweo National Supply Company
Drwrsvon of Aemco ing
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA

LUBRICANTS AND FLUIDS

HYDRAULIC FLUID*

CAUTION: When adding to or changing the hydraulic fluid every precaution must be taken to prevent
any contamination of the hydraulic fluid. Do not mix different types of hydraulic fluids.
The following fluids are recommended:
First Choice — Automatic Transmission Fluid, Type ‘F’
Second Choice — Automatic Transmission Fluid, ““Dexron”
Third Choice — Hydraulic Oil, Premium Grade with Anti-Wear Additive,
48-55 SSU at 210°F (6.8-8.9 cSt at 100°C), Minimum Viscosity index of 170.
Tank Capacity —- 60 U.S. Gallons (227Litres)

HOIST WINCHES (SHAFT ASSEMBLIES) AND SWING GEAR REDUCERS*

LUBRICANT: Use an industrial extreme pressure gear oil. The following charts give the recommended
grades for various-temperatures surrounding the gear housings.

U.S. UNITS OF MEASURE

TEMPERATURE AGMA INDUSTRIAL EP GEAR OIL

40°F to 140 °F AGMA #5 EP or ASTM/ISO-VG Grade 220 (Viscosity: 1047-1283 SSU at 100 °F)
-20°F fo 60°F AGMA #2 EP or ASTM/iSO-VG Grade 68 (Viscosity: 317-389 SSU at 100 °F)

METRIC UNITS OF MEASURE

TEMPERATURE AGMA INDUSTRIAL EP GEAR OIL

4.4°C to 60°C AGMA #5 EP or ASTWISO-VG Grade 220 (Viscosity: 198-242 cSt at 40°C)
-29 °C to 16°C AGMA #2 EP or ASTM/ISO-VG Grade 68 (Viscosity: 61.2-74.8 cSt at 40°C)

CAPACITIES: Boom Hoist Winch — 11 U.S. Quarts (10.4 Litres}

Main and Whip Hoist Winches — 24 U.S. Quarts (22.7 Litres)
Swing Gear Reducers — 24 U.S. Quarts (22.7 Litres), each

TRIPLE PUMP DRIVE*

LUBRICANT: The following charts give the recommended lfubricants for various temperatures
surrounding the pump drive.

U.S. UNITS OF MEASURE

TEMPERATURE LUBRICANT
ev
50°F 10 125°F AGMA #3 EP or ASTWISO-VG Grade 100 (Viscosity: 468-575 SSU at 100°F) 837 42
15°F to 60°F AGMA #2 EP or ASTW/ISO-VG Grade 68 (Viscosity: 317-389 SSU at 100 °F)
-20°F to 25°F SAE 10W/40 Motor Oil with Foam Suppressant, Rust and Oxidation Inhibitors.

METRIC UNITS OF MEASURE

TEMPERATURE LUBRICANT

10°C to 50°C AGMA #2 EP or ASTMW/ISO-VG Grade 100 (Viscosity: 90-110 cSt at 40°C)
-9°C to 16°C AGMA #2 EP or ASTWISO-VG Grade 68 (Viscosity: 61.2-74.8 cSt at 40°C)
-29°C to -4°C SAE 10W/40 Motor Oil with Foam Suppressant, Rust and Oxidation Inhibitors.
CAPACITY: 36 U.S. Quarts (34 Litres)

*NOTE: Fluids and lubricants must pour freely at minimum operating temperature. Change lubricants and
fluids every six months or as frequently as operating conditions require to maintain a clean, sludge-
free oi! of proper viscosity.

Rev. * July 19380 agi 13

Page
ARMCO Nalional Supply Company
Vv Orenson of Armco ine
NATIONAL
LUTHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435

AIR LINE LUBRICATORS

The hydraulic fluid, as used in the crane’s hydraulic system, is recommended to be used in these
lubricators. Do not overfill.

BRAKE CYLINDER LUBRICANT RESERVOIRS

The hydraulic fluid, as used in the crane’s hydraulic system, is recommended to be used in these
reservoirs. The reservoirs should befilled only 3/4 full.

GREASE FITTINGS

Figure 2 shows the greasefittings on the OS-435 pedestal crane. The following fittings should be lubricated
daily:

A. Boom foot (2 fittings in frame wal-beside the hydraulic tank)

The following fittings should be lubricated weekly:

B. Swing Bearings and swing pinions (8 fittings in frame wall beside the hydraulic tank)

C. Air throttle actuator (2 fittings)

D. Radiator fan sheave bearing, roller sheave bearing, and turbocharger (where applicable)

E. Triple pump drive clutch (3 fittings)

F. Lock pawl pin (1 fitting)

G. Gantry sheaves(5 fittings)

H. Floating block sheaves (5 fittings)

J. Turn sheaves (6 fittings)

K. Main load sheaves (5 fittings)

L. Sheave extension sheave (1 fitting)

M. Load block (sheaves and swivel)

N. Overhaul ball (swivel)

The following bearings should be inspected monthly and lubricated as required:

Main, whip and boom hoist brake linkage bearings.

The recommeded greases are:

Warm Weather — Number 2 EP Lithium Base Grease

Cold Weather — Number | EP Lithium Base Grease

SWING GEAR AND PINION TEETH

The teeth should be kept coated with Jet Lube, Inc., “Kopr-Kote” compound or an equivalent lubricant.

Page 14 Rev. July 1980

ARMCO Nations! Suppty Company
Orman of Armen ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

LUBRICATION POINTS

Figure 2 LT-160001

Rev. July 1980 Page 15

sapo National Supply Company
Deertean of Arce tne
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
FILTERS AND CONDITIONERS

Clean fluid is essential for the reliable operation of the crane’s hydraulic system. Therefore, filters have
been installed in the system to eliminate contaminants and increase the life of the hydraulic system
components.

SUCTION LINE FILTER - CHANGE EVERY 2 MONTHS OR 200 HOURS

The suction line filter (Figure 3) is located beneath the hydraulic fluid tank and contains two thraw-away
elements separated by an adapter which must be retained when the elements are replaced. The elementsin
the suction line filter should be changed every two months or every 200 hours, whichever occursfirst. There
is also an indicator in the filter head that can be used for daily checking of the condition ofthe filter elements.
If this indicator reads, “NEEDS CLEANING” when the hydraulic oil is warm and the engine is at full RPM, the
filter elements should be changed immediately.

NOTE: The recommended element change interval should be followed even if the indicator reads
“CLEAN” after 200 hours or two months of element usage.

To replace filter elements, first close the tank to filter valve, and drain the filter housing by removing the
magnetic plug located under the filter. Then remove the filter head, elements, and assembling rod. Clean
the magnetic plug and assembling rod magnetics and then reinstall. Insert new elements being sure that the
adaptor has been inserted between them. Carefully replace the filter head, taking precautions to properly
seal the filter cover “’O’’-ring in its groove.

IMPORTANT - OPEN TANK TO FILTER VALVE BEFORE STARTING CRANE ENGINE.

SUCTIONLINE FILTER

INDIGATOR COVER

BYPASS VALVE-——

va MAGNET ASSEMALY
INLET—

i i 7 mene’

ADAPTER ;

i
OUTLET

Figure 3 LT-160002

Page 16 Rev. July 1980 —_—

ARMCO Nations! Supply Company
Drerss0n of Armee ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

HIGH PRESSUREIN-LINE FILTERS - CHANGE ELEMENTS EVERY 2 MONTHS OR 200 HOURS

The main/whip, boom and swing high pressure hydraulic circuits are equipped with high pressure filters
designedfor reversible flow operation. These filters (Fig. 4) each contain a single element which should be
changed every two months or every 200 hours of operation, whichever occurs first. The main/whip circuit
filter is installed in the high pressure tubing line forward of the main/whip pump. The boom circuit filter is
installed in the high pressure tubing on the left side of the boom motor. The swing circuit filter is installed
above the swing pump.

A ‘’Pop-out” type indicator is installed in each filter head for periodic checking of the element. In order to
check the element's condition, the hydraulic oil must first be warmed up and the red indicator button reset
by pushing the button. Next the cab control lever associated with the filter to be checked should be pushed
forward completely with the engine at full RPM. This action will cause a full flow of oil through the filter. If
the red button pops out during this operation, the filter should be changed immediately.

To change an element of a high pressure in-line filter, first unscrew the bowl of the filter with a wrench
attachedto the 1-1/8” hex bossattached to the bottom of the filter bowl. Carefully lower the bowl away
from the filter head assembly and gently pry the element loose from its mounting. Push a new element into
the filter head and then screw the bowl back into place being careful not to damagethe sealing “O” ring or
back-up rings in the filter head.

NOTE: Be certain the bowl is properly tightened when reinstalled in filter head.

IN-LINE FILTER

t { HEAD

i
S 1
—
DIRTY ELEMENT INDICATOR i FILTERING

REVERSE FLOW VALVE [ \

SEAL

—FILTER ELEMENT

BOWL

DRAIN PLUG

Figure 4 LT-160003

PUMP DRIVE HOUSING LUBE Olt FILTER

An oil filter is located in the suction line of the pump drive housing’s lube oil pump (Fig. 5). This filter is
mountedto the side of the triple pump drive housing. The wire cloth element in the filter should be cleaned
every two months.

To clean the wire cloth element, disconnect the hose from the top ofthe filter housing and then remove the
four 1/4” screws that hold the bow! to the filter head. Lift the head away from thefilter bowl, and then
unscrew the element from the filter head. Clean the wire cloth element, magnets and bowl, and
reassemble.

Rev. July 1980 Page 17

ARMCO National Supply Company ow” .
VJ Overton of Aimee inc
NATIONAL
LITHOON USA
HYDRAULIC PEDESTAL CRANE OS-435
LUBE OlL FILTER

TO LUBRICATION PUMP

{DISASSEMBLING SCREWS

FROM TRIPLE PUMP

ORIVE CASE SUMP

Figure 5 LT-160004

CONTROL PRESSURE SYSTEM FILTER - CHANGE ELEMENT EVERY 2 MONTHS OR 200 HOURS.

The control pressure system is provided with a separatefilter to isolate it from cantamination generated by
the hoist and swing hydraulic systems. The filter is mounted on the inboard side of the triple pump drive in
the suction line of the control pressure pump.

The fitter (Fig. 6) utilizes a disposable cartridge type element. To change filter elements, the used element is
unscrewed from the filter head and the new element is installed in its place. The element should be hand
tightened, only.

HYDRAULIC TANK FILL FILTER

Fluid is added to the hydraulic tank by means of o hand pump. This pump and the fluid fill filter are located
on the hydraulic tank. This single element filter is provided between the hand pump and the hydraulic tank
to filter all fluid being added to the hydraulic tank. This filter element should be changed whenever the
crane’s hydraulic fluid is changed. Directions for changing the element are included in each new element
box.

Page 18 Rev. July 1980 c=

ARMCO National Suppty Company
\Z_ Dwisvon of Armes ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA

CONTROL PRESSURE SYSTEM FILTER

BYPASS VALVE sien

FLOW

__SPIN-ON
ELEMENT

|
Figure 6 LT-160043

AIR ODRYER-PURIFIER

All crane control air is dried andfiltered prior to being used. The compressedair dryer-purifier (Figure 7) is
located on the outside of the rear wall of the operator’s cab. This is a desiccant type dryer and should be
serviced every six months.

To service the dryer, follow these steps:

1. Cut off air supply to the dryer-purifier and drain the air pressure from the small air receiver.

2. Remove the top retaining nut using a 13/16” end wrench and remove the cap and bypassspring.

Using the bail, remove the canister from the housing. It may be necessary to loosen the canister from the
housing by using a twisting back and forth motion while pulling upwards.

Lightly lubricate all the O-rings.

Using a rotating motion to properly seat the O-ring below the housing shoulder, install the replacement
canister.

Replace the cap and bypass spring and secure with the retaining nut.

Restore the air supply to the dryer-purifier.

NOTE: Replacement desiccant canisters should be stored in a dry place.

— Rev. July 1980 Page 19

ARMCO Nations! Supply Company
VJ Dewrtan of Armcoine
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
AIR DRYER-PURIFIER

SEAL

DESICCANT CANISTER

SUMP

Figure 7 LT-160005

AIR LINE LUBRICATOR (CAB CONTROLS)

The air line lubricator (Figure 8) is a dynamic device. Oil is delivered into the compressed air line only when
air is flowing through the lubricator. The lubricator is mounted on the small air receiver on the rear wall of
the operator’s cab.

An oil feed adjusting screw is provided on the top of the lubricator. Rotating the oil feed adjusting screw
clockwise reduces the drip rate, counterclockwise increases the drip rate. Once the setting is established the
lubricator will automatically adjust the drip rate with changes in flow. The drip rate should be adequate to
provide a light film of lubrication for the seals and bearings of the air valves.

The drip rate is adjusted byfirst establishing a moderateair flow through the regulator. Next pull the red lock
ring up dnd turn the adjustment screw to the desired drip rate. Finally push the red lock ring back into place.
The rate of air fubrication should be observed for several days and adjusted further as may be required.

