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OPERATORS MANUAL

FOR
PIXEF 215
TIL Limited and our distributor network want to ensure your satisfaction with our products and customer support
services. Your local distributor is the best equipped and most knowledgeable resource available for help with
parts, service, and warranty issues. They have the facilities, parts, factory-trained personnel, and on-hand
information needed to assist you in a timely manner.

We request that you first contact your local distributor for assistance with problems. If you-and your local
distributor-determine that you do need factory assistance, please have your local distributor's service management
section coordinate the factory assistance contact for you.

NOTICE TO OWNER / USER

Should this crane become involved in an accident,


please contact your local TIL distributor immediately
and relate details of the incident so he can notify
TIL LIMITED.

If the distributor is unknown and/or cannot be reached,


NOTICE TO OWNER / USER
please contact:

TIL LIMITED
1, Taratolla Road, Garden Reach,
Kolkata 700 024, West Bengal
Telephone: + 91 33 2469 3732-6 / 6497 / 3983,
+ 91 33 6633 200 / 2845
Facsimile: + 91 33 2469 2143 / 3731
Toll Free No. : MHS Product Support : 1800 266 1535
Email : mhg_er@tilindia.com
FOREWORD

This handbook has been compiled to assist you in properly operating and maintaining your TIL Crane.

Before placing the crane in service, take time to thoroughly familiarize yourself with the contents of this manual. After
all sections have been read and understood, retain the manual for future reference in a readily accessible location.

The TIL Crane has been designed for maximum performance with minimum maintenance. With proper
care, years of trouble-free service can be expected.

Constant improvement and engineering progress makes it necessary that we reserve the right to make specification
and equipment changes without notice.

Engine operating procedures and routine maintenance procedures are supplied in a separate manual with
each crane, and should be referred to for detailed information.

Information in this manual does not replace state, or local regulations, safety codes, or insurance requirements.

TIL remains committed to providing reliable products that enable users and operators to safely lift and position
loads. TIL has been an industry leader in the incorporation of operational aids into the design of its
cranes. The cranes should be properly maintained and kept in good working condition. The manuals that TIL
provides that are specific for each crane and the manufacturer's manuals for the operational aids shall be followed. If
an operational aid should fail to work properly, the crane user or owner must assure that repair or recalibration is
accomplished as soon as is reasonably possible. If immediate repair or recalibration of an operational aid is not
possible and there are exceptional circumstances which justify continued short-term use of the crane when
operational aids are inoperative or malfunctioning, the following requirements shall apply for continued use or
shutdown of the crane.

1. Steps shall be taken to schedule repairs and recalibration immediately. The operational aids shall be
put back into service as soon as replacement parts, if required, are available and the repairs and
recalibration can be carried out. Every reasonable effort must be made to expedite repairs and
recalibration.

2. When a load indicator, rated capacity indicator, or rated capacity limiter is inoperative or
malfunctioning, the designated person responsible for supervising the lifting operations shall establish
procedures for determining load weights and shall ascertain that the weight of the load does not exceed the
crane ratings at the radius from the load center.
3. When a boom angle or radius indicator is inoperative or malfunctioning, the radius or boom angle shall be
determined by measurement.

4. When an anti-block device, two-blocking damage prevention or two-block warning device is


inoperative or malfunctioning, the designated person responsible for supervising the lifting operations
shall establish procedures, such as assigning an additional signal person to furnish equivalent
protection. This does not apply when lifting personnel in load-line supported personnel platforms. Personnel
shall not be lifted when anti-two block devices are not functioning properly.

5. When a boom length indicator is inoperative or malfunctioning, the designated person responsible for
supervising the lifting operations shall establish the boom lengths at which the lift will be made by actual
measurements or marking on the boom.

6. When a level indicator is inoperative or malfunctioning, other means shall be used to level the crane.

The definitions of DANGER, CAUTION, and NOTE as used in this manual apply as follows.

DANGER
A DANGER NOTE IS USED TO EMPHASIZE THAT

IF AN OPERATION, PROCEDURE, OR PRACTICE

IS NOT FOLLOWED EXACTLY, DEATH OR INJURY

TO PERSONNEL MAY RESULT.

CAUTION
A CAUTION IS USED TO EMPHASIZE THAT IF AN

OPERATION, PROCEDURE, OR PRACTICE IS NOT

FOLLOWED EXACTLY, EQUIPMENT DAMAGE

MAY RESULT.

NOTE
A NOTE IS USED TO EMPHASIZE AN IMPORTANT PROCEDURE OR CONDITION
TABLE OF CONTENTS

PAGE

Section 1 - INTRODUCTION 1-1

Section 2 - SAFETY PRECAUTIONS 2-45

Section 3 - CAB CONTROLS AND INDICATORS 46-67

Section 4 - OPERATING PROCEDURES 68-90

Section 5 - LUBRICATION 91-102

Section 6 - MAINTENANCE / SERVICING INSTRUCTION 103-131


PIXEF 215 INTRODUCTION

SECTION 1
INTRODUCTION

GENERAL

NOTE

Throughout this handbook, reference is made to left, front, and


rear when describing locations. These reference locations are
to be considered as those viewed from the operator's seat with the
superstructure facing forward over the front of the carrier frame.

This Handbook provides important information for the operator of the Model PIXEF 215..

The Pick N Carry crane incorporates an all welded steel frame, using planetary drive axles to provide two-wheel
drive. Axle steering is accomplished utilizing hydraulic steer cylinders. The engine is mounted at the rear of the
crane and provides motive power through a four speed forward and three speed reverse transmission. Hydraulic,
double box, sliding beam outriggers are integral with the frame.

The carrier frame incorporates an integral fifth wheel, to which the rear axle is mounted, to provide axle oscillation.
Axle oscillation lockout is automatic when the superstructure rotates from the travel position.

The superstructure is capable of 370 non continuous rotation in either direction. All crane functions are controlled
from the fully-enclosed cab mounted on the front of the chassis. The PIXEF 215 model is equipped with a
three-section, chain synchronized boom. Additional reach is obtained by utilizing a Lattice boom extension.
Lifting is provided by a main hoist and an optional auxiliary hoist.

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PIXEF 215 SAFETY PRECAUTION

SECTION 2
SAFETY PRECAUTION

GENERAL
NOTE

Illustrations have been included in this


section to emphasize certain proper and
improper points ; READ AND FOLLOW
PRINTED INSTRUCTIONS.

It is impossible to compile a list of safety precautions covering all situations. However, there are basic principles
that MUST be followed during your daily routine. Safety is YOUR PRIMARY RESPONSIBILITY, since any
piece of equipment is only as safe AS THE PERSON AT THE CONTROLS.

With this thought in mind, this information has been provided to assist you, the operator, in promoting a safe
working atmosphere for yourself and those around you. It is not meant to cover every conceivable
circumstance which could arise. It is intended to present basic safety precautions that should be followed in daily
operation.

You, the operator, are the only one who can be relied upon to assure the safety of yourself and those
around you. Be a PROFESSIONAL and follow the RULES of SAFETY.

REMEMBER, failure to follow just one safety precaution could cause an accident that results in death or serious
injury to personnel or damage to equipment. You are responsible for the safety of yourself and those around
you.

IMMEDIATELY report all accidents, malfunctions, and equipment damages to your local TIL distributor. Following
any accident or damage to equipment, the local TIL distributor must be immediately advised of the incident and
consulted on necessary inspections and repairs. Should the distributor not be immediately available, contact should
be made directly with TIL LIMITED. The crane must not be returned to service until it is thoroughly inspected for any
evidence of damage. All damaged parts must be repaired or replaced as authorized by your local TIL distributor and
/ or TIL LIMITED.

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PIXEF 215 SAFETY PRECAUTION

OPERATOR'S INFORMATION

You must READ and UNDERSTAND the Operator's and Safety Handbook and the Load Chart before
operating the crane. You must also VIEW and UNDERSTAND the safety video titled "The Real Key to Crane Safety"
supplied with your new TIL product. The handbook and Load Chart must be readily available to the operator at all
times and must remain in the cab while the crane is in use.

Ensure that all personnel working around the crane are thoroughly familiar with safe operating practices. You
must be thoroughly familiar with the location and content of all placards and decals on the crane. Decals provide
important instructions and warnings and must be read prior to any operational or maintenance function. You
must be familiar with the regulations and standards governing cranes and their operation. Work practice
requirements may vary slightly between government regulations, industry standards, and employer policies
so a thorough knowledge of all such relevant work rules is necessary.