NOTE: DO NOT OVERFILL LUBRICATOR RESERVOIR.

f~

Page 20 Rev. July 1980

ARMCO National Suppty Company
\JA_ Oweson of Armco ine.
NATIONAL HYDRAULIC PEDESTAL CRANE OS.435
LITHO INUSA,

AIR LINE LUBRICATOR

ADJUSTMENT SCREW
WITH LOCK RING
SIGHT GLASS —, FILL PLUG

HEAD

BOWL

ORAIN
Figure 8 LT-160006

_-= Rev. July 1980 Page 21

ano National Supply Company
Dewsion of Armen Ine
 SATA ONY ~"
JAVA TOULNGY avhS
ol aunBig W3IN4 ANIT NI LSiOK WOOS
£2€09T-11
OS-435

BATVA DNIQTON 1SI0H HOO

BATWA YOLOTISS 1S10H
JAVA SNIOTOH LSIOH dl HM / NIV
HLIM 3LVIdENG FATWA YOLDSI3S 110K
HYDRAULIC PEDESTAL CRANE

ARMCO National Suppty Company

WOLWU3dO BATA
¥YOLOTTIS LSIOK

Deviscon of Arenco ine,

—
YBONMAD BVH LSIOH WOOK,
"_NOINId
DNIMS "HT
SLIVHS
UAONIIAD AxVEE 1SIOK NIV

Rev. July 1980

NATIONAL

MOLOM ONIMS HH
MRINdIe HVT ONIMS “HT
DivEG ONIMS Hd
LITHO INUS A.

Page 24
JATWA SLLLNHS JOVB ONIMS:
HLIM NOLOW NIMS “H
SAVES ONIMS HT
 BZE09T-17 tL asnBiy
08-435

JATWA 433M FUNSS34d TONLNOD

QTOSINYA NIVEO 3S¥9 -- NOHLINS ——

Page 25
¥31T13 NOLLONS:
BAING dWNd 3dIuL dWNd 3OyvHO
dWd 15/OH MOOD whe
BATWA 330LNAS i
WAYS OTINVHCAH Y

Rev. July 1980

HYDRAULIC PEDESTAL CRANE

W3ONITA9 TOALNOD WOUNTO—

M3 INI-NI
ASIOH dim / NW
A \. WILVSH ON
dnd 3YNSS3Ud OU LNOD» SHINYEOAH —
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ONILYOLOY dd
dWNd ASIOn
IMM 7 AYN

aARMCO National Supply Company

© BBLS 3NI-NI ONIAS.
dWnd Td

Owition of Armco ing

HBHIVaNE _/

_—
NATIONAL

wad GINTs INNVEIAN

ANIWLYYdWOD 3NIONI
NATIONAL
UTHO IN USA
HYDRAULIC PEDESTAL CRANE OS-435

REAR CAB WALL

CHECK VALVE AIR ORYER

RELIEF VALVE

SMALL AIR RECEIVER

CUT OFF VALVE

ORYER BLOW-DOWN
VALVE

CONTROL AIR
LUBRICATOR

AIR PRESSURE GAGE

MANIFOLD

ORAIN VALVE

Figure 12 L¥-160010

Page 26 Rev. July 1980 =_=

es y anwpo National Supply Company
Onision of Armeg ine
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

TRIPLE PUMP DRIVE

TRIPLE PUMP DRIVE HOUSING O

INPUT SHAFT

INSPECTION COVER
FILL CAP / _— 7

ORIVE LUBE Olt FILTER CONTROL PRESSURE

PUMP SUCTION FILTER

LUBE OIL PRESSURE GAGE

LUBE MANIFOLD

a
oO
oO
oVes
Sy

! La S. - >
i
;
Er !
I

OO = | CHOO
— 1

{
it-----+~. !1ot |''
tot
LUBE OL PUMP \ t----4 CONTROL PRESSURE PUMP
I

LUBE O1L RELIEF VALVE

(OPENS AT 100 PSI) ‘THERMOSTAT

{ OPTIONAL }

TS

AD
SASY

‘SUMP DRAIN VALVE

INDICATOR IN OPERATORS CAB-

PUMP ORIVE LUBE OIL COOLER

( OPTIONAL )

Figure 13 LT-160330

Rev. July 1980 Page 27

anupe National Supply Company
Onision af Aimca ine
NATIONAL
LITHO IN U.S.A
HYDRAULIC PEDESTAL CRANE OS-435

FIXED MOTOR AND VARIABLE PUMP

FIXED
WASH PLATE

VALVE

HIGH
PRESSURE
RELIEF VALVE
CHARGE
PRESSURE
CONTROL VALVE

CYLINDER
BEARING BLOCK TRUNNION

PUMP

Figure 14 LT-160012

Page 28 Rev. July 1980 _=

B y ARMCO National Supply Company
Vv
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

HYDROSTATIC DRIVE

With the exception of the charge pressure, lubrication and control pressure pumps, all pumps and motors are
of the axial piston type. These are incorporated for their high efficiency, long life and trouble free service.

Each system (main hoist, whip line hoist, boom hoist and swing) is a closed loop hydrostatic drive.

The hydrostatic drive offers infinite control of speed. The operator has complete control of the system with
one lever for starting, stopping, load hoisting, or load towering. The dynamic braking capabilities inherent
with the closed loop hydrostatic drive provide normal braking requirements.

Control of the variable displacement, axial piston pump is the key to controlling the hoist or swing functions.
Engine horsepoweris transmitted to the pump. When the operator movesthe control lever, the swashplate in
the pump is tilted from neutral (camming the pump). The position of the control lever will determine the
angle of the swashplate and, therefore, the volume of oil delivered by the pump. The control lever is
stepless; therefore, the speed ofthe hoist or swingis infinitely variable from zera to maximum.

The variable displacement, reversing swashplate pump is controlled by a servo system. The pump contro!
lever can be moved to some predetermined position with the servo system moving the swoshplate of the
pump to this predetermined point. The use of a servo system on the variable pump controls permits a ~
minimum force requirement to move the pump contro! handle.

When the variable pump swashplateis tilted, a positive stroke of the pistons is created. This, in turn, ata
given input speed, produces a certain flow of oil from the pump. This flow is transferred through high
pressurelines to the motor. The ratio of the volume of flow from the pump to the volume displacement of the
motor will determine the speed of the motor output shaft. Moving the control lever to the opposite side of
neutral, the direction of flow from the pump is reversed and the motor output shaft turns in the opposite
direction. Speed of the motor output shaft is controlled by adjusting the volume displacement (flow) of the
pump. Working pressure is determined by the load andthis establishes the demand on the system.

The crane’s hydrostatic drive system consists of: pumps, motors, high pressure fines, low pressure drain lines,
selector valve, holding valves, miscellaneous valves and pump manifold block.

Kawco National Suppty Company Rev. July 1980 Page 29

NZ Dewetion of Armee ine,
 verge NeaaNet tPALSNENEBATTBg NATIONAL
UTHO IN USA,
HYDRAULIC PEDESTAL CRANE OS-435

HYDRAULIC SCHEMATIC

MAIN WHIP HOIST PUMP nOLoe me vaure

ede ay scryaTon MAIN HOIST MOTOR:
a ——1ower GS \.
tot

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(aes
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proce ce nce ree ceee CONTROL PRESSURE 0, a a Ren nee nee

Manisa? EST Low CHANSE,

anaxe SEY.
tht N.

200M stunt LOW CHARGE

case oman
(800M HOIST PUMP WOUDiwe VALE
[eo pokes 1
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reat (10 MICRO MOM 1
735 w
SWING BRAKE CYLINDERS

LT-160331

s
Page 40 Rev. July 1980
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
dad

LITHO IN USA.

wm AIR CONTROL SYSTEM

All control of the OS-435, hoisting, lowering and swinging, is accomplished using air control devices. With
pressure regulating valves, manually operated valves, piston operated valves, diaphragm operated valves,
shuttle valves and positioning cylinders, control of the hydrostatic drives is accomplished.

The controls were designed to meet the following requirements:

All brakes must set with the absolute loss of air pressure.
BON >

All hoist brakes must set and pump return to neutral with the loss of charge pressure.
The main and whip hoist brakes must set when the contro! handle is returned to neutral.
The boom hoist brake must set and the lock paw! must engage when the boom hoist control handle is
returned to neutral. :
. The emergency brake set valve must apply all hoist brakes and the boom hoist lock paw! when
on

depressed. The emergency brake set valve must also prevent the use of the hoist functions,
6. The emergency load release valve must release the main or whip brake (as determined by the
position of the hoist selector control valve) and permit the load to “freefall” when depressed.

The air contro! system consists of the following:

AIR COMPRESSOR (WHERE APPLICABLE}

Mounted to the engine is an air compressor. This compressor will supply an adequate air supply to operate
the controls of the crane. The discharge pressure of the compressor should be regulated to a maximum of
110 psi (7.6 bar) and a minimum of 100 psi (6.9 bar).

AIR COMPRESSOR UNLOADER (WHERE APPLICABLE)

The air compressor unloader regulates the discharge pressure and pressure differential of the air
compressor, This valve is located near the rear of the crane beneath the engine and above the large air
receiver. The unloader should beset to regulate the compressor discharge within the range of 100 to 110 psi
(6.9 to 7.6 bar).

This valve serves to control the unloading mechanism whichlifts the intake valves of the air compressor. The
valve senses the air pressure in the large air receiver. When the pressure reaches 110 psi (7.6 bar}, the valve
directs air pressure to the unloading mechanism in the compressor. When the pressure in the receiver drops
to 95 psi (6.6 bar), the valve shifts and permits the air pressure to the unloading mechanism to be exhausted.
Without pressure to the unloading mechanism the compressor beings increasing the receiver air pressure.

UNLOADER VALVE ADJUSTMENT (Figure 27)

The unfoad pressure (maximum pressure) is adjusted by turning the pressure adjusting nut clockwise to
increase the pressure and counterclockwise to decrease the pressure.

Changing the differential {difference between load (minimum pressure) and unload (maximum pressure)
pressure] is accomplished by holding the lock nut closest to the body of the valve so it does not move, then
turning the large nut next to it very slightly clockwise to increase the differential and counterclockwise to
decrease the differential.

Rev. . July 1980 Page 4 45

auco National Supply Company
JZ Omision of Ameo ine
ee NATIONAL HYDRAULIC PEDESTAL CRANE OS..435
LITHO IN USA.

ro AIR SCHEMATIC

WINDSHIELD wiPERS

‘BOOM ANGLE UMITER

on. ao Rr
LOM HYDRAULIC no
.
waa WH var‘LEVEL. ARNING ae 23
ES SELECTOA -
" 4
1
4

} 7
i
ner Po
O63 7

00M
oce pw

swine
Oca t

5 ¥ HUF HOIST MOTOR

LS eg MO SPEED CONTROL VALVE

elTEth MAIN HOIST MOTOR TWO SPEED CONTROL VALVE

ew

3 . L____~____sf7t 800M HOST BRAKE AND

{ ‘LOCK PAW. RELEASING WALYE

|
m : -aTBe __@i vas

P-20 t
}
ota] igre
.
{34
Pig

t “ ti WOST SELECTOR
* OPERATOR
VALVE, TOR

!
i
}:
pte
!

Figure 28 AT-260333

Rev. July 1980 Page 51

MEO National Supply Company
Oreann of Arneinc
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LUTHO INUSA

OPERATION OF THE PRIMARY FUNCTIONS

MAIN LINE HOISTING A LOAD, LOWERING A LOAD AND POWERING DOWN

With the hoist selector contra] valve (Fig. 1, Item 30) pushed for “MAIN”, the main hoist pneumatic system is
made operable and the hois! selector valve operator (P-16) receives on air pressure signal, shifts and directs
control pressure to shift the selector valve for operation of the main hois). Control handle (Fig. 1, Item 20)
movement, in either the hoist or lower direction, sends air pressure to the main hois! brake releasing valve
(P-13} shifting the valve which directs contro! pressure into the main hoist brake cylinder. Pressure to the
brake cytinder reteases the brake. The movement of the contro! handle also directs air pressure to the
“BRAKE OFF’ indicator (1-6) which turns amber to indicate the main hoist brake has been signaled to
release.

When the control handle is moved in the hoist direction the main/whip pump actuator (DC-3) receives air
pressure on the piston end. The actuator then pushes the pump displacement control valve fever and causes
the pump the “cam”. When the pump cams high pressure (5000 psi (340 bar} max) fluid is pumped out of
port “A” and through the tubing to the holding valve, through the hoist selector valve and then to port “A”
of the main hoist motor. At port “A” the high pressure fluid shifts the shuttle valve in the motor valve mani-
fold and then rotates the motor. The fluid leaves port ’B’ of the mator at charge pressure. Part of the fluid
passes through the shutile valve and charge pressure relief valve in the motor valve manifold and enters the
motor case. Most of the fluid leaving the motor goes through the tubing to the tee in the hoist selector valve
subplate, by-passes the in-line filter element and returns to port ““B” of the main/whip pump. At pump port
“BY the fluid from the motor mixes with fluid from the charge pump and then re-enters the main/whip
pump.

When the control handle (Fig. 1, Itern 20) is moved in the lower direction, with a load on the hook, the
main/whip pumps actuator (DC-3) receives air pressure on the rod end. The actuator then pulls on the pump
displacement control valve lever and causes the pump to “cam”. When the pumps cams, fluid is discharged
out of port “B” at charge pressure. As the fluid feaves the main/whip pump it mixes with fluid from the
charge pump.The fluid now passes through the tubing and is filtered by the in-line filter. The filtered fluid
now goes to the tee in the hoist selector valve subplate and then to port “B” of the main hoist motor. At port
“'B’’ part of the fluid passes through the shuttle valve and charge pressure relief valve in the motor valve
manifold and enters the motor case. Most of the fluid enters the motor and is pressurized from charge
pressure to high pressure (5000 psi (340 bar] max). (While lowering a load the motoris pressurizing the fluid.
The load on the hook attemptsto rotate the motor but the speed of the mataris limited by the amountof fluid
passing through if. The pump serves to regulate the amount of fluid passing through the moter.) The high
pressure fluid at motor port “A” shifts the shuttle valve and then passes through the tubing and hoist selector
volve to the holding valve. At the holding valve the fluid must pass through the flow control valve before it
continues on through the tubing to the main/whip pump “A” port. At pump port “A”, the fluid re-enters the
cylinder block and its pressure is dropped to charge pressure as it passes through the pump,

When the control handle (Fig. 1, Item 20} is moved in the lower direction, with no load on the hook, the
main/whip pump actuator (BC-3} receives air pressure on the rod end. The actuator then pulls the pump
displacement control valve lever and causes the pump to “cam’’. When the pump cams, high pressure (1500
psi (102 bar] max) fiuid is pumped out of port “B” of the pump andpasses through the tubing to the in-line
filter. After filtration the fluid continues on through the tubing to port “B” of the main hoist motor. The high
pressure fluid then passes through the main motor, causing it fo rotate, and leaves port “A” of the motor at
charge pressure. The fluid now passes through the tubing, hoist selector valve and holding vaive re-entering
the pump at port “A”. During this operation the shuttle valve and charge pressure relief valve in the motor
valve manifold do not have fluid passing through them and the only fluid entering the system from the
charge pump is fluid replacing internal pump and motor leakage.

Returning the control handle to neutral exhausts the air pressure to the piston of the main hoist brake
releasing valve (P-11) and the valve returns, exhausting the pressure in the brake cylinder. With the release
of the pressure in the main hoist broke cylinder, the main hoist brake sets. At the same time, the air pressure
to the pump activating cylinder (DC-3) is exhausted and the main/whip pumpreturns to the neutral, na flow
of fluid, pasition.

—_- Rev. Jul:

ARMCO National Supply Company uly 1980 Page 53
Divison ot Armco ne
NATIONAL
LUTHO INUSA
HYDRAULIC PEDESTAL CRANE OS-435
WHIP LINE HOISTING A LOAD LOWERING A LOAD AND POWERING DOWN

With the hoist selector control valve (Fig. 1, tem 30) pulled for “WHIP”, the whip haist pneumatic system is
made operable and the hoist selector valve operator (P-16) receives an air pressure signal, shifts and directs
contro! pressure to shift the selector valve for operation of the whip hoist. Control handle (Fig. 1, item 20)
movement in either the hoist or lower direction sends air pressure to the whip hoist brake releasing valve
(P-10), shifting the vatve which directs contro! pressure into the whip hoist brake cylinder. Pressure to the
brake cylinder releases the brake. The movement of the control handie also directs air pressure to the
“BRAKE OFF” indicator (I-7) which turns amber to indicate the hoist brake has been signaled to release.

When the control handle (Fig. 1, Item 20) is moved in the hoist direction the main/whip pump actuator
(DC-3) receives air pressure on the piston end. The actuator then pushes the pump displacement control
valve lever and causes the pump to “‘cam’’. When the pump cams, high pressure (5000 psi (340 bar] max)
fluid is pumped out of port “A” and through the tubing to the holding valve, through the hoist selector valve
and then to port “A” of the whip hoist motor. At port “A” the high pressure fluid shifts the shuttle valve in the
motor valve manifold and then rotates the motor. The fluid leaves port ‘’B’’ of the motor at charge pressure.
Part of the fluid passes through the shuttle valve and charge pressure relief valve in the motor valve
manifoid ond enters the motor case. Mostofthe fluid leaving the motor goes through the tubing to the tee in
the hoist selector valve subplate, by-passes the in-line filter element and returns to port “BY of the
main/whip pump. At pump port “BY”, the fluid fram the motor mixes with the fluid from the charge pump
and then re-enters the main/whip pump.

When the control handle (Fig. 1, tem 20) is moved in the lower direction, with a load on the hook, the
main/whip pump actuator (DC-3) receives air pressure on the rod end. The actuator then pulls the pump
displacement control valve lever and causes the pump to “cam”. When the pump cams,fluid is discharged
out of the port “B” at charge pressure. As the fluid (eaves the main/whip pump it mixes with the fluid from
the charge pump. The fluid now passes through the tubing and is filtered by the in-line filter. The filtered
fluid now goes to the tee in the hoist selector valve subplate and then to port B” of the whip hoist motor. At
port ““B”’ part of the fluid passes through the shuttle valve and charge pressure relief valve in the motor valve
manifold and enters the motor case. Most of the fluid enters the motor and is pressurized from charge
pressure to high pressure (5000 psi [340 bar] max). (While lowering a load the motor is pressurizing the
fluid. The load on the hook attempts to rotate the motor but the speed of the motoris limited by the amount
of fluid passing through it. The pump serves to regulate the amount of fluid passing through the motor.) The
high pressure fluid at motor port “A” shifts the shuttle valve and then passes through the tubing and hoist
selector valve to the holding valve. At the holding valve, the fluid must pass through the flow control valve
before it continues on through the tubing to the main/whip pump “A” port. At pump part “A”, the fluid re-
enters the cylinder block and its pressure is dropped to charge pressure as it passes through the pump.

When the contra! handle (Fig. 1, Item 20) is moved in the lower direction, with no load on the hook, the
main/whip pump actuator (DC-3) receives air pressure on the rod end. The actuator then pulls the pump
displacement control valve lever and causes the pump fo ’cam’’. When the pump cams, high pressure (1500
psi [102 bar] max) fluid is pumped out of port “B” of the pump and passes through the tubing to the in-line
filter. After filtration, the fluid continues on through the tubing to port “B” of the whip hoist motor. The high
pressure fluid then passes through the whip motor, causing it to rotate, and leaves the motor port “A” at
charge pressure. The fluid now passes through the tubing, haist, selector valve, and halding valve re-
entering the pump at port “A”. During this operation the shuttle valve and charge pressure relief valve in the
motor valve manifold do not have fluid passing through them and the only fluid entering the system from
the charge pump is fluid replacing internal pump and motor leakage.

Returning the controt handle (Fig. 1, Item 20) to neutral exhausts air pressure to the piston of the whip hoist
brake releasing valve (P-10) and the valve returns, exhausting the pressure in the brake cylinder. With the
release of the pressure in the whip hoist brake cylinder, the whip hoist brake sets. At the same time, the air
pressure to the pump acctyating cylinder (DC-3) is exhausted and the main/whip pump returns to the
neutral, no flow of fluid, position.

BOOM HOISTING, LOWERING AND POWERING DOWN

With the control handle (Fig. 1, Item 19) in neutral, the boom hoist brake is set and the lock paw! is engaged.
Controi handle movement, in either the hoist or lower direction, sends air pressure to the boom hoist brake
releasing valve (P-13) shifting the valve which directs control pressure into the boom hoist brake cylinder

Page 54 Rev. July 1980 cc

ARMCO National Supply Company
V0 wsion at armeoine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA

and boom hoist lock paw! cylinder. Pressure to the brake cylinder releases the brake. Pressure to the lock
pow! cylinder releases the pawl. The movement of the control handle also directs air pressure to the “brake
off” indicator (I-2) which turns amber to indicate the hoist brake has been signaled to release.

When the contro} handle is moved in the hoist direction, the boom pump actuator (DC-2) receives air
pressure on the piston end. The actuator then pushes the pump displacement control valve jever and causes
the pump to “cam”. When the pump cams, high pressure (6000 psi [408 bar] max) fluid is pumped out of
port “A” and through the tubing to the holding valve. From the holding valve the fluid goes through the
tubing to part “A” of the boom hoist motor. At port “A” the high pressure fluid shifts the shuttle valve in the
motor valve manifold and then rotates the motor. The fluid leaves port “B” of the motor at charge pressure.
Part of the-fluid leaving the motor passes through the shuitle valve and charge pressure relief valve in the
motor valve manifold and enters the motor case. Most of the fluid leaving the motor goes through the
tubing, by-passing the in-line filter element, to port “B” of the boom pump. At pump port ’B” the fluid from
the motor mixes with fluid from the charge pump and re-enters the boom pump.

When the control handie (Fig. 1, tem 19) is moved in the lower direction, the boom pump actuator (DC-2)
receives air pressure on the rod end. The actuator then pulls the pump displacement cantral valve lever and
causes the pump to “cam”. When the pump cams,fluid is discharged out of port 8” at charge pressure. As
the fluid leaves the boom pump it mixes with fluid from the charge pump. The fluid now passes through the
tubing andis filtered by the in-line filter. The filtered fluid now goes through the tubing to port “B’ of the
boom hoist motor. At port “B”, part of the fluid passes through the shuttle valve and charge pressure relief
valve in the motor valve manifold and enters the motor case. Most of the fluid enters the motor and is
pressurized from charge pressure to high pressure (6000 psi [408 bar] max). (While lowering the boom, the
motoris pressurizing the fluid. The weight of the boom andload attemptto rotate the motor, but the speed of
the motoris limited by the amount of fluid passing through it. The pump serves to regulate the amount of
fluid passing through the motor.) The high pressure fluid at motor port “A” shifts the shuttle valve in the
motor valve manifold and then passes through the tubing to the holding valve. At the holding valve, the
fiuid must pass through the flow control valve before it continues through the tubing to the boom pump “A”
port. At pump port “A”, the fluid re-enters the pump cylinder block and its pressure is dropped to charge
pressure as it passes through the pump.

When the control handle (Fig. 1, Item 19) is moved in the lower direction, with the boom at high angles and
no load on the hook, the boom pump actuator (DC-2) receives air pressure on the rod end. The actuator then
pulls the pump displacement control valve lever and causes the pump to ‘cam’. When the pump cams, high
pressure (1500 psi [102 bar] max) fluid is pumped out of port “B” of the pump and passes through the tubing
to the in-line filter. After filtration the fluid continues on through the tubing to port “B’” of the boom motor.
The high pressure fluid then passes through the boom motor causing it to rotate and leaves port “A” of the
motor at charge pressure. The fluid now passes through the tubing to the holding valve and on to re-enter
the pump at port “A”. During this operation the shuttle valve and charge pressure relief valve in the motor
valve manifold do not have fluid passing through them and the only fluid entering the system from the
charge pump is fluid replacing interna! pump and motor leakage.

Returning the control handle (Fig. t, tem 19} to neutral exhausts the air pressure to the piston of the boom
hoist brake releasing valve (P-13) and the valve returns, exhausting the pressure in the brake and lock pawl
cylinders. With the release of pressure in the cylinders the boom brake and lock pawl set. At the sametime,
the air pressure to the pump actuating cylinder (DC-2) is exhausted and the boom pump returns to the
neutral, no flow of fluid, position.

SWING CIRCUIT OPERATION

With the swing handle (Fig. 1, Item 18) in neutral, pulling the swing broke valve (Fig. 1, Item 28) supplies air
pressure to the swing brake releasing valve (P-12) piston and acutates the swing control system. The brake
releasing valve shifts and directs contro! pressure to the swing brakes, releasing the brakes.

With the swing brakes released, control handle (Fig. 1, tem 18) movement toward the operator (swing left)
directs air pressure to the piston end of the pump actuator (DC-1). The actuator then pushes on the pump
displacement cantral valve lever and causes the pumpto “cam”. When the pump cams, high pressure (5000
psi [340 bar] max) fluid is pumped out port “A” of the pump, through a hose to the manifold inside the main
frame, through the distribution hoses to port “A” of the swing motors. At port “A” the high pressure fluid

Rev. July 1980 Page 55

ARMCO National Supply Company
Ouergion of Armco ine
NATIONAL
LITHO IN USA,
HYDRAULIC PEDESTAL CRANE OS-435
shifts the shuttle vaive in the motor valve manifolds. The fluid tren passes through the motors causing
rotation and leaves the motors at charge pressure. At motor ports ““B’, part of the fluid passes over the
shuttle valves and charge pressure relief valves in the motor valve manifolds and enters the motor cases.
Mostof the fluid leaving the motors returns to the swing pump “’B” port through the hose and distribution
manifold, by passing the in-line filter element. At pump port ‘’B’ the fluid from the motor mixes with fluid
from the charge pump and re-enters the swing pump.