DO NOT REMOVE the Load Chart, this Operator's and Safety Handbook, or any decal from this crane. Inspect the
crane every day (before the start of each shift). Ensure that routine maintenance and lubrication are being dutifully
performed. Dont operate a damaged or poorly maintained crane. You risk lives when operating faulty machinery
including your own.

Allow No One other than the operator to be on the crane while the crane is functioning or moving, unless they are
seated in a two-man cab.

3
PIXEF 215 SAFETY PRECAUTION

OPERATOR'S QUALIFICATIONS

An untrained operator subjects himself and others to death or serious injury.

YOU MUST NOT OPERATE THIS MACHINE UNLESS:-

You have been trained in the safe operation of this machine.

You read, understand, and follow the safety and operating recommendations contained in the
manufacturer's manuals, your employer's work rules, and applicable government regulations.

You are sure the machine is operating properly and has been inspected and maintained in accordance with
the manufacturer's manuals.

You are sure that all safety signs, guards, and other safety features are in place and in proper condition.

4
PIXEF 215 SAFETY PRECAUTION

Do not attempt to operate the crane unless you are trained and thoroughly familiar with all operational functions.
Controls and design may vary from crane to crane; therefore, it is important that you have specific training on the
particular crane you will be operating.

Training is ESSENTIAL for proper crane operation. Never jeopardize your own well being or that of others by
attempting to operate a crane on which you have not been trained.

You must be mentally and physically fit to operate a crane. Never attempt to operate a crane while under the
influence of medication, narcotics, or alcohol. Any type of drug could impair physical, visual and mental reactions,
and capabilities.

CRANE STABILITY / STRUCTURAL STRENGTH

To avoid death or serious injury, ensure that the crane is on a firm surface with load and crane's configuration within
capacity as shown on the crane's Load Chart and notes.

Do not lift loads unless the outriggers are properly extended and the crane leveled. On models equipped with
outriggers that can be pinned at the mid-extend position, the outriggers must also be pinned when operating
from the mid-extend position.

This crane should have a functional load moment indicator and control lock-out system. Test daily for proper
operation. Never interfere with the proper functioning of operational aids or warning devices. Before swinging the
superstructure over the side when the outriggers are retracted, check the load chart for backwards stability.

Long cantilever booms can create a tipping condition when in an extended and lowered position. Retract the boom
proportionally with reference to the capacity of the applicable Load Chart.

5
PIXEF 215 SAFETY PRECAUTION

Check crane stability before lifting loads. Ensure the outriggers (or tires if lifting on rubber) are firmly positioned on
solid surfaces. Ensure the crane is level, brakes are set, and the load is properly rigged and attached to the hook.
Check the Load Chart against the weight of the load. Lift the load slightly off the ground and recheck the
stability before proceeding with the lift. Determine the weight of the load before you attempt the lift. Ensure all
pins and floats are properly installed and outrigger beams are properly extended before lifting on outriggers.
Unless lifting within On Rubber capacities, outrigger beams must be properly extended and jack cylinders
extended and set to provide maximum leveling of the crane. Tires must be clear of the ground before lifting on
outriggers. Remove all weight from tires before lifting on outriggers.

Use adequate cribbing under outrigger floats to distribute weight over a greater area. Check frequently for settling

6
PIXEF 215 SAFETY PRECAUTION

Carefully follow the procedures in this handbook when extending or retracting the outriggers. Death or serious
injury could result from improper crane setup on outriggers.

Be sure the outriggers are properly extended and set, and the crane is level for operation on outriggers. All
outrigger beams must be equally extended position before beginning operation.

The operator must select the proper Load Chart and Load Moment Indicating (LMI) System program for the
out KEEP THE BOOM SHORT. Swinging loads with a long line can create an unstable condition and possible
structural failure of the boom.

7
PIXEF 215 SAFETY PRECAUTION

LOAD CHARTS

Load Charts represent the absolute maximum allowable loads, which are based on either tipping or structural
limitations of the crane under specific conditions. Knowing the precise load radius, boom length, and boom
angle should be a part of your routine planning and operation. Actual loads, including necessary allowances,
should be kept below the capacity shown on the applicable Load Chart.

You must use the appropriate Load Chart when determining the capability of the crane in the configuration required
performing the lift.

Maximum lifting capacity is available at the shortest radius, minimum boom length, and highest boom angle. Do not
remove the Load Charts from the crane.

WORK SITE

Prior to any operation, you must inspect the ENTIRE work site, (including ground conditions) where the
crane will travel and operate. Be sure that the surfaces will support a load greater than the crane's weight and
maximum capacity.

Barricade the area where the crane is working and keep all unnecessary personnel out of that area. Use caution
when operating in the vicinity of overhanging banks and edges.

Be aware of all conditions that could adversely affect the stability of the crane.

Wind can have a significant effect on loads that may be lifted by a crane. Wind forces act differently on a crane
depending upon the direction from which the wind is blowing (e.g., wind on the rear of the boom can result in
decreased forward stability, wind on the underside of the boom can result in decreased backward stability, wind on
the side of the boom can result in structural damages, etc.). To assist you in determining prevailing wind conditions,
refer to the "WIND VELOCITY CHART".

8
PIXEF 215 SAFETY PRECAUTION

LIFTING OPERATIONS

If the boom extension, jib, or auxiliary boom nose is to be used, ensure the electrical cable and the weight for the
anti-two-block switch are properly installed and the LMI is programmed for the crane configuration. Refer to the LMI
handbook supplied with the crane.

Before lifting, position the crane on a firm surface, properly extend and set the outriggers, and level the
crane.

If the boom extension or auxiliary boom nose is to be used, you must ensure that the cable for the LMI system is
properly connected at the junction box located on the boom nose.

Depending on the nature of the supporting surface, adequate cribbing may be required to obtain a larger bearing
surface.

DO NOT OVERLOAD THE CRANE by exceeding the capacities shown on the appropriate Load Chart. Death
or serious injury could result from the crane tipping over or failing structurally from overload.

Do not rely on the crane's tipping to determine your lifting capacity.

If you should encounter a tipping condition, immediately lower the load with the hoist line and retract or elevate the
boom to decrease the load radius. Never lower or extend the boom, this will aggravate the condition.

Be sure the load is properly rigged and attached. Always determine the weight of the load before you attempt to lift it
and remember that all rigging (slings, etc.) and lifting devices (hook block, jib, etc.) must be considered part of the
load.

Measure the load radius before making a lift and stay within approved lifting areas based on the range
diagrams and working area diagrams on the crane's load chart.

9
PIXEF 215 SAFETY PRECAUTION

Verify the crane's capacity by checking the Load Chart against the weight of the load. Then, lift the load slightly at
first to ensure stability before proceeding with the lift.

Always keep the load as near to the crane and as close to the ground as possible.

The crane can tip over or fail structurally if: -

The load and crane's configuration is not within the capacity as shown on the applicable load rating chart
and notes.

The ground is soft and/or the surface conditions are poor.

Outriggers are not properly extended and set. On models equipped with outriggers that can be pinned at
the mid-extend position, the outriggers must also be pinned when operating from the mid-extend position.

Cribbing under the outrigger pads is inadequate.

The crane is improperly operated.

Wind forces can exert extreme dynamic loads. TIL recommends that a lift not be made if the wind can cause a loss
of control in handling the load. TIL recommends if the wind speed (velocity) is between 32 km/h (20 mph) to 48
km/h (30 mph), that the load capacities shall be reduced to account for the size and shape of the load and the
wind direction in relation to the machine for all boom, boom extension, and jib lengths. Further, operation of
the crane in wind velocities over 48 km/h (30 mph) is not recommended. To assist you in determining
prevailing wind conditions, refer to the "WIND VELOCITY CHART".

The crane cab is equipped with a sight level bubble that should be used to determine whether the crane is level. The
load line can also be used to estimate the levelness of the crane by checking to be sure it is in-line with the center of
the boom at all points on the swing circle.

Use tag lines whenever possible to help control the movement of the load.

10
PIXEF 215 SAFETY PRECAUTION
P

When
n lifting load
ds, the cran
ne will lean
n toward the boom an
nd the load will swing out, increassing the load
d
radius
s. Ensure the
e load capaciity chart is no
ot exceeded when this oc
ccurs.

Be su
ure the hoist line is vertica
al before liftin ubject the crane to side loading. A sid
ng. Do not su de load can tip
t the crane
e
or cau
use it to fail structurally.
s

ot strike any obstruction with the boo


Do no om. If the bo
oom should accidentally
a contact an object,
o stop immediately..
Inspect the boom. Remove the
e crane from service if the
e boom is da
amaged.