With the swing brakes released, control handle (Fig. 1, item 18) movement away from the operator (swing
right) directs air pressure to the rod end of the pump actuator (DC-1). The actuator then pulls on the pump
displacement control valve lever and causes the pump fo “cam”. When the pump cams high pressure (5000
psi (340 bar] max) fluid is pumped out of port ““B” of the pump, through the tubing to the in-line filter.
Following filtration, the fluid passes through the tubing and hose to the distribution manifold and then
through the hosesto port “B” of the swing motors. The fluid then passes through the motors causing rotation
and leaves the motors at charge pressure. At motor port “A”, part of the fluid passes over the shuttle valves
and charge pressurerelief valves in the motor valve manifolds and enters the motor cases. Most of the fluid
leaving the motors passes through the hoses and returns to the swing pump “A” port. At port “A”, the fluid
from the motor mixes with fluid from the charge pump and re-enters the swing pump.

To reset the swing brake, the swing brake valve (Fig. 1, Item 28) is pushed. This action exhausts the air
pressure to the swing control valve (C-1) and the piston of the swing brake releasing valve (P-12). When air
pressure is removed from the brake releasing valve piston, the valve return, exhausting the control pressure
to the brake cylinders, permitting the brakes to set.

Page 56 Rev. July 1980 —

ARMCO National Supply Company
VJ dwtranat armen ine
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INUSA

BRAKES

HOIST BRAKES

The brakes on the three hoist drums are identical. These are on the right hand end of the hoist drums and are
protected by easily removabie rain shields. They are band type brekes on a 29-1/2" diameter drum that is an
integral part of the shaft assembly (hoist winch).

Each of these brakes has a cylinder in the motor compartment that operates the brake through a rocker arm
assembly. The rod end of these cylinders contains springs to maintain the brake in the set position. The
springs of the brake cylinder are lubricated for protection against rust and wear. A reservoir is mounted to
each cylinder to provide for lubricant displacement when the brakeis released, The brakes are released by
applying control pressure behind the piston. This hydraulic pressure compresses the springs and releases the
brake.

Whenever a hoist contro! handle is returned to the neutral position, the brake sets automatically to hold the
load and prevent creeping. Wher the control handle is moved out of neutral, in either the hoist or lower
direction, the brake is fully released. During load Jowering, the load is controlled entirely through the
hydraulic system. This gives sure, precise control that makes the spotting of heavy loads safe and easy.
een

HOIST BRAKE ADJUSTMENT(Fig. 30)

if the crane has not been working regularly it should be worked for a short period to dry the linings and
remove any rust that may be on the drum. This can be done easily by hoisting the empty hook and boom
(simultaneously) a few times with the brake pedal depressed.

The control pressure shauld be in the 700/750 psi (48.3/51.7 bar} range while adjusting the brakes.

The pressure at the main and whip brake cylinder pressure taps, Fig. 26,shauld also be checked.{f this reads
less than the control pressure the foot operated brake valve needs adjusting (see “Brake Pedal’ page 58).
This should be done before proceeding with brake adjustment.

The brake bands are suspended from the main frame with coil springs (two springs are used on the boom
brake). These should be adjusted so that they lift the upper most brake block clear of the drum about 1/32”
(0.8 mm) when the brake is released.

There are also two threaded rods protruding from the main frame that restrain the brake band in the fore and
aft direction when the brake is released. These should be set approximately 1/32" (0.8 mm) from the brake
band when the brakeis set.

When the above adjustments have been madethe brake can be adjusted with the brake adjusting nut. This
requires two men; one to release the brakes by operating the crane and the other to adjust the brake.

There are two holes through the top of the main frame in line with the main and whip brake cylinders and
one hole below the boom hoist wire rope drum. These holes give easy access to the brake adjusting nuts. A
1-1/2" deep socket is required for the adjustment. A brake adjusting tool which incorporatesa 1-1/2" deep
socket is shipped with each crane.

For proper hoist brake adjustment the brake cylinder rod travel should be 1/4” (6 mm). The brake should
then be checked under load.If the load creeps down with the control handle in neutral, the brake band is
not holding.If the brake is properly adjusted and will not hold the load, check the brake lining and drum for
lubricant contamination or the brake cylinder for broken springs.

Rev. July 1980 Page 57

ARMCO National Supply Company
Deveson of Armco inc
 NATIONAL
LITHO IN USA,
HYDRAULIC PEDESTAL CRANE OS-435
SWING BRAKES(Fig. 31)
The swing brakes are multiple disc, spring applied and hydraulically released brakes. The brakes have no
adjustment point. If the brakes have no hydraulic pressure to them and do nat hold the crane from swinging,
they must be rebuilt or replaced.

BRAKE PEDAL(Fig. 29)

When the emergency load release button is depressed, the load can be controlled by modulating the
pressure in the end of the main or whip hoist brake cylinder. This is done with the foot brake pedal (see Fig.
22 for a schematic of the brake system). The valve in the brake pedal is a direct acting pressure regulating
valve. This valve controls the pressure to the main or whip brake cylinders when the pedal is depressed.

Fig. 29 shows the linkage adjustment between the foot pedal and the valve. With the brake pedalall the
way up and while hoisting the whip line, the pressure at the whip hoist brake cylinder pressure tap (Fig. 26)
should read the same as the control pressure (700/750 psi). With the brake pedal depressed all the way
down and while hoisting the whip line_the pressure at the pressure tap should read 150 psi or less. To
increase the pressure, lengthen the linkage. To decrease the pressure, shorten the linkage. The linkage is
adjusted by loosening the jam nut. This is most easily accomplished by removing the hinge pin and then the
upper half of the brake pedal. CAUTION: Do Not remove the plunger from the valve body or attempt to
adjust the brake pedal when the clutch is engaged and the engine is running.

BRAKE PEDAL —
8

un ZB

- a/
ADJUSTMENT POINT SE, PRESSURE PORT

Figure 29 LT-160028
%

Page 58 Rev. July 1980 =

es ¥ ARMCO Nationa! Supply Company
Dwrsson of Armen ing
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

HOIST BRAKES

BAND LIFTING SPRING

Gute Roo

HA
aR —
6 —

vane
—_ AOSUSTING NUT

XN

evunoer
.uBRICATOR

:
'
!

' ' MAIN AND WHIP

ae

NX
Figure 30 LT-160026

igo Me Supply oy Rev. July 1980 Page 59

Greman of Armed ine
NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435

SWING BRAKE ™

¢
t ws

~
ao2 4
5 &
< 3
¢
o za@z 36U€@
ze4e —- &
€&a #3
a C4
28a Z£
no
9«

a
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w
n
&
we
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an

i
9
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xz

aw
2
4
a

o
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Figure 31 LT-160334

Page 60 Rev. July 1980 _

aRMCO National Supply Company
\Z_ evision of Atmee ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO INU SA.

BRAKE CYLINDER ASSEMBLY(16010250)

LT-160087
item Part No.
No. No. Description Req‘d.

1 1610251 CAP ee rennet een e eee eae 1

2 1610252 BARREL, Cylinder... 2.0. .ceceeeeeeteeee eens 1
3 1610253 RETAINER 22 neenee eee eee e enna 1
4 1610254 PISTON 2000 cent ett eee eee eet eens 1
5 1610255 ROD,Piston. 0... eee ete eens 1
6 1610256 CAP, ClevisEnd 020... eect n nee t eee eee 1
7 1610257 BUSHING, Hydraulic Brake Cylinder... 2... 0c ee 1
8 1610258 STUD, Brake Cylinder 20.000 cnet eens 4
9 1610259 CLEVIS, Brake 200 e tet e eee e een te ee eee J
10 1610833 PIN, Brake Cylinder 20.2.0 eter eens 1
nN ZB-1120 BEARING . 000 nee nnn entree ene tee eeae 2
12 YS-1507 SEAL, OF cnet tenet beeen ene e eee 1
13 2410022-222 PACKING, O-Ring 2.02.00 t ene t ents 1
14 2410022-240 PACKING, O-Ring 200066 e nee ene nes 2
15 6310243 NUT,Flexloc #30FK2406, 1-1/2°-6UNC Thin. 202.000. ee 1
16 6320080 NUT, Hex Jam 1/2” 0 etc n bette ete eens 4
17 6501212 PIN, Cotter 3/167 x VV/27 cee eee eee 2
18 6571632 PIN, Spring Slotted Steel Standard 1/4” x27 eee eee 1
19 7600068 WASHER,1-1/2N. Type A 3.0" 0.0. 00 eee eee tenes |
20 7818034 SEAL, Piston o.oo ec cee eee eteee een beeen eee enae 1
21 7818249 SPRING, Disc... ee cent teen eee ee een eee e tees 4

samco National Supply Company Rev. April 1979 Page C-1

NJ Omen Armen ine
NATIONAL
LITHO IN U.S.A,
HYDRAULIC PEDESTAL CRANE OS-435
BOOM HOIST HOUSING ASSEMBLY(1613860)

“1Ad Bey wos

SLNGNOdNOT Ian assy
1-9 ‘id FS 19
SANJNOdNOD ANEW3SSY
44VHS YO4 S-) Od 395 OG

LT-160098

Page C-2 Rev. April 1979 —)

A RMCO National Supply Company
Orman of Armco tn
NATIONAL HYDRAULIC PEDESTAL CRANE OS-43
LITHO IN USA.

SWING BEARING MAINTENANCE REQUIREMENTS

The swing bearing of the crane is a forged alloy steel ball type bearing with hardened and ground races. The
inner race of the bearing is attachedto the crane frame and the outer race is attachedto the pedestal! flange.
The gear teeth of the bearing are an integral part of the outer race. The bearing must be mounted to the
pedestal flange as directed by the National Supply Company technical standard TD-16001.

tn order to assure trouble free operation of the swing bearing, several maintenance operations must be
regularly performed. The bearing balls and races must be thoroughly lubricated once a week with a suitable
grease as specified in the lubrication section. There are lubrication fittings for the swing bearing in the wall
of the main frame below the left-hand end plate of the main and whip hoist winches. Hoses are attached
from these fittings to the inner race of the swing bearing for piping the grease to the bearing. The bearing
and swing pinion teeth must have an adequate coating of a high quality lubricant such as Jet Lube, Inc.
“Kopr-Kote” compound for lubrication and corrosion resistance.

Grease sampling and tilt or lift measurement can be good indicators of swing bearing wear and general
condition. However, the condifions must be closely monitored on a regular and long term basis. Since
loading and mounting greatly affect the “in servicelift (tilt)of a bearing, the exact conditions must be
duplicated each time the lift is measured. These conditions include swing bearing bolt torque, crane
orientation, indicator location, boom angle(s} and load(s). Knowingthe lift of a newly mounted bearing, the
lift can be periodically measured (approximately 6 month intervals), monitored and evaluated. A substantial
increase in lift could indicate bearing damage, bearing abnormal wear, the approach of the end of the
service life of the bearing or bearing mounting abnormalities. The lift figures are substantially more
valuable as a case history.

Grease sampling must also be maintained as a case history. The significant numberof variables involved
with bearing service prohibit establishing a “normal” metallic particle concentration in the lubricant. Each
grease sample, taken from the bearing assembly hole, will likely show some metallic particles. The samples
should be checked for a marked increase in metallic particle concentration.

A spot check of the tightness of the inner and outer race swing bearing bolts should be performed monthly.
Every six months of the inner and outer race bolts should be re-torqued. Loose bolts can lead to fatigue
failure of the bolts and to detrimental binding and wear of the swing bearing balls and races. The required
bolt torque is given in the table on page 62.

STRUCTURAL MAINTENANCE

The structural members of the OS-435 crane are coated with a zinc-rich primer, epoxy second coat, poly-
urethanetie coat and acrylic top coat. The boom, main frame and gantry should be inspected for deformed,
cracked, corroded or missing members on a monthly basis. Corroded areas should be cleaned of corrosion,
properly primed and painted. Cracked or deformed members should be repaired. Missing members should
be replaced. Prior to conducting structural repair or replacement the National Supply Company should be
contacted for feasibility of repair, material specifications and welding procedures.

Crane assembling cap screws should be checkedfor tightness every six months. The chart given on page 62
can be used as a guide for proper torque requirements.

CAUTION: When welding on the crane, the ground (earth) for the welder must be above the swing bearing.
DO NOT ground through the swing bearing.

Rev. July 1980 Page 61

anupe National Supply Company
Oregon of Armca tne.
NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435

CRANE ASSEMBLING TORQUE VALUESIN FT-LBS*

SCREW ©) > CD ey, ©) ©

ISIZE
INCHES GRADE 2 GRADE5 GRADE 7 GRADE8 HEX SOCKET HEAD} 12 POINT HEAD

1/4 6 (.8) 19 (1.2)] 12. (1.6) 13 (1.8) 14 (1.9) —

6716 {1 (1.5) 18 (2.5)| 24-— (3.3) 28 (3.9)| 30 (4.1)
378 19___(2.6) 31 (4.3)| 43 _(5.9)| 46 _(6.4)| 50 (6.9) =
7716130 (4.1) {50 (6.9) 69 (9.5) 75 (1o)| 81 (iT)
172 45 (6.2) [75 ___(10-4)| 106 (14)| 115 (95) 121 (16) =
6/16 [66 _(9.1)[ 110 _(15)| 150 (20) 165 (22){ 176 (24} —
578 93 (12.9) {150 __(20)| 209 _(28)| 225 _(3i)| 240 (33) =
374 150 (20.7) 250. (34) 350 (48) 370 (51) 395 (54) =
7/8 202 (27.9) 378 (52)| 550 (76) 591 (BI) 629 (86) —
1 300 (41.5) 583 (80)| 825 (lia) 893 (123) 964 (133) —
176474 (65.5) 762 ___(108){ 1304 (180) [1410 _(195){ 1523 (210) =
11741659 __(91.1) 1097 (151) 1650 F (228) 1750 | (242)| 1908 (263) [2100 Tt (290) —
1-3/8 884 (122.3) 1461 (202) 2400 (331) 2400 (331)| 2400 (331) —
1-172__| 1057 (146.2) 1748 (241)| 2600 | (360) 2850 } (394)| 3060 (423) [3550 T (463)
1-5/8 __|1448 (200) 2392 _(330)| 3985 (551) 4311 _(596)| 4655 (643) _
1-3/4 — —_ 4650 f (643}| 5050 7 (698}| 5450 (753) 5950 + (622)

*VALUES IN PARENTHESES ARE IN M-Kg. LT-160044

**BOLT GRADE IS !SO 12.9

tThreads lubricated in accordance with National Supply Company Technical Standard TD-16001. Other
torque values are for clean, dry threads.

Page 62 Rev. July 1980 —,

ARMCO National Supply Company
\J7_ owsion ot Armea ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

HYDROSTATIC DRIVE TROUBLE SHOOTING

The following instructions and fault-logic diagrams should provide a comprehensive guide to trouble
shooting the hydrostatic drives of the OS-435 crane.

A fault-logic diagram is provided for each of the five problems which experience has shown to cover the
majority of problems encountered with hydrostatic drives. The applicable diagram should first be found and
then followed to trouble shoot the hydraulic transmission. The paragraphs below give specific instructions
covering steps in the fault-logic diagrams.

DISPLACEMENT CONTROL VALVE INSPECTION

Disconnect the pump actuating cylinder and remove the mounting bracket and cylinder from the pump.
Removethe valve mounting cap screws andlift the valve away from the pump. A gasket and three O-Rings
are used beneath the valve and the swing pump has an orifice inside the inner most O-Ring. Care must be
exercised to be certain no parts G?@ dropped into the pump case. Refer to figure 42.

The valve linkage (connection to swashplate), pins and retaining rings should all be closely examined.
Confirm the torsional spring is not broken andthe orifice (when used) is not plugged. Inspect the O-Rings for
damage.

The vaive is removed form the pump by removing the pin connecting the valve linkage to the swashplate
angle feedback link. Upon replacement of the valve, new O-rings and a new gasket of the proper thickness
should be used. The valve must be carefully lowered to insure proper location of the O-Rings, gasket and
orifice.

DISPLACEMENT CONTROL VALVE MOUNTING

| -- fy

MOUNTING SCREW

CONTROL LEVER

ot PLUG

GASKET- Q

© == Se oe— 0-RINGS
PIN WITH RETAINING RING oN ' ORIFICE (WHEN USED)

PIN WITH COTTER PIN PIN WITH RETAINING RINGS

CONTROL LINK
SWASHPLATE— L
PIN WITH COTTER PIN

FEEDBACK LINK

Figure 42 LT-160037

Rev. July 1980 Page 91

ARMCO National Supply Company
Orrtran of Aemea tng
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
DISPLACEMENT CONTROL VALVE ADJUSTMENT

WARNING: The variable pump control valve assembly is adjusted at the factory. At no time should the
control valve be readjusted in the field. If the adjustment screws have been tampered with, use the
following procedure to make the correct control valve adjustment. Refer to Figure 43.

1. Remove the control valve assembly from the pump prior to making the adjustments. See “Displacement
Control Valve Inspection”.

. Remove the end plug from the centering spring mechanism. With locknut (Item 1) loose and holding the
centering spring housing (Item 3}, turn the spring adjusting screw (Item 2) until the screw is just touching
the centering spring washer; thus taking the free end play out of the centering spring mechanism. This is
best done by exerting a light back and forth force on the control valve spool (Item 6) at the same time the
adjusting screw is being turned down. Care must be taken not to compress the centering spring (Item 4)
beyond its installed height. Tighten the locknut (Item 1) and recheck the spool (Item 6) for end play.

Adjust the control valve spool (Item 6) for the neutral position. Remove the 7/16”-20 boss seal plugs (Item
5) on either side of the control valvetausing (Item 7) in the control valve spool bore location of the
casting to reveal the servo cylinder porting holes (Item 8). Loosen the locknut (Item 9) and adjust the
control valve spool by screwing the centering spring housing (Item 3) in or out so that the open areas
(Reference A) between the spool lands and sides of th porting holes ore equal. Tighten the locknut (Item
9), recheck the open areas, and reinstall the two 7/16’-20 boss seal plugs.

Re-install contro! valve on pump. Care should be exercised not to damage the O-Rings under the valve
and to properly position the orifice (If used). Carefully check the operation of the pump after the control
valve adjustment.

DISPLACEMENT CONTROL VALVE ADJUSTMENT

Figure 43 LT-160038 Se
Page 92 Rev. July 1980
aawpe National Suppty Company
Deveson at Ameo ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-4
LITHO IN USA.

STYSTEM RELIEF VALVE INSPECTION (Figure 47%

Using a new or borrowed relief valve of the same setting, replace the system relief valves one at a time,
checking the system operation after each replacement. If the problem ceases, discard the faulty relief valve.

Inspect the valves for the proper setting. The first two digits of the setting are stamped on the end of the
valve. For instance 50 for 5000 psi (340 bar), 60 for 6000 psi (413.8 bars}, and 15 for 15000 psi (103.4). Both of
the swing motorrelief valves are stamped 50. The main and whip hoist motors have a 5000 psi relief valve
on the left side and a 1500 psi relief valve on the right side, when viewed from the valve manifold block
end. The boom hoist motor has a 6000 psi relief valve on the left side and a 1500 psi relief valve on the right
side, when viewed from the valve manifold block end.

RELIEF VALVE OPERATION

SYSTEM PRESSURE “A”

/—— HIGH PRESSURE RELIEF VALVE

Figure 44 LT-160039

SHUTTLE VALVE INSPECTION (Figure 47)

The valve spool must move smoothly in the bore. Inspect for worn, galled or broken parts. The spool and
valve manifold block are matched and are not interchangeable.

The swing motor shuttle valve spool has a spring and washer on each end. The hoist motor shuttle valves are
blocked to shift only when the system has high pressure at motor port “A”. For this reason the hoist motor
shuttle valve spools, when viewed from the valve manifold block end, have a spring and washer on the
left-hand end and a spool extension or spacer on the right-hand end.

Supe National Supply ny Rev. July 1980 Page 93

Owssion of Armeg ine
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
CHARGE PRESSURE CHECK VALVE INSPECTION (Figure 45)

CHARGE PRESSURE CHECK VALVE

TYPICAL CHARGE PUMP

CHARGE SUMP CHARGE PRESSURE

RELIEF VALVE~——

CHARGE PUMP GASKET

TYPICAL CHARGE PUMPj

CHARGE PRESSURE CHECK VALVES

TYPICAL AXIAL PISTON “r——

Figure 45 LT-160040

Carefully remove the charge pump to expose the cartridge check valves. Inspect the valves for spring load,
proper seating, damaged O-rings and foreign material. When the problem is in one direction only,
interchange the check valves to see if the problem changes sides. A new gasket shousd be used when the
charge pump is replaced on the axial piston pump.

CHARGE PRESSURE RELIEF VALVE INSPECTION (Figures 46 and 47)

Inspectfor foreign material holding the poppet open, galling or wear on the poppet and seat, a broken
spring or an improper setting.

Page 94 Rev. July 1980

ARMCO National Supply Company
Orerson of Armed inc
 NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
%

LITHO IN USA.

CHARGE PUMP
TYPICAL CHARGE PUMP.

CHARGE PUMP CHARGE PRESSURE REUEF

VALVE COMPONENTS,

TYPICAL AXIAL PISTON PUMP:

vt

Figure 46 LT-160041
‘Be

snugo National Supply Company

Rev. July 1980 Page 95
Orertson of Armee ine
NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435
~.
MOTOR VALVE MANIFOLO ASSEMBLY —

4
SWING SWING
MOTOR MOTOR
PORT
* PORT
te"
|
AA
SWING MOTOR A “|
SHUTTLE VALVE

SWING MOTOR CHARGE

f PRESSURE RELIEF VALVE

SWING
MOTOR
— CASE

HOIST HOIST
MOTOR MOTOR
PORT
* PORT

i , i

HOIST MOTOR b— - \
SHUTTLE VALVE—*E |. id .

c
f HOIST MOTOR CHARGE
PRESSURE RELIEF VALVE
!
HOIST
MOTOR
CASE

0, HIGH PRESSURE
RELIEF VALVE
V7E BD

HIGH PRESSURE i
RELIEF VALVE |O \

MOTOR MOTOR
PORT
38 PORT
oR

Figure 47 LT160015

Page 96 Rev. July 1980 _

8 ¥ ARMCO National Supply Company
Vv Owision of Armco ine
NATIONAL HYDRAULIC PEDESTAL CRANE OS-435
LITHO IN USA.

CHARGE PUMP INSPECTION (Figures 45 and 46)

Carefully remove the charge pump. The shaft and internal gears must turn smoothly, Futherdisassembly of
the charge pump is not recommended. Check the condition of the pump drive clevis and tang.

CHECKING CHARGE PRESSURE

The proper gages for checking charge pressure are provided in the operator’s cab on the right-hand reer
panel. In neutral charge pressure should be 190 to 300 psi (13.1 to 20.7 bar). While powering down charge
pressure should be 180 to 290 psi (17.4 to 20 bar). While hoisting or lowering o load, or while swinging,
charge pressure should be 160 to 280 psi (9.3/19.3 bar). NOTE: PRESSURES SLIGHTLY ABOVE THOSE NOTED
ARE NOT UNCOMMON. THE PRESSURE, HOWEVER, SHOULD NOT EXCEED 400 PSI (27.6 BAR).

The charge pressure system has tworelief valves, one in the charge pump and one at the motor. The charge
pressure relief valve at the motor has a lower pressure setting to provide for system cooling. In neutral and
while powering down, the chargé pressure relief valve at the pump is used. While hoisting or lowering a
load, or swinging the crane, the charge pressure relief valve at the motoris in use.

INTERPRETING CHARGE PRESSURE

NO CHARGEPRESSURE- If there is no charge pressure at any position of the control lever, the charge pump is
probably at fault. Most likely the drive shaft has been broken. To confirm the diagnosis, remove the charge
pump and examine for broken parts.

Complete lack of charge pressure could also be due to spring breakage, damage, or dirt in the charge
pressure relief valve located in the charge pump. Examine the relief valve for dirt, wear, and possible
sticking,

FLUCTUATING PRESSURE - !f the charge pressure is erratic with control lever in neutral and in the side
position, with pressure level perhaps little lower than expected, this may indicate cavitation of the charge
pump from low fluid level in the hydraulic tank, collapsed suction hose, or dirty suction filter elements.
Check for these conditions and replace the suction line filter elements.

CHARGE PRESSURE DROPS WHEN CONTROL LEVER JS SHIFTED - If the charge pressure holds steady when the
control lever is in neutral, with about the right expected pressure, then falls rapidly as the control leveris
moved to a side position, this usually indicates that the charge fluid is escaping into the case through
clearances which open up as the control fevertries to cam the pump. The most likely fault is a scored valve
plate. When the valve plate becomes scored, fluid pressure can get underit and tendstolift it from intimate
contact with the bearing plate. This allows some of the high pressure loop fluid and some of the charge
pump fluid to escape into the pump or motor case. With this condition the charge pressure may fall very low,
too low to cam the pump swashplate to more than a small angle. If charge pressure falls below 140 psi (9.7
bar), replacement of the damaged pump and motoris necessary.

tf charge pressure drops only when trying to power down an empty hook or boom or drops only when
swinging one direction, the shuttle valve in the motor valve manifold is probably shifted and held. A similar
condition, however, will exist if an O-ring underneath the displacement controt valve is damaged and
leaking. (See Figures 42 and 47).