Neverr push or pull with the cra


ane boom.

Avoid sudden starrts and stops


s when moviing the load. The inertia and an incre
eased load ra
adius could ttip the crane
e
over or
o cause it to
o fail structura
ally.

WIND VEL
LOCITY CH
HART

Load Chart capacities are base


ed on freely suspended lo
oads. Do nott pull posts, p
pilings, or submerged artiicles. Be
sure the load is not frozen or otherwise
e attached tto the groun
nd before liftin
ng.
PIXEF 215 SAFETY PRECAUTION

Use only one hoist at a time when lifting loads.

Always use enough parts-of-line to accommodate the load to be lifted. Lifting with too few parts-of-line can result in
failure of the wire rope.

Never operate the crane with less than two wraps of wire rope on the hoist drum.

COUNTERWEIGHT

On cranes equipped with removable counterweights, ensure the appropriate counterweight sections are
properly installed for the lift being considered.

To reduce the crushing hazard and to prevent death or serious injury, always clear all personnel from the
counterweight and superstructure area before moving the counterweight or rotating the superstructure.

Do not add material to the counterweight to increase capacity.

MULTIPLE CRANE LIFTS

Multiple crane lifts are not recommended.

Any lift that requires more than one crane must be precisely planned and coordinated by a qualified engineer.

12
PIXEF 215 SAFETY PRECAUTION

If it is necessary to perform a multi-crane lift, the operator shall be responsible for assuring that the
following minimum safety precautions are taken.

1. Secure the services of a qualified engineer to direct the operation.

2. Use one qualified signal person.

3. Coordinate lifting plans with the operator, engineer, and signal person prior to beginning the lift.

4. Communication between all parties must be maintained throughout the entire operation. If possible,
Provide approved radio equipment for voice communication between all parties engaged in the lift.

5. Use cranes and rigging of equal capabilities and use the same boom length.

6. Use outriggers on cranes so equipped.

7. Be certain cranes are of adequate lifting capacity.

8. Calculate the amount of weight to be lifted by each crane and attach slings at the correct points for proper
weight distribution.

9. Ensure the load lines are directly over the attach points to avoid side loading and transfer of loading from
one crane to the other.

10. DO NOT TRAVEL. Lift only from a stationary position.

13
PIXEF 215 SAFETY PRECAUTION

LOAD MOMENT INDICATING (LMI) SYSTEM

The LMI system is an electronic safety control system designed to alert the operator of impending capacity limits
when the system has been properly preset by the crane operator. The control panel is mounted on the instrument
panel in the cab. When an overload condition is sensed, the LMI system provides the operator with a visual and
audible warning, and locks out the control levers to prevent lowering the boom, extending the boom, raising the hoist
cables or slew operation. Anti-two block (optional) devices are also incorporated into the system to prevent the
hook block from coming into contact with the boom nose or jibs. This condition will also cause a lockout of the above
mentioned control functions. Boom angle, length and rotation angle indication is provided on the control panel. The
details of LMI are given in separate manual.

ANTI-TWO-BLOCK SYSTEM (OPTIONAL)

The anti-two-block system provides a warning to the operator of an impending two block condition. The system
consists of anti-two-block switch connected to load moment indicator system. The switches are held in the
closed position by a weight suspended on a chain from the switch. The closed switch maintains the relay
energized, which silences the buzzer. As the hook block comes closer to the boom tip, the weight is contacted
and the switch is allowed to spring open. This action de-energizes the relay, which sounds the warning buzzer.

LOAD MOMENT INDICATOR (LMI) SYSTEM

The Load Moment Indicator (LMI) is an electro-mechanical sensing system designed to alert the crane operator of
impending capacity when the system has been properly preset by the operator. The control panel is mounted in
the dashboard of the operator's cab. When an overload condition is sensed, the system provides the operator with a
visual and audible warning, and locks out the control levers to prevent lowering the boom, extending the
boom, or raising the main or auxiliary hoist cables. In addition to the audible warning in the cab, an audible warning
alarm is also mounted in the vicinity of the boom floodlights to warn all personnel that a lockout has occurred.

Three additional features are included within the LMI system:

Swing Angle Set Limitation


Work Area Definition
Anti-two Block Device

14
PIXEF 215 SAFETY PRECAUTION

Swing Angle Set Limitation allows left and right swing angle to be preset. When the preset angle is reached, the
system will provide an audible warning.

Work Area Definition allows the crane operator to describe the crane's working area by setting up "virtual walls".
They are referred to as virtual walls because they exist in the system and are not real walls. The virtual walls
represent obstacles (i.e. buildings, towers, poles, etc.) in the crane's working range. They are set by defining points
along the outer limits of the working area with the tip of the boom. Once the working area has been defined, the
system will provide a visual and an audible warning if the boom approaches a virtual wall.

CAUTION

WHEN DEFINING VIRTUAL WALL(S), ALWAYS ALLOW


A SAFE WORKING DISTANCE TO ANY OBSTACLES.
NEVER WORK OUTSIDE A SAFE WORKING AREA
AS DEFINED BY COMMON PRACTICE, STANDARDS,
AND MANUALS.

WARNING

THERE ARE NO CUTOUTS ASSOCIATED WITH THE


SWING ANGLE SET LIMITATION OR THE WORK
AREA DEFINITION FEATURES.

An Anti-two Block Device is also incorporated into the system to prevent the hook block or headache ball from
coming into contact with the boom nose or boom extension. This condition will also cause a lockout of hoist up,
boom down, and telescope out, and also provide a visual and an audible alarm. Refer to the LMI Operator's
Handbook for more detailed information on the function of the LMI system.

15
PIXEF 215 SAFETY PRECAUTION

WORK ARE DEFINITON SYSTEM

You must read and understand the manufacturers Operators Handbook before operating the system. Become
familiar with all proper operating procedures and with the identification of symbol usage.

Barricade the area where the crane is working and keep all personnel out of the selected work area
definition. The work area definition system is intended as an aid to the operator. It is not a substitute for safe crane
operating practices, experience and good operator judgments.

For detailed information concerning the operation and maintenance of the Work Area Definition system installed on
this crane, refer to the load chart binder supplied with the crane.

ELECTRONIC HAZARD

16
PIXEF 215 SAFETY PRECAUTION

To avoid death or serious injury, keep all parts of this machine, the rigging, and materials being lifted at
least 6 m (20 ft) away from all electrical power lines and equipment.

Keep all personnel away from this machine if it is being operated near electrical power lines or equipment. Before
operating this crane in the vicinity of electrical power lines or equipment, notify the power utility company. Obtain
positive and absolute assurance that the power has been turned off.

This machine is NOT INSULATED. Always consider all parts of the load and the crane, including the wire rope,
hoist cable, pendant cables, and tag lines, as conductors.

Most overhead power lines ARE NOT insulated. Treat all overhead power lines as being energized unless
you have reliable information to the contrary from the utility company or owner.

The rules in this handbook must be followed at all times, even if the electrical power lines or equipment have been
de-energized.

Crane operation is dangerous when close to an energized electrical power source. Exercise extreme caution
and prudent judgment. Operate slowly and cautiously when in the vicinity of power lines.

If the load, wire rope, crane boom, or any portion of the crane contacts or comes too close to an electrical power
source, everyone in, on, and around the crane can be seriously injured or killed.

The safest way to avoid electrocution is to stay away from electrical power lines and electrical power sources.

17
PIXEF 215 SAFETY PRECAUTION

You the operator, are responsible for alerting all personnel of dangers associated with electrical power lines and
equipment. The crane is not insulated. Do not allow unnecessary personnel in the vicinity of the crane while
operating. Permit no one to lean against or touch the crane. Permit no one, including riggers and load handlers, to
hold the load, load lines, tag lines, or rigging gear.

Even if the crane operator is not affected by an electrical contact, others in the area may become seriously injured or
killed.

It is not always necessary to contact a power line or power source to become electrocuted. Electricity,
depending on magnitude, can arc or jump to any part of the load, load line, or crane boom if it comes too close to an
electrical power source. Low voltages can also be dangerous.

Thoroughly read, understand, and abide by all applicable state, and local regulations.

18
PIXEF 215 SAFETY PRECAUTION

SET UP AND OPERATION

During crane use, assume that every line is energized ("hot" or "live") and take the necessary precautions.