NOTE: Charge pressure tends to increase with an increase in engine speed. The lowest acceptable
charge pressure is 140 psi (9.7 bar).

Rev. July 1980 Page 97

aRMCO National Supply Company
Dension of Armen ine
« NATIONAL
LITHO IN U.S.A.
HYDRAULIC PEDESTAL CRANE OS-435
CHECKING HIGH PRESSURE

If the charge pressure seems to respond normally as the control handle, in the operator's cab, is moved out
of the neutral position, perhaps drooping slightly but not drastically, check the high pressure gage in the
right-hand console in the operator’s cab. For a properly operating system, the pressure in the loop should be
charge pressure when the control handle is in neutral. However, as the control handle is moved to hoist a
load or swing the crane, the pressure should immediately rise to the value required by the load on the
system.

INTERPRETING HIGH PRESSURE

NO HIGH PRESSURE CAN BE DEVELOPED- If there is verylittle or no rise in loop pressure when the control
handle, in the operator’s cab, is moved out of neutral, one of the high pressure relief valves, in the motor
valve manifold may be seized in the open position or damaged. Since there are two high pressure relief
valves, one for each direction of operation, try moving the control handle (without a suspended |aod) into
hoist and powerdown. If pressure can be developed in one direction and not in the other, one of the relief
valve poppets is probably damagedor seized. If pressure cannot be developed in either direction, a relief
valve spool may be seized open. Suspected relief valves should be removed, inspected, cleaned and
replacedif such is required. See figures 44 and 47 for pictorial descriptions. NOTE: When replacing o relief
valve be certain the pressure setting of the replacement is correct. See “System Relief Valve Inspection’’.

FULL HIGH PRESSURE CANNOTBE DEVELOPED- If only partial pressure is obtained on the high pressure gage
when the control handle is moved out of neutral, one of three faults may be present. Assuming charge
pressure had been checked and found to be normal, the first fault may be a leaking charge pressure check
valve. One or both check valves which permit the feeding of charge pump fluid into the loop may be
damagedarsticking. If this condition exists, fluid is escaping from one side of the system loap into the
opposite side of the system loop through the charge pump circuit. Symptomsof this fault would be fairly
normal operation of the system when unloaded, but an inability to build up high pressure (therefore torque)
for heavy loads. A system with this fault may also experience overheating. If the system will not develop
pressure in either hoist or powerdown, a leaking check valveis nota likely fault unless, by coincidence, both
check valves are damaged and leaking. If the system fails to develop pressure in one direction, inspect these
valves.

The secand passible fault is excessively worn piston slippers. Worn slippers cause excessive leakage of fluid
into the case, seriously reducing performance of the system. Sypmtoms would be similar to leaky check
valves. A major factory overhaul is recommended for the hydraulic transmission.

The third possible fault is the installation of a relief valve with a pressure setting below the specified
requirement. (See “System Relief Valve inspection’). Replace any relief valves of improper setting.

EXCESSIVE HYDRAULIC SYSTEM NOISE

Cavitation or internal pump or motor damage from contamination are the most common causesof excessive
pump or motor noise. When excessive noise is apparent the following items may be the cause:

\. Dirty Charge Pump Suction Line Filter - causes cavitation of charge pump.

2. Restriction in Charge Pump Suction Line - causes cavitation of charge pump,

3. Improper Hydraulic Fluid - heavy fluids can cause cavitation.

4. Water in the Hydraulic Fiuid Forming an Emulsion - can act like a heavy fluid and cause cavitation.

5. Air Enirained in the Hydraulic Fluid - causes cavitation and excessive noise, (See air in hydraulic fluid)

Page 98 Rev. July 1980 _

8 ARMCO National Supply Company
VJ Don ot Armes ine
NATIONAL HYDRAULIC PEDESTALCRANE =OS-435
UTHO INUSA.

AIR IN HYDRAULIC FLUID

Air entrained in the hydraulic fluid- can be the cause of excessive noise, low pressures and extensive
damage to hydraulic components. Check all lines and connections, especially those in the charge pump
suction routing, for possible leaks which would permit air to enter the system. Check the fluid level in the
hydraulic tank. A law fluid tevel will allow air to enter the system through the charge pump suction line.

PUMP AND MOTOR SHAFT SEAL REPLACEMENT(Figure 48)

NOTE: It is recommendedthat all shaft seal parts be replaced.

. Remove the large retaining ring located on the shaft end of the pump or motor. Remove the side
opposite the tangs from the groove first.

Removethe aluminum housing.It is held in place by the friction of the O-Ring on its outside diameter.
Pry the housing toward the end of the shaft until the O-Ring is free.

. Remove the aluminum housing from the shaft. This part is actually an assembly that is being held
together by the friction of an internal O-Ring. It will normally remain assembled until physically
separated. .

Behind the aluminum housingis the bronze sealing ring. This ring is also held in place by internal O-Ring
friction. Work this part free and carefully slide over the shaft.

CAUTION: This part is easily damaged and extreme care must be exercised when handling.

All of the shaft seal parts, which are included in the shaft seal kit, have now been removed. {t is
recommendedthat this entire shaft seal be replaced.

Prior to assembly, lightly lubricate all parts with clean hydraulic fluid, place one O-Ring in the inside
diameter of the aluminum housing. Place the six (6) springs in the cavities in the aluminum housing.
The shaft spline should be covered with thin, clean plastic to protect the parts from damage by the shaft
during assembly.

Slide the bronze sealing ring over the shaft and onto the shaft pilot diameter with the O-Ring facing the
motor or pump. Using clean hands, work the ring into place using hand force only.

With clean hands, insert the stationary seal pilot into the aluminum housing, locating the notch in the
stationary seal over the pin in the housing.

Install the O-Ring on the outside diameter of the aluminum housing then slide it into place against
the bronze sealing ring. Since this is a spring loaded assembly,it may be necessary to push against the
aluminum housing to expose the retaining ring grooves.

10. Install the retaining ring with the beveled side out putting the side opposite the tangs into the groove
first. Be certain the retaining ring has snappedinto its groove completely.

Rev. July 1980 Page 99

arnmca Nationa! Supply Company
Orton of Armco ine
NATIONAL
LITHO IN USA.
HYDRAULIC PEDESTAL CRANE OS-435
PUMP OR MOTORSHAFT SEAL

PUMP OR MOTOR

RETAINING RING GROOVE

“O° RING
BRONZE SEALING RING
STATIONARY SEAL
“O*RING
/ i
hssRING

CY ALUMINUM HOUSING

@ RETAINING RING
sonne! Og

Figure 48 LT-160042

Page 100 Rev. . July 19 80 Shua> Na Supply c ay

Donteon of Armen ine
NATIONAL HYDRAULIC PEDESTALCRANE 5.435
LITHO IN USA.

PUMP AND MOTOR REPLACEMENT

Whenevertrouble shooting procedures have determined that the hydrostatic transmission must be replaced
certain precautions and steps should be followed. Generally the pump and motor(s) should be changed out
os a system. A new pump or motor can become damaged if operated in conjunction with a used unit.

As always, the prime consideration when working on the hydraulic system is to insure no contamination is
introducted into the system. When replacing a pump and/or motor the following basic outline should be
used. The kill valve in the operator’s cab should be depressed prior to opening any hydraulic connections.

1, Remove the damaged units and replace with the new units.

2. Using the plugs and covers from the new units, cover and plug the ports of the old units. Many old
units are salvageable when removedfrom service, but can suffer irreparable damageif not properly
protected,

3. Replace all filter elements-~-

4. If any debris is present in the hoses or tubing, the hoses and tubing should be flushed clean with a
suitable solvent and blown dry.

§. Connect all tubing and hosesreplacing ail related O-Rings.

6. Using clean hydrulic fluid, hand fiil the pump and motor cases.

7. Fill the hydraulic tank to the proper operating level.

8. Double check all hydraulic connections which have been disturbed.

9. Double check all pump and motor mounting screws.

10. Double check the adjustment of the pump acutating cylinder.

11. Disengage the clutch.

12, Start the engine and set at the low idle speed (1000 RPM).

13. Manually engage the clutch briefly six to eight times. This action permits the pumps to receive
Subrication prior to being run continuously.

14, Fully engage the clutch and observe the chorge pressure in the operators cab. The charge pressure
should be 180-200 psi.

15. Observe the level of the fluid in the hydraulic tank and add fluid if necessary.

16. Operate the crane under no load, observing charge pressures.

17. Operate the crane under load, observing charge pressures. Engine RPM should be 1500 anytime a
load is lifted. Charge pressure should be 160-180 psi during operation.

18. Inspect the system for hydraulic leaks and correct any abnormalities.

— Rev, Jul
ARMCO National Supply Company ev, July 1980 Page 107
VV owritsan of Aomea tne
 NATIONAL
LITHO IN U.S.A,
HYDRAULIC PEDESTAL CRANE OS-435
PUMP AND MOTOR REPAIR

Any repair of the axial piston pumps and motors requiring the removal of the end cap or front cover is not
recommended to be performed in the field. Major repairs should only be attempted by experienced,
qualified and properly equipped personnel. Only minor repairs, such as those discussed in the hydrostatic
drive trouble shooting section, should be performedin the field.

EMERGENCY LOAD LOWERING

in an emergency created by the loss of control pressure, loss of air pressure, loss of diesel power or
malfunction of the hydraulic transmission, a load can be lowered by the following procedure. WARNING:
THIS PROCEDURE IS NOT FOR USE ON THE BOOM HOIST SYSTEM.

} Kill the diesel engine.

2. Engage the clutch by hand.

Remove the shuttle valve spool from the hydraulic motorof the hoist which must be lowered. Note the
orientation of the valve spool and replace the plugs in the manifold block.

Remove the hose from the bottom of the brake cylinder of the hoist which must be lowered and
connect a hand operated hydraulic pump to the brake cylinder.

Slowly apply hydraulic pressure io the brake cylinder until the wire rope drum begins to turn. The
speed of the drum should not exceed 30 RPM. The drum can be slowed or stopped by lowering the
pressure to the brake cylinder. CAUTION: Do not over pressure the brake cylinder. Maximum pressure
should not exceed 800 psi (55.2 bar).

Upon completion of the lowering, clean and properly re-install the shuttle valve spool, reconnect the
hose to the brake cylinder and disengage the clutch by hand.

NOTE: Light line loads may not be able to over come the friction forces in the hoist system even when
the brake is fully released.

Page 108 Rev. July 1980 _

ARMCO National Supply Company
VV OwenotArmcoine
 TECHNICAL STANDARDS OATES
€ ? . 2-25-80 PAGE
ARMCO National Supply Company
Division of Armco
Gainesville. Texas 76240 SUBJECT
INSTALLATION OF PEDESTAL MOUNTED
PREPARED BY APPROVED BY
CRANE; MOUNTING FLANGE, SWING
J.E. Cabb Ill A.B. Shockley BEARING AND POWER PACKAGE.

PROCEDURE FOR ATTACHING MOUNTING FLANGE TO PEDESTAL

The top of the pedestal is to be round within 1/4” (6.4 mm) on the diameter without temporary braces,
jacks, wedges or any other restraint.

The top of the pedestal is to be flat, square and in a plane to within +0.030” (0.762 mm) and +0°-30’.

Outside nominal diameter of the pedestal top is to be:

CRANE MODEL PEDESTAL DIAMETER
OS-435 90”(2.286 m)
O$-215 79-1/2” (2.019 m)
OS-105 66” (1.676 m)
H-65A 71-1/2" (1.816 m)
05-45 54-172” (1.384 m)
Welding procedures used to join the mounting flange to the pedestal should be such that the distortion
introduced into the bearing mounting surface conformsto the limits outlined below. Welding procedures to
be compatible with mounting flange material.
NOTE: The welding of the mounting flange to the pedestal and the installation of the pedestal must be
complete prior to the swing bearing and the crane power packageinstallation.

N PROCEDURE FOR INSTALLING THE SWING BEARING AND CRANE POWER PACKAGE

1. Check the twist between the swing beoring and mounting flange (see Figure 2).

A. Prepare the mounting surfaces by removing paint and surface imperfections. Do Not use tools or
abrasives that will damage the machined mounting surfaces.

Install three guide bolts, approximately 10” long (25.4 cm), in the outer race of the bearing, spaced
120° apart. Set only the bearing on three spacers of equal length with the guide bolts inside the
spacers (see Figure 3).

NOTE: The outer race ball path hardness gap is marked with a “G” stampedin the upper or lower face
of the race. This point should be placed 90° from the direction of highest anticipated bearing load.

Move a suitably mounted dial indicator radially from the outside edge of the mounting flange to the
inside edge of the flange surface beside each hole in the mounting flange. (see Figure 4).

Record the total indicator reading. The maximum allowable total reading for twist is 0.010 inches
(0.254 mm).
\f the mounting flange is out of tolerance corrective measures must be executed and new twist
readings obtained.

Obtain the shim gap between the swing bearing ond mounting flange.

A. With the bearing in place on spacers as in 1B above, measure the distance between the bearing and
flange beside each hole in the mounting flangeat the bolt circle of the flange with a suitably mounted
dial indicator. Record each measurement. The minimum distance will be the zero point (no shim
required).

The maximum total waviness or out of flat (shim thickness) is not to exceed 0.050 inches (1.27 mm).
(see Figure 1).

If the mounting flange is out of tolerance, corrective measures must be executed and new out offlat
readings obtained.
eno fo.
 With the mounting flange within the tolerances outlined above for twist and wave and shim
thicknesses for each bolt hole determined, raise the swing bearing, remove the three spacers and
lubricate the mounting surfaces with Jet Lube, Inc., “Kopr-Kote’” compound or equivalent. Lower the
bearing (placing the guide bolts in the same holes) to within approximately 1/4” (6.4 mm) of the
mounting flange.

NOTE: Small! spacers may be used to maintain the 1/4” (6.4 mm) gap.

Install the proper thickness shim(s) (as determined in 2A) at each bolt location to shim the mounting
flange flat within 0.005 inches (0.127 mm) total indicator reading andinstall the bolt and washer. (see
Figure 5). Do Not allow the shims to overlap.

NOTE: The shims, boits, and washers are to be those provided by National Supply Company.The bolts
should be lubricated with Jet Lube, Inc., “Kopr-Kote’” compoundor equivalent.

Lower the swing bearing onto the shimmedsurface of the mounting flange. Do Not allow the shims to
overlap.

D. Tigthen the outer race bolts to approximately 500 ft.-Ibs. (70 m-kg).

Mount the crane power package on the swing bearing.

A. Prepare the mounting surfaces by removing paint and surface imperfections. Do Not use tools or
abrasives that will damage the machined mounting surfaces.

Lubricate the power package and swing bearing mounting surfaces with Jet Lube, Inc., ““Kopr-Kote”
compound or equivalent.

Install two guide bolts, of appropriate lengths, in the power package.

Lower the crane onto the swing bearing aligning the bolt patterns in the bearing and crane frame.

CAUTION: Care must be used to prevent damageto the swing pinion(s) or swing bearing gear as the
crane is lowered.

Install two bolts fore and twobolts aft through the swing bearing into the power package (see Figure
5).
CAUTION: Do Not release the power package from thelifting apparatus until it is securely balted to
the swing bearing.

NOTE: All bolts should be lubricated with Jet Lube, Inc., “Kopr-Kote” compound or equivalent. Some
crane models incorporate frames requiring nuts and lockwashers. All bolts, nuts and washers to be
those supplied by National Supply Company.
a

F. Rotate the crane andinstall the remainder of the inner race bolis as the crane is indexed around.

Torque the inner and outer race swing bearing bolts in accordance with the table below.

BOLT DIAMETER GRADE7 BOLT GRADE8 BOLT GRADEISO 12.9 BOLT

1-1/4" (31.75 mm) —-1650 fi.-tb. (228 m-kg) 1750 ft-lb. (242 m-kg) 2100 ft.-Ib. (290 m-kg)
1-1/2" (31.1 mm} 2600 ft.-Ib. (360 m-kg) 2850 ft.-Ib. (394 m-kg) 3350 ft.-Ib. (463 m-kg)
1-3/4” (44.45 mm) 4650 ft.-Ib. (643 m-kg) 5050 ft.-Ib. (698 m-kg) 5950 ft.-Ib. (822 m-kg)

NOTE: Grade 7 bolts are identified by 5 radial lines on the head. Grade 8 bolts are identified by 6 radial
lines on the head. Grade ISO 12.9 bolts are identified by the use of a 12 point head. To develop uniform bolt
torque, all bolts should be tightened in three steps. Bolt torques are based on clean, properly lubricated
threads.

6. Install swing bearing lubrication hoses.

7. Complete crane installation in accordance with applicable installation drawing(s).

 WAVINESS OR OUT OF FLAT

FIGURE |

TWiST

FIGURE 2

LS,
— o o

Qo
°
°o

SPACER, 3 PLACES

FIGURE 3
 N
IN

|_[ oO) DIAL INDICATOR

IS

SS
FIGURE 4

NOTE POSITION OF
CHAMFER IN WASHERS

FIGURE 5
(TYPICAL EXAMPLE)
 ICAL STANDARDS pare | [40+ TD-16003
ARMCO National Supply Division 2-23-73 PAGE 1 of J
Armco Stee! Corporation
GAINESVILLE, TEXAS SueJECT PROCEDURE FOR APPLYING
Sea = 7 LOCTITE RETAINING COMPOUND #35
WER TO PRESS OR INTERFERENCE FITTED
7ELR. PARTS TO INCREASE JOINT RELIABILI
7

PROCEDURE FOR ASSEMBLING PINS AND PLANET GEARS

This procedure is for applications where press or interference fitted parts are
given added joint reliability by use of Loctite RETAINING COMPOUND 35. It is
specifically applicable to the following listed crane planet gear assemblies:

0S-105 Main, Whip & Boom Hoists Second Stage Only

08-215 Main & Whip Hoist Second Stage Only
Boom Hoist First & Second Stages
08-435 Main, Whip & Boom Hoists First & Second Stages

A small oven or oxy-acetylene torch will be needed to heat the crane planet gears.

PROCEDURE:
1. Throughly clean the gears and pins to be assembled in CLEAN solvent. Blow
the parts dry being careful not to touch the surfaces to be bonded with hands or
dirty rags as contamination could result.

2. Rinse pins and gears with a degreasing solvent such as Loctite Partsaver brand
Safety Solvent, trichlorethylene, or a non petroleum base lacquer thinner being
careful not to contaminate the surfaces to be bonded. Let parts dry by
evaporation. Test for clean surfaces by putting cool water on the parts. Parts
are sufficiently clean if the water covers*the part “in a filmi” tf water puddles
or forms beads resulting in dry spots, use fresh solvent and reclean and let dry.

3. Coat surfaces to be bonded on both pins and gears with a thin film of Loctite
Locquic Primer T and allow to dry.

4. Heat the-gears to 300-350°F (149-177°C). This may be done [In an ovenor by

placing the gears on a stee! plate and applying heat to the underside of the plate
with an oxy-acetylene torch. When using the plate and torch the gears must be
turned periodically to assure the temperature will be uniform through-out the gear.
The temperature of the gears may be checked with “Temp-Sticks"'.

5. Install bearings in the side of the planet carrier with the "cast in'' retainer.
Position the planet carrier with the installed bearings down and shim-up under
the bearings so that the pin will not drop past the end of the bearing when
assembled. Do Not pass Loctite coated area on pins through the bearings.

6. Apply a thin coating of Loctite "Retaining Compound #35'' (green in color) to

the primed pins in the area to be covered by the gear. Be careful not to
contaminate surface to be bonded.

7. Remove one heated gear from the oven or plate and position it in the planet
carrier so that the bore of the gear and bearing are in line. Then quickly drop
a coated pin through the gear and bearing. Make sure the pin does not protrude
past the end of the bearing. Repeat this step for each remaining gear.

8. Let the assembties cool completely. Then install the remaining bearings
being careful not to misatign them as this could cause damage to the bearings.

FORM 64-4
 Sales & Service

~ bulletin
{ Gainesville Plant
National Hydraulic Pedestal Cranes
Windshield Wiper Air Motors
Pedestal Crane Service Bulletin No. 10
September 1979

The air motor currently used to power windshield wipers on National pedestal cranes has been discontinued by the
manufacturer. The installation of the replacement air motor requires only minor modifications to the operator's cab. However,
the replacement motor requires several parts not required on the original motor.

The figures on the reverse side of this page and parts list below should be retalned as the partslist for the replacementalr
motor and associated components. The motor and components are avallable in a kit. To replace the top alr powered wiper on
all OS-105, OS-435 and OS-215 models, order kit part number G-X16-2101-TOP. To replace the front wiper on all OS-105
models and all OS-435 and OS-215 models with serial numbers above 230, order kit part number G-X16-2101-FRP. To replace
the front wiper on all OS-215 and OS-435 models with serial numbers 230 and below, order kit part number G-X-16-2101-FRT.

NOTE: Electrically powered windshield wipers can be replaced by the above kits provided new arms (part number 7800020)
and new blades (part number 7801171 [18] for front windshield or part number 7801176 [18"] for top windshield) are ordered in
addition to the kits. Copies of drawing G-X16-2101 can be provided upon request to assist with the installation of the kits.

REC'D.
ITEM PART NUMBER OESCRIPTION -TOP -FRP -FAT

1 G-7800023-001 0 1 0
2 G-7800023-002 9 1 0
3 G-7800023-003 0 1 0
4 G-7800023-004 0 1 0
5 G-7800023-005 0 1 Q
6 G-7801173 0 1 o
7 G-7802337 8 ° 2
8 G-7812050-001 1 1 1
9 G-7812050-002 VALVE........ 1 1 1
10 G-7815244-001 PLATE, (Short) ... 1 Q Q
Ww G-7815244-002 PLATE, (Medium). 0 1 0
12 G-7815244-003 PLATE, (Long)..... 9 9 1
13 G-7818350-001 SHAFT, (Short).... 1 0 0
14 G-7818350-002 SHAFT, (Medium) 0 1 0
15 G-7818350-003 SHAFT, (Long) .. ° QO 1
16 6300001 NUT, #10-24........... 2 2 4
“47 6806001 GOUPLING, 1/8” NPT ..........-.. 1 9 1
“18 6806002 COUPLING, 1/4” NPT ...... 0... eee 1 0 1
19 6817001 NIPPLE, 1/8” NPT ... 1 1 0
20 7051079-01 SCREW, #8-32 x 3/4” . Qo 2 0
at 7053092-13, SCREW, #10-24 x 3/4” 2 2 4
22 7619025 WASHER, #10 Lock ...... 2 2 4
23 7804220 ELBOW 1 1 2
24 7802477 CONNECTOR .. 3 2 2
25 7819106-0 TUBING ............ ¥ v 10°
26 Not Suppiled Fabricate as required... 0 0 1.
27 Not Supplied Fabricate as required ... 9 0 2

*Not Shown

NATIONAL SUPPLY COMPANY «© DIVISION OF ARMCO

 PREVIOUS ARM
PREVIOUS BLADE

=e
———
°
un
m
4
=z

)
ABOVE, RIGHT_
OF OPERATOR

G-X16-2101 -FRP G-X16-2101-FRT

 Sales & Service

_ b Ul | | eti ni National Hydraulic Pedestal Cranes

Gainesville Plant Hydraulic Pump and Motor Repair
Pedestal Crane Service Bulletin No. 9
dune 1979

The hydraulic pumps and motors used for the holst and swing functions of NATIONAL’s OS-435 (with single pinion swing
drive), OS-215, OS-105 and H-65A cranes require special techniques and equipment to be properly remanufactured. Repairs
not requiring the removalof the housing end capor front cover may be undertaken in the field by a consientious mechanic.
However, repairs requiring the removalof the housing end cap orfront cover should be referred to a competent representative
of the hydraulic unit manufacturer. Partial or complete repairs to the rotating components are no longer recommended to be
performedin the field. NOTE: Replacementunits on-handwill permit a change out and repair program which minimizes the
time the crane is out of service.

The following table is a guide to identify and labe! pumps and motors to have them remanufactured. CAUTION: Pumps and
motors should always be labeled with current identifying numbers. Additional information is available on request.

MODEL OS-435
UNIT. NSCO PART NO. SUNSTRAND MODEL NO.
Main/Whip Pump 1612927 26-2014
Boom Pump (Thru S/N 193) 1612927 26-2014
Boom Pump (Above S/N 193) 1613930 26-2020
Swing Pump 1612928 23-2136
Main or Whip Motor 1612204 26-4009
Boom Motor 1612205 26-3007
Swing Motor 1612206 24-3021
MODEL OS-215
UNIT NSCO PART NO. DYNAPOWERPARTNO. (DRAWING NO.}
Main/Whip & Boom Pump 7815256 895427 /892913 (825400/822902)
Swing Pump 7815255 895169/892806 (825160/822565)
Boom Motor* 1607259* 896421-50-15 (821851)
Main or Whip Motor * 1607289° 896421-50-15 (821851)
Swing Motor 7812039 896108-45 (826101)
MODEL OS-105
UNIT NSCO PART NO. SUNDSTRAND MODEL NO.
Main/Whip Pump 7815258 23-2144
Boom & Swing Pump 7815257 22-2134
Hoist Motors 7812044 24-3036
Swing Motor 7842042 23-3056
MODEL H-65A
UNIT NSCO PART NO. PART OR MODEL NO. (DRAWING NO.}
Main Pump ** 1600298°* Dynapower 896423-40/892902
{811901 Sht. 1 of 2)
Swing Pump 1600913 Oynapower 896068/892629 (816075)
Charge Pump 1600912 Hydreco 3035A1A1AR
Two Speed Hoist Motor 1600594 Dynapower896437-40/898902
(811904 Sht. 1 of 2)
Single Speed Hoist Motor 1600550 Dynapower896420 (811859 Sht. 1 of 2)
Swing Motor TE00353 Sunstrand 21-3031

NOTE:
* The boom, main and whip hoists of the OS-215 all use the same basic motor (NSCO part no. 7812040). This motor has
oo. the high pressure relief valve cartridges exchanged to be made into a 1607259 motor (boom hoist motor) and the
modifications shown on page B-4 of the Jan. 1975 OS-215 parts list to be made into a 1607289 motor (main and whip
hoist motor).