Set up the crane in a position such that the load, boom, or any part of the crane and its attachments cannot be
moved to within 6 m (20 ft) of electrical power lines or equipment. This includes the crane boom (fully
extended to maximum height, radius, and length) and all attachments (jibs, boom extensions, rigging, loads, etc.).
Overhead lines tend to blow in the wind so allow for lines' movement when determining safe operating
distance.

A suitable barricade should be erected to physically restrain the crane and all attachments (including the
load) from entering into an unsafe distance from electrical power lines or equipment.

Pan ahead and always plan a safe route before traveling under power lines. Rider poles should be erected on
each side of a crossing to assure sufficient clearance is maintained.

Appoint a reliable and qualified signal person, equipped with a loud signal whistle or horn and voice communication
equipment, to warn the operator when any part of the crane or load moves near a power source. This person should
have no other duties while the crane is working.

Tag lines should always be made of non-conductive materials. Any tag line that is wet or dirty can conduct
electricity.

DO NOT store materials under power lines or close to electrical power sources.

19
PIXEF 215 SAFETY PRECAUTION

ELECTROCUTION HAZARD DEVICES

The use of insulated links, insulated boom cages/guards, proximity warning devices, or mechanical limit stops
does not assure that electrical contact will not occur. Even if codes or regulations require the use of such
devices, failure to follow the rules listed here may result in serious injury or death. You should be aware that such
devices have limitations and you should follow the rules and precautions outlined in this handbook at all times even
if the crane is equipped with these devices.

Insulating links installed into the load line afford limited protection from electrocution hazards. Links are
limited in their lifting abilities, insulating properties, and other properties that affect their performance.
Moisture, dust, dirt, oils, and other contaminants can cause a link to conduct electricity. Due to their capacity
ratings, some links are not effective for large cranes and/or high voltages / currents.

The only protection that may be afforded by an insulated link is below the link (electrically downstream),
provided the link has been kept clean, free of contamination, has not been scratched or damaged, and is periodically
tested (just before use) for its dielectric integrity.

Boom cages and boom guards afford limited protection from electrocution hazards. They are designed to
cover only the boom nose and a small portion of the boom. Performance of boom cages and boom
guards is limited by their physical size, insulating characteristics, and operating environment (e.g. dust, dirt,
moisture, etc.). The insulating characteristics of these devices can be compromised if not kept clean, free of
contamination, and undamaged.

Proximity sensing and warning devices are available in different types. Some use boom nose (localized) sensors
and others use full boom length sensors. No warning may be given for components, cables, loads, and other
attachments located outside of the sensing area. Much reliance is placed upon you, the operator, in selecting and
properly setting the sensitivity of these devices.

Never rely solely on a device to protect you and your fellow workers from danger.

20
PIXEF 215 SAFETY PRECAUTION

Some variables you must know and understand are: -

Proximity devices are supposed to detect the existence of electricity and not its quantity or magnitude.

Some proximity devices will detect only alternating current (AC) and not direct current (DC).

Some proximity devices detect radio frequency (RF) energy and others do not.

Most proximity devices simply provide a signal (audible, visual, or both) for the operator and this signal must
not be ignored.

Sometimes the sensing portion of the proximity devices becomes confused by complex or
differing arrays of power lines and power sources.

DO NOT depend on grounding. Grounding of a crane affords little or no protection from electrical hazards. The
effectiveness of grounding is limited by the size of the (wire) conductor used, the condition of the ground, the
magnitude of the voltage and current present, and numerous other factors.

ELECTRICAL CONTACT

If the crane should come in contact with an energized power source, you must :-

1. Stay in the crane cab. DON'T PANIC.

2. Immediately warn personnel in the vicinity to stay away.

3. Attempt to move the crane away from the contacted power source using the crane's controls which are likely
to remain functional.

4. Stay in the crane until the power company has been contacted and the power source has been de-
energized. NO ONE must attempt to come close to the crane or load until the power has been turned off.

21
PIXEF 215 SAFETY PRECAUTION

Only as a last resort should an operator attempt to leave the crane upon contacting a power source. If it is
absolutely necessary to leave the operator station, JUMP COMPLETELY CLEAR OF THE CRANE. DO
NOT STEP OFF. Hop away with both feet together. DO NOT walk or run.

Following any contact with an energized electrical source, the local, authorized, TIL distributor must be
immediately advised of the incident and consulted on necessary inspections and repairs. Thoroughly inspect
the wire rope and all points of contact on the crane. Should the distributor not be immediately available, contact TIL
Limited. The crane must not be returned to service until it is thoroughly inspected for any evidence of damage and
all damaged parts are repaired or replaced as authorized by TIL Limited or your local TIL distributor.

SPECIAL OPERATING CONDITIONS AND EQUIPMENT

Never operate the crane during an electrical thunderstorm.

Working in the vicinity of radio frequency transmission towers and other transmission sources may cause a crane to
become "electrically charged."

When operating cranes equipped with electromagnets you must take additional precautions. Permit no
one to touch the magnet or load. Alert personnel by sounding a warning signal when moving a load. Do not allow the
cover of the electromagnet power supply to be open during operation or at any time the electrical system is
activated. Shut down the crane completely and open the magnet controls switch prior to connecting or
disconnecting magnet leads. Use only a non-conductive device when positioning a load. Lower the magnet
to the stowing area and shut off power before leaving the operator's cab.

22
PIXEF 215 SAFETY PRECAUTION

CRUSHING HAZARDS

Death or serious injury could result from being crushed by moving machinery.

Clear all personnel from the counterweight and superstructure area before removing the counterweight or rotating
the superstructure.

Barricade the entire area where the crane is working and keep all unnecessary personnel out of the work
area.

Never allow anyone to stand or work on or near the superstructure while the crane is in operation. Always barricade
the tail-swing of the rotating superstructure.

Before actuating swing or any other crane function, sound the horn and verify that all personnel are clear of rotating
and moving parts.

Watch the path of the boom and load when swinging. Avoid lowering or swinging the boom and load into ground
personnel, equipment, or other objects.

Always be aware of your working environment during operation of the crane. Avoid contacting any part of the
crane with external objects.

You must always be aware of everything around the crane while lifting or traveling. If you are unable to clearly see in
the direction of motion, you must post a look out or signal person before moving the crane or making a lift.
Sound the horn to warn personnel.

23
PIXEF 215 SAFETY PRECAUTION

Clear all personnel from the outrigger area before extending or retracting the outriggers.

Carefully follow the procedures in this handbook when extending or retracting the outriggers. Death or
serious injury could result from improper crane set up on outriggers.

Be sure the outriggers are properly extended, set and the crane is level for operation on outriggers.

24
PIXEF 215 SAFETY PRECAUTION

All outrigger beam lock pins must be engaged before operating from the close extend position.

The operator must select the proper Load Chart and LMI program for the outrigger position selected.

Only the crane operator shall occupy the crane when traveling or in operation.

Death or serious injury could result from being crushed by revolving tires.

25
PIXEF 215 SAFETY PRECAUTION

PERSONNEL HANDLING

Use of a TIL crane to handle personnel is acceptable provided:

The requirements of the applicable national, state and local regulations and safety codes are met.

A determination has been made that use of a crane to handle personnel is the least hazardous means to
perform the work.

The crane operator shall be qualified to operate the specific type of hoisting equipment used in the personnel
lift.

The crane operator and occupants have been instructed in the recognized hazards of personnel platform
lifts.

The crane is in proper working order.

The crane is equipped with a functional anti-two block device.

The crane's load capacity chart is affixed inside the crane's cab, readily accessible to the Operator. The
total weight of the loaded personnel platform and related rigging shall not exceed 50 percent of the
rated capacity for the radius and configuration of the crane.

The crane is uniformly level within one percent of level grade and located on a firm footing. Cranes with
outriggers shall have them all fully deployed following manufacturer's specifications.

The crane's Operator's And Safety Handbook and other operating manuals are inside the crane's
cab, readily accessible to the Operator.

The platform meets the requirements as prescribed by applicable standards and regulations.

For wire rope suspended platforms, the crane is equipped with a hook that can be closed and locked,
eliminating the throat opening.

The platform is properly attached and secure.

26
PIXEF 215 SAFETY PRECAUTION

To avoid death or serious injury:

NEVER use this crane for bungee jumping or any form of amusement or sport.

NEVER permit anyone to ride loads, hooks, slings or other rigging for any reason.

NEVER get on or off a moving crane.

NEVER allow anyone other than the operator to be on this crane while the machine is operating or traveling.

TIL LIMITED continues to recommend that cranes be properly maintained, regularly inspected and repaired
as necessary. TIL reminds crane owners to ensure that all safety decals are in place and legible. TIL
continues to urge TIL crane owners to upgrade their cranes with load moment indicator (LMI) and control
lever lockout systems for all lifting operations.

27
PIXEF 215 SAFETY PRECAUTION

TRAVEL OPERATION

Strictly adhere to the guidelines and restrictions in the Load Chart for pick and carry operations.

When traveling, the boom should be completely retracted and lowered to the travel position and the turntable
pin swing lock should be engaged.

Secure the hook block and other items before moving the crane.

Watch clearances when traveling. Do not take a chance of running into overhead or side obstructions.

When moving in tight quarters, post a signal person to help guard against collisions or bumping structures.

Before traveling a crane, check suitability of proposed route with regard to crane height, width, and length.

Never back up without the aid of a signal person to verify the area behind the crane is clear of obstructions and/or
personnel.

On cranes equipped with air-operated brakes, do not attempt to move the crane until brake system air pressure is at
operating level.

Check load limit of bridges. Before traveling across bridges, ensure they will carry a load greater than the crane's
weight.

If it is necessary to take the crane on a road or highway, check state and local restrictions and regulations.

Drive carefully and avoid speeding.

Stay alert at the wheel.

When parking on a grade, apply the parking brake and chock the wheels

28
PIXEF 215 SAFETY PRECAUTION

MAINTENANCE

The crane must be inspected prior to use on each work shift. The owner, user, and operator must ensure
that routine maintenance and lubrication are being dutifully performed. NEVER operate a damaged or poorly
maintained crane.

Keep the crane properly maintained and adjusted at all times. Shut down the crane while making repairs or
adjustments.

Always perform a function check after repairs have been made to ensure proper operation. Load tests
should be performed when structural or lifting members are involved.

Follow all applicable safety precautions in this handbook when performing crane maintenance as well as
crane operations.

Before crane use:

Conduct a visual inspection for cracked welds, damaged components, loose pin/bolt, and wire connections.
Any item or component that is found to be loose or damaged (broken, chipped, cracked, worn-through, etc.)
must be repaired or replaced.

Check for proper functioning of all controls and operator aids (e.g. LMI).

Check all braking (e.g. Wheel, hoist, and swing brakes) and holding devices before operation. Keep the
crane clean at all times, free of mud, dirt, and grease. Dirty equipment introduces hazards, wears-out faster,
and makes proper maintenance difficult. Cleaning solutions used should be non-flammable, non-toxic and
appropriate for the job.

ROUTINE MAINTENANCE and INSPECTION of this crane must be performed by a qualified person(s)
according to the recommendations in the TIL Crane Maintenance and Inspection Manual. Any questions
regarding procedures and specifications should be directed to the local, authorized TIL Distributor.

29
PIXEF 215 SAFETY PRECAUTION

SERVICE AND REPAIRS

Service and repairs to the crane must only be performed by a qualified person. All service and repairs
must be performed in accordance with manufacturer's recommendations, this handbook, and the service
manual for this machine. All replacement parts must be TIL LIMITED approved.

Any modification, alteration, or change to a crane which affects its original design and is not authorized and
approved by TIL LIMITED is STRICTLY PROHIBITED. Such action invalidates all warranties and makes the
owner/user liable for any resultant accidents.

Before performing any maintenance, service or repairs on the crane:

The boom should be fully retracted and lowered and the load placed on the ground.

Stop the engine and disconnect the battery.

Controls should be properly tagged. Never operate the crane if it is TAGGED-OUT nor attempt to do so until
it is restored to proper operating condition and all tags have been removed by the person(s) who installed
them.

Recognize and avoid pinch-points while performing maintenance. Stay clear of sheave wheels and holes in crane
booms.

After maintenance or repairs:

Replace all guards and covers that have been removed.

Remove all tags, connect the battery, and perform a function check of all operating controls.

Perform load tests when a structural or lifting member is involved in a repair.

30
PIXEF 215 SAFETY PRECAUTION

LUBRICATION

The crane must be lubricated according to the factory recommendations for lubrication points, time intervals, and
types. Lubricate at more frequent intervals when working under severe conditions.

Exercise care when servicing the hydraulic system of the crane, as pressurized hydraulic oil can cause
serious injury. The following precautions must be taken when servicing the hydraulic system :

1. Follow the manufacturers recommendations when adding oil to the system. Mixing the wrong fluids could
destroy seals, causing machine failure.

2. Be certain all lines, components, and fittings are tight before resuming operation.

3. When checking for suspected leaks, use a piece of wood or cardboard and wear appropriate personal
protective equipment.

4. Never exceed the manufacturer's recommended relief valve settings.

TIRES

Inspect the tires for nicks, cuts, embedded material, and abnormal wear.

Ensure all lug nuts are properly torque.

Ensure pneumatic tires are inflated to the proper pressure (refer to the Load Chart Book in the crane cab). When
inflating tires, use a tire gauge, clip-on inflator, and extension hose which will permit standing clear of the tire while
inflating.

31
PIXEF 215 SAFETY PRECAUTION

WIRE ROPE

Use ONLY the wire rope specified by TIL as indicated on the crane's load capacity chart. Substitution of an
alternate wire rope may require the use of a different permissible line pull and, therefore, require different
reeving.

NOTE

Wire rope may be purchased by contacting


the TIL LIMITED SPARE PARTS Department.

Always make daily inspections of the wire rope, keeping in mind that all wire rope will eventually deteriorate to a
point where it is no longer usable. Wire rope shall be taken out of service when any of the following conditions exist :

1. For rotation-resistant running ropes-more than two (2) broken wires in a length of rope equal to six (6) times
the rope diameter, or more than four (4) broken wires in a length of rope equal to thirty (30) times the
rope diameter.

2. For running ropes other than rotation resistant-six (6) broken wires in one rope lay or three (3) broken wires
in one strand.

3. One valley break where the wire fractures between strands in a running rope is cause for removal.

4. Abrasion of the rope resulting in wear of the individual outside wires of 1/3 of the original wire diameter.

5. Any kinking, bird caging, crushing, corrosion, or other damage resulting in distortion of the rope structure.

6. Rope that has been in contact with a live power line or has been used as a ground in an electric circuit (e.g.
welding) may have wires that are fused or annealed and must be removed from service.

7. In standing ropes, more than three (3) breaks in one rope lay in sections beyond the end connection or more
than two (2) broken wires at an end connection.

8. Core deterioration is usually observed as a rapid reduction in rope diameter and is cause for
immediate removal of the rope.

32
PIXEF 215 SAFETY PRECAUTION

Refuse to work with worn or damaged wire rope.

When installing and inspecting wire ropes and attachments, keep all parts of your body and clothing away from
rotating hoist drums and all rotating sheaves.

Never handle the wire rope with bare hands.

Periodic rope inspection records are required by law. Make sure these records have been reviewed and are up
to date.

When installing a new rope:

Follow proper instructions for removing rope from a reel.

Apply back tension to the storage/payoff reel of the new rope to insure tight, even spooling onto the
hoist drum.

Operate the new rope - first through several cycles at light load and then through several cycles at
intermediate load to allow the rope to adjust to operating conditions.

When using a wedge socket:

Always inspect socket, wedge, and pin for correct size and condition.

Do not use parts that are damaged, cracked, or modified.

Assemble the wedge socket with live end of rope aligned with the centerline of pin and assure
proper length of tail (dead end) protrudes beyond the socket.

Never overload or shock load a wire rope.

Lubricate the wire rope periodically as the lubricant becomes depleted.

33
PIXEF 215 SAFETY PRECAUTION

Inspect the boom nose and hook block sheaves for wear.

Damaged sheaves cause rapid deterioration of wire rope.

To attain maximum wire rope life and minimize hook block rotation, it is recommended that even numbers of parts-
of-line be used in multiple-part reeving whenever possible.

If applicable to your crane, the use of nylon (nylatron) sheaves, as compared with metallic sheaves, may
change the replacement criteria of rotation- resistant wire rope.

NOTE

If applicable to your crane, the use of cast nylon (nylatron) sheaves,


as compared with steel sheaves, will substantially increase the service
life of wire rope. However, conventional rope retirement criteria based
only upon visible wire breaks may prove inadequate in predicting
rope failure. The user of cast nylon sheaves is therefore cautioned that
a retirement criteria should be established based upon the user's
experience and the demands of his application.

34
PIXEF 215 SAFETY PRECAUTION

BATTERIES

Battery electrolyte must not be allowed to contact the skin or eyes. If this occurs, flush the contacted area with water
and consult a doctor immediately.