** A 1600298 main pump requires the modifications shown on page B-17 of the February 1976 H-65Aparts list before being
placed into service.

NATIONAL SUPPLY COMPANY * DIVISION OF ARMCOINC. ARMCO

Sales & Service

bulletin National Hydraulic Pedestal Crane

Gainesville Plant OS-105 Boom Hoist Winch

PEDESTAL CRANE SERVICE BULLETIN NO. 11

AUGUST 1980

INSTALLATION OF A SPACER BETWEEN THE BOOM HOIST WINCH

LEFT HAND END PLATE AND THE BOOM HOIST WINCH HOUSING

This service bulletin applies to 05-105 cranes up through and including

serial number G~266.

In order to eliminate excessive bearing preloading and prevent premature

boom hoist winch support bearing failure a spacer must be installed
between the boom hoist winch left hand end plate and the boom hoist winch
housing.

The procedure for installing the spacer is as follows:

1. Place the boom in its rest and remove the tension from the
boom hoist lines.
2. Release the tension on the boom hoist brake by turning the
brake adjusting nut counterclockwise.
Support the weight of the left hand end (cab side) of the
Ww

winch.
Remove the dipstick and disconnect the hose to the breather.
wrk

Remove the six 3/4'' bolts holding the left hand end plate to
the winch housing and remove the left hand end plate.
Re-assemble in the reverse order, installing the spacer (NSC part
no

number G-1617525) and longer cap screws (NSC part number 7000441-11)
as shown on the following page. New lock washers should also
be fitted (NSCO part number 7619066).
7. Re-adjust the boom hoist brake (see Operator's Manual for procedure).

The parts will be supplied at no cost. However, it will be necessary to

issue a purchase order to the National Supply Company for the following pieces.

QTY. NSC PART NUMBER DESCRIPTION

] G-1617525 Spacer

6 7000441-11 Screw, Hex Head Cap

3/4"! x 2-1/4", Grade 5,
Cadmium Plated

6 7619066 Washer, 3/4'' Regular

Spring Lock, Cadmium
Plated

NATIONAL SUPPLY COMPANY @ ~—_—dIVISION OF ARMCO ARMCO

 é

7619066
WASHER \

a,

7000441— i
SCREW
 Sales & Service

~ bulletin
Gainesville Plant
Inspection of Hoist Brake Linkage Pin 1610832
Model OS-215 and Model OS-435
Pedestal Crane Service Bulletin No. 12
September 1980

A review of the design of the hoist brake linkage pin, 1610832 (shown in the figure below), has revealed the need to
replace a numberof pins currently in service. An analytical and experimental examination indicates an abnormally
high unit stress can readily occur in the pins with a nominal center diameter of 1-7/8 inches (47.6 mm). All three
1610832 pins used on each National model OS-435 and model OS-215 crane should beinspected. If the pins are of the
August 1975 design, with a nominal diameter of 1-7/8 inches (47.6 mm), the pins should be replaced as soon as
possible. Replacement pins of an improved design and higher strength material and new support bearing inner races
will be provided at no cost. However,it will be necessary to issue a purchase order to National Supply Company and
specify the quantity of replacement 1610832 pins required. Two new bearing inner races, part number ZB-1771, should
be ordered for each pin ordered.

If the inspection of the pins reveals pins of a nominal diameter of 2 inches (50.8 mm), the pins maybeleft in service
provided special attention is given not to overtighten the linkage when adjusting the brakes. A brake linkage is
properly adjusted when the brake cylinder rod travels approximately 1/4” (6.3 mm)from the brake “‘on" position to the
brake ’’off’’ position.

Note: Total brake cylinder rod travel is limited to 1-1/8 inches (28.6 mm).

WARNING: Overtightening of the brake linkage can cause excessive stresses in the 1610832 pins which are not of the
improved design and higher strength material.

ADJUSTING NUT NOMINAL DIAMETER, 2°

1610832 PIN BRAKE LINKAGE YOKE C)

INITIAL DESIGN

BEARING INNER NOMINAL DIAMETER, IZ”

RACE [
“EO ©)

: f
4 AUGUST 1975 DESIGN
‘CYUNDER ROD
| promnas DIAMETER, 2°

BRAKE BAND BRAKE CYLINDER (OC)

_ t
REPLACEMENT DESIGN

NN BRAKE LINKAGE LT-160315,

—9
ARMCO
NATIONAL SUPPLY COMPANY e_—sé@DIVISION OF ARMCO
Vv
NATIONAL-OILWELL
TIVi FICE: MANUFACTURING
HOUSTON HEADQUARTERS HOUSTON PLANT MCALESTER WORKS
, 5555 San Felipe 11919 FM 529 Road 501 N. George Nigh Expressway
Houston, TX 77056 Houston, TX 77041 tHwy. 69 Bypass North)
P.O. Box 4638 PHONE: 713/849-8000 McAlester, OK 74501
Houston, TX 77210-4638 PHONE: 918/423-8000
PHONE: 713/960-5100
Fax: 713/960-5428 KILGORE FAs CENTER
East Texas Fabrication Center
104 Powderhorn Road
Kilgore, TX 75662
PHONE: (903) 983-1505

SALES OFFICES
ANCHORAGE, AK DENVER, CO MIDLAND, TX Rio VISTA, CA
PHONE: 907/522-3727 PHONE: 303/298-8112 PHONE: 915/684-5576 PHONE: 707/374-2580
BAKERSFIELD, CA HOUSTON, TX NEw ORLEANS, LA TULSA, OK
PHONE: 805/589-5750 PHONE: 713/960-5100 PHONE: 504/586-1301 PHONE: 918/492-5580
CasPEeR, WY LONG BEACH, CA Ovessa, TX VENTURA, CA
PHONE: 307/235-2751 PHONE: 310/998-4900 PHONE: 915/332-9472 PHONE: 805/653-6670
DaLtas, TX Los ANGELES, CA OKLAHOMACITY, OK WICHITA, KS
PHONE: 214/265-8840 PHONE: 310/802-2638 PHONE: 405/632-7600 PHONE: 316/262-4557
WILLISTON, ND
PHONE: 701/572-3781

UNITED STATES STORES

ANCHORAGE, AK CHEYENNE WELLS, CO GILLETTE, WY LAUREL, MS
PHONE: 907/522-3727 PHONE: 719/767-8801 PHONE: 307/682-9337 PHONE: 601/649-8671
ANDREWS, TX CLAYCITY, IL GREAT BEND, KS LIBERAL, KS
PHONE: 915/523-2954 PHONE: 618/676-1653 PHONE: 316/793-8433 PHONE: 316/642-2518
BaKER, MT CORPUS CHRISTI, TX HARTSHORNE, OK LINDSAY, OK
PHONE: 406/778-3378 PHONE: 512/883-0871 PHONE: 918/297-2578 PHONE: 405/756-3147
BAKERSFIELD, CA CorRTEZ, CO Harvey, LA LONG BEACH, CA
PHONE: 805/589-5750 PHONE: 303/565-8428 PHONE: 504/366-6426 PHONE: 310/988-4900
BiG LAKE, TX CROSSVILLE, tL HENDERSON, KY MCALLEN, TX
PHONE: 915/884-2556 PHONE: 618/966-2165 PHONE: 502/826-5774 PHONE: 210/686-4329
Bia PINEY, WY Cut BANK, MT Hoses, NM MccooK, NB
PHONE: 307/276-3916 PHONE: 406/873-2227 PHONE: 505/393-3138 PHONE: 308/345-2210
BIG SPRING, TX DENVER CITY, TX HomINy, OK MOBILE, AL
PHONE: 915/267-2539 PHONE: 806/592-2161 PHONE: 918/885-2108 PHONE: 205/479-0100
BILLINGS, MT DICKINSON, ND HOUMA, LA MOHALL, ND
PHONE: 406/252-7771 PHONE: 701/227-0861 PHONE: 504/872-6876 PHONE: 701/756-6834
BRADFORD, PA ELK CITY, OK Houston, Tx MONAHANS, TX
PHONE: 814/368-4127 PHONE: 405/225-7150 PHONE: 713/675-6661 PHONE: 915/943-4351
BROOKHAVEN, MS ELLINWOOD, KS KALKASKA, Mt MORGANCITY, LA
PHONE: 601/833-6511 PHONE: 316/564-2320 PHONE: 616/258-8712 PHONE: 504/384-0810
BRYAN, TX EVANSTON, WY KENAL, AK MT. CARMEL, IL
PHONE: 409/778-1585 PHONE: 307/789-2034 PHONE: 907/283-6080 PHONE: 618/262-4148
CAMERON, LA FT LUPTON, CO KENEDY, TX MT. PLEASANT, Mi
PHONE: 318/775-7078 PHONE: 303/857-6242 PHONE: 210/583-3355 PHONE: 517/773-9948
CASPER, WY FT. SMITH, AR KILGORE, TX NATCHEZ, MS
PHONE: 307/235-2751 PHONE: 501/646-1672 PHONE: 903/984-3043 PHONE: 601/446-8513
CHARLESTON, WV FREER, TX LAREDO, TX NESsCITY, KS
PHONE: 304/342-5193 PHONE: 512/394-6115 PHONE, 210/722-0581 PHONE: 313/798-3607

BC. 4/96 PRINTED W U.S.A.

JATIONAL-OILWELL
UNITED STATES STORES
NEW IBERIA, LA PENNSBORO, WV Rock spriNGs, WY VENICE, LA
PHONE: 318/364-7251 PHONE: 304/659-2993 PHONE: 307/362-3745 PHONE: 504/534-9671
ODESSA, TX PLAINVILLE, KS SABINE Pass, TX VENTURA, CA
PHONE: 915/337-3541 PHONE: 913/434-4624 PHONE: 409/971-2449 PHONE: 805/653-'e666
OKLAHOMACITY, OK POWELL, WY SHIDLER, OK VERNAL, UT
PHONE: 405/632-7600 PHONE: 307/754-2294 PHONE: 918/793-2781 PHONE: 801/789-1104
PAINTSVILLE, KY PUNXSUTAWNEY, PA SHREVEPORT, LA VICTORIA, TX
PHONE: 606/789-3791 PHONE: 814/938-3060 PHONE: 318/221-5214 PHONE: 512/575-2345
PAMPA, TX RATLIFF CITY, OK SNYDER, TX WATFORDCITY, NO
PHONE: 806/669-7321 PHONE: 405/856-3264 PHONE: 915/573-2663 PHONE: 701/842-2902
PEARSALL, TX RIVERTON, WY SUNDOWN, TX WILLISTON, ND
PHONE: 210/334-8961 PHONE: 307/856-6533 PHONE: 806/229-3701 PHONE: 701/572-3781
WOODLAND, CA
PHONE: 916/662-1034

INTERNATIONAL DISTRIBUTORS

NATIONAL-OILWELL CANADA LTb. NATIONAL-ONLWELL NATIONAL-OILWELL, INT'L

CANADA De VENEZUELA,C.A. UNITED STATES
Main Sates OFFICE: HEADQUARTERS: MAIN SALES OFFICE:
2300 Bow VALLEY Square Ill APARTADO 1146, 4001-A 5555 SAN FELIPE
255 - 5TH AVENUE S.W. CALLE 158 CON AVENIDA 68 Houston, TX 77056
CALGARY, ALBERTA AMPLIACION ZONA INDUSTRIAL P.o. BOX 4638
CANADA T2P 3G6 MARACAIBO, EDO, ZULIA, HOUSTON, TX 77210-4638
PHONE: (403) 294-4500 VENEZUELA PHone: 713/960-5100
FAX: (403) 262-9166 PHONE: (011-58-61) 361850 Fax: 713/960-5428
FAX: {011-58-61) 362561

NATIONAL-OiLWELL (U.K.) LTD. NATIONAL-OILWELL PTE. Lp.

Macuinery Oo AST ASIA SALES OFFICE:
BapdENToY ROAD MACHINERY AND SERVICE CENTRE
BADENTOY INDUSTRIAL PARK 12 GUL AVENUE, JURONG
PORTLETHEN, ABERDEEN SINGAPORE 2262
SCOTLAND agi 4va PHone: (011-65) 861-1566
PHONE: (011-44-1224) 783-060 Fax: (011-65) 861-0796
Fax: (011-44-1224) 783-266

PANATIONAE
a
ie CHWERI
NATIONAL-OILWELL
P.O. BOX 4638
HOUSTON, TEXAS 77210-4638

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