When checking and maintaining batteries exercise the following procedures and precautions :

Disconnect the batteries.

Wear safety glasses when servicing batteries.

Do not short across the battery posts to check charge. Short circuit, spark, or flame could cause battery
explosion.

Maintain battery electrolyte at the proper level. Check the electrolyte with a flashlight.

If applicable to your crane, check battery test indicator on maintenance- free batteries.

Do not break a live circuit at the battery terminal. Disconnect the ground battery cable first when removing
a battery and connect it last when installing a battery.

Check battery condition only with proper test equipment. Batteries shall not be charged except in an
open, well-ventilated area that is free of flame, smoking, sparks, and fire.

ENGINE

Be careful when checking the engine coolant level. The fluid may be hot and under pressure. Shut down the engine
and allow the radiator time to cool before removing the radiator cap.

Shut down the engine and disconnect the battery before performing maintenance. If unable to do so for
the task required, keep hands clear of the engine fan and other moving parts while performing maintenance.

Be careful of hot surfaces and hot fluids when performing maintenance on or around the engine.

35
PIXEF 215 SAFETY PRECAUTION

WORK PRACTICES

CRANE ACCESS

You must take every precaution to ensure you do not slip and/or fall off the crane. Falling from any
elevation could result in serious injury or death.

Never exit or enter the crane cab or deck by any other means than the access system(s) provided (i.e.,
steps and grab handles).

If necessary, use a ladder or aerial work platform to access the boom nose.

Do not step on surfaces on the crane that are not approved or suitable for walking and working. All walking and
working surfaces on the crane should be clean, dry, slip- resistant, and have adequate supporting capacity.
Do not walk on a surface if slip- resistant material is missing or excessively worn.

Do not use the top of the boom as a walkway.

Do not step on the outrigger beams or outrigger pads (floats) to enter or exit the crane.

Wear shoes with a highly slip-resistant sole material. Clean any mud or debris from shoes before entering the
crane cab or climbing onto the crane superstructure. Excessive dirt and debris on the hand-holds, access steps,
or walking/working surfaces could cause a slipping accident. A shoe that is not clean might slip off a control pedal
during operation.

Do not make modifications or additions to the crane's access system that have not been evaluated and
approved by TIL LIMITED.

36
PIXEF 215 SAFETY PRECAUTION

JOB PREPARATION

You must inspect the crane prior to your work shift - checking for cracked welds, damaged components,
and evidence of improper maintenance (consult TIL LIMITED Maintenance and Inspection Manual).

You must ensure that the crane is properly equipped including access steps, covers, doors, guards, and controls.

You must ensure that the outriggers are properly extended and set before performing any lifting operations. On
models equipped with outriggers that can be pinned at the mid-extend position, the outriggers must also be pinned
when operating from the mid- extend position.

Wear appropriate clothing and personal protective equipment whether or not required by local or job regulations. Be
prepared for the work day.

Before entering the cab, you must be THOROUGHLY familiar with the planned route of travel and area of operation,
including surface conditions and the presence of overhead obstructions and power lines.

Always keep the crane clean, free of dirt, debris, and grease.

Fuel the crane ONLY with the engine turned off. Do not smoke while fueling the crane.

Do not store flammable materials on the crane or in the operator's cab.

Follow standard safety precautions when refueling. FUEL IT SAFELY.

Be familiar with the location and use of the nearest fire extinguisher.

Cold weather requires special starting procedures, use of built-in starting aids, if provided, and ample time for
hydraulic oil to warm-up. Keep the crane free of ice and snow.

WORKING

Never operate the crane when darkness, fog, or other visibility restrictions make operation unsafe. Never operate a
crane in thunderstorms or high winds.

Keep unauthorized personnel clear of the working area during operation.

37
PIXEF 215 SAFETY PRECAUTION

Operate the crane only from the operator's seat. Do not reach in a window or door to operate any controls.

Operate the crane slowly and cautiously, looking carefully in the direction of movement.

"Stunt" driving and horse-play are strictly prohibited. Never allow anyone to hitch a ride or get on or off a moving
crane.

A good practice is to make a "dry run" without a load before making the first lift. Become familiar with all factors
peculiar to the job site.

Ensure the wire rope is properly routed on the hook block and boom nose and that all rope guards are in place.

USE ENOUGH PARTS OF LINE FOR ALL LIFTS AND CHECK ALL LINES, SLINGS, AND CHAINS FOR
CORRECT ATTACHMENT. To obtain maximum lifting capacities, the hook block must be set up with enough parts
of line. NO LESS THAN THREE WRAPS of wire rope should remain on the hoist drum. When slings, ties, hooks,
etc., are used, make certain they are correctly positioned and secured before raising or lowering the loads.

38
PIXEF 215 SAFETY PRECAUTION

Be sure the rigging is adequate before lifting. Use tag lines when possible to position and restrain loads. Personnel
using tag lines should be on the ground.

Be sure good rigging practices are being used. Refuse to use any poorly maintained or damaged equipment. Never
wrap the hoist cable around a load.

LIFTING

Check the hoist brake by raising the load a few inches, stopping the hoist and holding the load. Be sure the hoist
brake is working correctly before continuing the lift.

When lowering a load always slow down the load's descent before stopping the hoist. Do not attempt to change
speeds on multiple-speed hoists while the hoist is in motion.

LIFT ONE LOAD AT A TIME. Do not lift two or more separately rigged loads at one time, even if the loads are within
the crane's rated capacity.

Never leave the crane with a load suspended. Should it become necessary to leave the crane, lower the load to the
ground and stop the engine before leaving the cab.

Remember - all rigging equipment must be considered as part of the load. Lifting capacities vary with
working areas. Permissible working areas are posted in the crane cab. When swinging from one working area to
another, ensure load chart capacities are not exceeded. Know your crane!

Stop the hook block from swinging when unhooking a load.

Swinging rapidly can cause the load to swing out and increase the load radius. Swing the load slowly. Swing with
caution and keep the load lines vertical.

Look before swinging your crane. Even though the original setup may have been checked, situations do change.

39
PIXEF 215 SAFETY PRECAUTION

Keep everyone away from suspended loads. Allow no one to walk under a load. Ensure that all slings, ties, and
hooks are correctly placed and secured before raising or lowering the load.

Use tag lines (as appropriate) for positioning and restraining loads. Check the load slings before lifting.

Be sure everyone is clear of the crane and work area before making any lifts.

Never swing over personnel, regardless of whether load is suspended from or attached to the boom.

Be sure the load is well secured and attached to the hook with rigging of proper size and in good condition.

Use only slings or other rigging devices rated for the job and use them properly. Never wrap the hoist cable around a
load.

Check all tackle, hardware, and slings before use. Refuse to use faulty equipment.

Never work the crane when darkness, fog, or other visibility restrictions make such operations unsafe.

HAND SIGNALS

A qualified signal person shall be used at all times when:

Working in the vicinity of power lines.

The crane operator cannot clearly see the load at all times.

Moving the crane in an area or direction in which the operator cannot clearly see the path of travel.

At all times use standardized hand signals - previously agreed upon and completely understood by the
operator and signal person.

If communication with the signal person is lost, crane movement must be stopped until communications are
restored.

Keep your attention focused on the crane's operation. If for some reason you must look in another direction, stop all
crane movement first.

When vision is obscured, use and follow the directions of a single qualified signal person.

Obey a signal to stop from anyone.

40
PIXEF 215 SAFETY PRECAUTION

41
PIXEF 215 SAFETY PRECAUTION

TRANSPORTING THE CRANE

When loading or unloading the crane on a trailer or railroad car, use a ramp capable of supporting the weight of the
crane. The crane is equipped with swing-up steps on front and rear to facilitate loading and unloading.

Ensure the crane is adequately secured to the transporting vehicle.

If it is necessary to take the crane on a road or highway, first check state and local restrictions and
regulations.

Check load limits of bridges on the travel route and ensure they are greater than the combined weight of the crane
and transporting vehicle.

Always drive the crane carefully, obeying speed limits and highway regulations. Keep lights on and use traffic
warning flags and signs and front and rear flag vehicles as applicable.

SHUTDOWN

Never leave the crane with load suspended. Lower the load to the ground before shutting down the crane.

Use the following steps when shutting down the crane:

Engage the parking brake.

Fully retract and lower the boom.

Engage the pin swing lock or 360 degree swing lock.

Place controls in neutral position.

Shut down the engine and remove the ignition key.

Chock the wheels.

Lock the operator's cab and install vandal guards, if used.

In cold weather, never park the crane where the tires can become frozen to the ground.

42
PIXEF 215 SAFETY PRECAUTION

BOOM EXTENSION /JIB

To avoid death or serious injury, follow proper procedures during erection, stowage, and use of the boom
extension/jib.

Install and secure all pins properly.

Control movement of boom extension/jib at all times.

Do not remove right side boom nose pins unless boom extension is properly pinned and secured on front and/or rear
stowage brackets.

Do not remove all the pins from both front and rear stowage brackets unless the boom extension is pinned to the
right side of the boom nose.

See the appropriate section of this handbook for the proper boom extension/jib erection and stowage procedure.

Properly inspect, maintain, and adjust boom extension/jib and mounting.

Sling jib sections from the main chords or the end fittings.

When assembling and disassembling jib sections, use blocking to adequately support each section and to provide
proper alignment.

Stay outside of jib sections and lattice work.

Watch for falling or flying pins when they are being removed.

43
PIXEF 215 SAFETY PRECAUTION

COLD WEATHER OPERATION

Cold weather operation requires additional caution on the part of the operator.

Check operating procedures for cold weather starting.

Don't touch metal surfaces that could freeze you to them.

Clean the crane of all ice and snow.

Allow ample time for hydraulic oil to warm up.

In freezing weather, park the crane in an area where it cannot become frozen to the ground. The drive line can be
damaged when attempting to free a frozen crane.

If applicable to your crane, frequently check all air tanks for water in freezing weather.

If applicable to your crane, always handle propane tanks according to the supplier's instructions.

Never store flammable materials on the crane.

If cold weather starting aids are provided on your crane, use them. The use of aerosol spray or other types of
starting fluids containing ether/volatiles can cause explosions or fire.

TEMPERATURE EFFECTS ON HYDRAULIC CYLINDERS

Hydraulic oil expands when heated and contracts when cooled. This is a natural phenomenon that happens to all
liquids. The coefficient of expansion for API Group 1 hydraulic oil is approximately 0.00043 cubic inches per cubic
inch of volume for 1F of temperature change. Thermal contraction will allow a cylinder to retract as the
hydraulic fluid which is trapped in the cylinder cools. The change in the length of a cylinder is proportional to the
extended length of the cylinder and to the change in temperature of the oil in the cylinder. For example, a
cylinder extended 25 feet in which the oil cools 60F would retract approximately 7 3/4 inches (see chart below). A
cylinder extended 5 feet in which the oil cools 60F would only retract approximately 1 1/2 inches. The rate
at which the oil cools depends on many factors and will be more noticeable with a larger difference in oil
temperature verses the ambient temperature.

44
PIXEF 215 SAFETY PRECAUTION
P

mal
Therm contracction couple
ed with im
mproper lub
brication or improper wear pad adjustmentss may, underr
certain conditions, cause a "stick-slip" con
ndition in the
e boom. Thiss stick-slip ccondition cou
uld result in the load nott
ng smoothly. Proper boo
movin om lubricatio
on and wear pad adjustm
ment is impo
ortant to perm
mit the boom
m sections to
o
slide freely.
f Slow movement,
m o the boom may
of m be unde
etected by the
e operator un
nless a load
is susspended for a long period of time.

e boom is allowed to remain statio


If a load and the onary for a period of ttime and the
e ambient temperature iss
cooler than the tra
apped oil tem
mperature, the
e trapped oil in the cylind
ders will cool. The load will
w lower as th
he telescope
e
der(s) retractss allowing th
cylind he boom to come
c in. Alsso, the boom angle w
will decrease
e as the liftt cylinder(s))
retraccts causing an increase in
n radius and a decrease in load height.

This situation
s i reverse. Iff a crane is set up in the
will also occur in e morning w
with cool oil and
a the daytime ambientt
tempe
erature heatss the oil, the cylinders
c willl extend in similar proporttions.

The chart belo


ow has be
een preparred to asssist you in determin
ning the a
approximate amount off
retracction/extensio
on that may
y be expecte
ed from a h
hydraulic cylinder as a rresult of chan
nge in the tem
mperature off
the hyydraulic oil in
nside the cylinder. The ch
hart is for dryy rod cylinderrs. If the cylin
nder rod is filled with hydrraulic oil, the
e
contra
action rate is somewhat greater.
g
N
NOTE
Operators and service
s pers
sonnel must be aware th
hat load mov
vement,
as a result of this phenome
ena, can be easily
e mista
aken as leaking
nder seals or
cylin o faulty hold
ding valves. If leaking s
seals or faultty
hold
ding valves are
a suspecte
ed to be the
e problem, re
efer to
Serv
vice Bulletin
n 98-036 dea
aling with tes
sting telesco
ope cylinders.
PIXEF 215 CAB CONTROLS AND INDICATORS

SECTION 3

CAB CONTROLS AND INDICATORS

46
PIXEF 215 CAB CONTROLS AND INDICATORS

13 27 15 18 24

11 12 14 16 19 20 21 23
17 22

10 7 5 2
9 8 67 4 3 1 26 25
FIGURE 3 : OPERATOR CONTROLS

1 - IGNITION KEY 14 - LH JACK


2 - BRAKE PEDAL 15 - LH O/R EXTENSION
3 - ADJUSTER 16 - RH O/R EXTENSION
4 - PARKING BRAKE LEVER 17 - RH JACK
5 - LMI INDICATOR PANEL 18 - ELECTRIC GEAR SHIFTER
6 - TACHO METER 19 - SLEWING LEVER
7 - AIR PRESSURE GAUGE 2 20 - STEERING WHEEL
8 - OIL PRESSURE 21 - COMBINATION SWITCH
9 - CIGERETTE LIGHTER 22 - TELE CONTROL
10 - TRANSMISSION TEMP. 23 - DERRICK CONTROL
11 - VOLTMETER 24 - HOIST CONTROL
12 - AIR PRESSURE GAUGE 1 25 - DASH PANEL
13 - REAR VIEW MONITOR 26 - ACCELERATOR PEDAL
27 - LMI BYPASS SWITCH

47
PIXEF 215 CAB CONTROLS AND INDICATORS

FIGURE 2: INSTRUMENT CLUSTER

1- SPEEDOMETER 15 - SAFE LOAD


2- LEFT TURN 16 - ILLUMINATION SIDE LIGHT
3- QUADRANT DIAL 17 - HIGH BEAM
4- FUEL LEVEL GAUGE 18 - SLEW LOCKED
5- INDICATOR POINTER 19 - ENGINE WATER TEMPERATURE
6- REAR WHEELS STEERED 20 - WATER TEMPERATURE GAUGE
7- CONSOLE CASE 21 - RIGHT TURN
8- BATTERY 22 - LOW BEAM
9- ENGINE OIL PRESSURE 23 - NEUTRAL GEAR
10- TRANSMISSION OIL TEMPERATURE 24 - THIRD WRAP
11- LOW AIR PRESSURE 25 - SUSPENSION UNLOCK
13- PARKING BRAKE 26 - OUTRIGGER FULLY EXTENDED
14- OVERLOAD 27 - O/R JACK EXTENDED

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PIXEF 215 CAB CONTROLS AND INDICATORS

1 2 3 4 5 6 7

FIGURE 3: SWITCH PANEL - STEERING COLUMN

1- WIPER SWITCH 5- LMI CONFIGUARATION SWITCH


2- FAN SWITCH 6- BEACON LAMP SWITCH
3- AXLE UNLOCK SWITCH 7- WORK LAMP SWITCH
4- ENGINE STOP SWITCH

49
PIXEF 215 CAB CONTROLS AND INDICATORS

FIGURE 4: CRANE CONTROLS

50
PIXEF 215 CAB CONTROLS AND INDICATORS

FIGURE 5 : CRANE CONTROLS

51
PIXEF 215 CAB CONTROLS AND INDICATORS

IGNITION SWITCH

The (IGNITION) switch (1) is located at the bottom of the front console, to the right of the steering column. The
switch is key-operated and has three positions: OFF [0], IGN [1], and START [2]. In the OFF position, all electrical
power is off except for the lights controlled by the Headlight switch, horn, cab light, flasher Turn / hazard / stop lights,
and work lights. Positioning the switch to IGN energizes all the electrical components except the start solenoid.
Positioning switch to START energizes the start relay, which in turn energizes the cranking motor solenoid and
cranks the engine for starting. The switch is spring returned from START to IGN position.

BRAKE PEDAL

The brake pedal (2) is placed on the right hand side of the steering column. Depressing the pedal actuates a
pneumatic valve that positions the air brake chambers attached to the brake drums of all the wheels.

ENGINE COOLANT TEMPERATURE GAUGE

The engine coolant temperature (WATER TEMP) gauge (2) is located in the right side of the front console. It
indicates the engine coolant temperature on a scale calibrated from 40 to 120C. The gauge receives a signal from a
temperature sending unit in the engine cooling system.

LIGHT SWITCH

Light switch (21) is located on the right side of the steering column. Pressing the head of the switch lever horn
blows. Moving the lever in forward an reverse direction horizontally left turn lights and right turn lights glow.
Pushing the lever up from its natural position Headlights get dimmed. When its end part is rotated to 1st position,
marker lamps and gauge lights flow, at 2nd position headlamps glow with other lights and in the 3rd position
Headlights get dimmed.

AIR PRESS GAUGE

The Air pressure Gauge (7 & 12) are located on the right side of the front console panel. They are
connected to the outlet ports of Dual brake valve which allows air supply to front and read axles for braking ;
they show air pressure of the pneumatic circuit on a scale calibrated from 0 to 10 kg /cm 2.

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PIXEF 215 CAB CONTROLS AND INDICATORS

CIGARETTE LIGHTER

The CIGARETTE LIGHTER (9) is located on the left-side panel.

WORK LIGHT

The WORK LIGHT switch (7) is a two - position toggle switch (ON / OFF), located on the right side of the front
console panel integrated with the steering column.

HAZARD LIGHTS SWITCH

The HAZARD lights switch is located near the adjuster (3) on the left side of the steering column. The switch is a
two-position push pull type switch (ON/OFF). It causes the four turn signal lights to flash at the same time
when the switch is pulled to ON.

FUEL LEVEL GAUGE

The fuel gauge (4) is located inside the cluster The gauge indicates the quantity of fuel in the fuel tank and has
a scale calibrated from zero [0] to 1/1. The fuel gauge receives a signal from a sending unit in the fuel tank.

ENGINE OIL PRESSURE GAUGE

The Engine Oil Pressure Gauge (8) is located in the left-side panel. The gauge indicates the engine oil pressure and
has a scale calibrated from 0 to 10 bar. The engine oil pressure gauge receives a signal from a sending unit at the
engine side.

LMI DISPLAY

The Indicator Light Alert Display is located in the left-side panel. It contains a group LED Indicators connected to
the PCB, which indicate different Working and alarming conditions.

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PIXEF 215 CAB CONTROLS AND INDICATORS

TRANSMISSION OIL TEMPERATURE GAUGE

The transmission oil temperature (10) gauge is located in the left-side panel. The gauge indicates the transmission
oil temperature on a scale calibrated from 50 to 150 C. The gauge receives a signal from a temperature sending
unit in the oil line at the torque converter.

VOLTMETER

The voltmeter (BATTERY) gauge (11) is located in the left-side panel. The voltmeter indicates the voltage being
supplied to or from the battery and has a scale of 0 to 18 volts.

TACHOMETER

The tachometer (6) is located in the left-side panel. The tachometer registers engine rpm and is calibrated in rpm
x 100 with a range of zero [0] to 30. The tachometer receives a signal from a sending unit from engine.

BEACON LAMP SWITCH (OPTIONAL)

Beacon lamp switch (6) is located in the right middle side of switch panel. It is a two-position toggle switch (ON/
OFF) controls the operation of beacon lights, mounted on cabin roof.

LMI BY PASS SWITCH

LMI bypass switch (27) is located in the left-side panel. When it is positioned ON the electrical system bypasses
Load Moment Indicator and motion cut solenoid is energized Bypassing the LMI safety system.

REAR AXLE UNLOCK SWITCH

The Rear Axle Unlock switch is located in the switch panel. It is a two-position toggle switch (ON/ OFF) which,
when ON, i.e. is in UNLOCK position, power goes to axle oscillation solenoid valve which unlocks the
suspension of rear axle. Locking is done when the crane is lifting load.

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PIXEF 215 CAB CONTROLS AND INDICATORS

CAB FAN SWITCH

The FAN control switch (2) is located on in the switch panel. It is a two-position toggle switch,. While the switch
is on, Fan inside the cabin is operated.

ENGINE STOP SWITCH

The engine stop switch (4) is located in the switch panel. It is a spring return type toggle switch. When pressed it
actuates engine stop solenoid valve that causes to stop engine.

WINDSHIELD WIPER SWITCH

A WINDSHIELD WIPER switch (1) is located in the switch panel. It is a two position toggle switch, operates the
wiper.

HOUR METER GAUGE

Hour meter gauge is integrated in the speedometer (1). It indicates total hours of engine operation.

LEFT TURN INDICATOR

It (2) is located in the instrument cluster. It is a green LED that flashes when the light switch is pulled toward
reverse direction or the Hazard Switch is pulled to ON.

AXLE UNLOCK INDICATOR

It (25) is located in the instrument cluster. It is a red LED that turns ON when the Axle Lock switch is pressed.

MAIN HEAD LIGHT BEAM INDICATOR

It (17) is located in the instrument cluster. It is a blue LED that turns ON when the headlight main beam is selected.

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PIXEF 215 CAB CONTROLS AND INDICATORS

ALTERNATOR WARNING LIGHT

It (8) is located in the instrument cluster. It is a battery symbol that flashes when the alternator output voltage is less
that the desired value.

RIGHT TURN INDICATOR

It (21) is located in the instrument cluster. It is a green LED that flashes when the combination switch is pushed in
the forward direction or the Hazard switch is pulled to ON.

ENGINE COOLANT TEMPERATURE WARNING

It (19) is located in the instrument cluster. It is a red LED that glows when the engine coolant temperature is
higher than the normal working condition. The LED gets signal from a temperature switch connected at the engine
side.

3RD WRAP INDICATOR

It (34) is located in the instrument cluster. It is a red LED that glows when the 3rd wrap limiting condition arises.

LOW AIR PRESSURE INDICATOR

It (11) is located in the instrument cluster. It is a red Led that glows when the air pressure of the system is lower than
the normal working conditions.

PARKING BRAKE INDICATOR

It (13) is located in the instrument cluster. It is amber Led that glows when the parking brake is applied.

REAR WHEEL STEERED INDICATOR

It (6) is located in the instrument cluster It is a red LED that glows when the rear wheels are not centered.

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PIXEF 215 CAB CONTROLS AND INDICATORS

LOAD MOMENT INDICATOR DEVICE

Load Moment Indicator Device is mounted in the left-side panel. The details of LMI system is provided in a
separate manual.

SWING / TELE / DERRICK / HOIST CONTROLLER

Swing / Tele / Derrick / Hoist control levers (Illustrated above) are located in the left-front and right-front of the
steering-column. The control levers when positioned forward and backward, actuates the control valve for out / down
and in / up operation.

STEERING WHEEL

The Steering wheel (20) protrudes out from the center of the front console towards the drivers Seat.

CAB FAN

The cab circulating fan (2) is located on a mounting bracket on the left front side of the cab. Cab fan switch on the
dash panel allows the fan to be rotated.

WINDSHIELD WIPER

A windshield wiper is installed on the front of the cab. The wiper is controlled by Wiper switch as dash panel. It is
used to remove moisture from the windshield.

ACCELERATOR PEDAL

The foot throttle pedal (26) is the right most pedal on the cab floor. Depressing the pedal actuates a master cylinder
which in turn controls a slave cylinder attached to the engine throttle through mechanical linkage.

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PIXEF 215 CAB CONTROLS AND INDICATORS

PARK BRAKE CONTROLLER

The pneumatic hand brake valve is placed on the left-hand side, beside the steering column. Moving the lever
actuates the spring brake chambers attached to the brake drums of the rear axle wheels thereby making parking
brakes on/off. To apply the brake, the locking collar is to be lifted and moved the knob to ON position. similarly for
releasing again The locking collar is to be lifted and moved the knob to OFF position. The hand brake valve can also
be used for emergency application of brake.

DERRICK HOIST CONTROLLER

Derrick / Hoist Controller (23, 24) is located on the right armrest. The controller when positioned forward
and backward, actuates the control valve for Hoist Up and Hoist Down operation and the joystick when
positioned left and right, actuates the control valves for Derrick Out and Derrick In Operation.

PIN SWING LOCK CONTROL

The swing lock control handle is located on the right side of the front console. The purpose of the swing lock is to
secure the superstructure in position. When the control handle is pushed forward, the swing lock is disengaged and
wing can be accomplished. When the control handle is pulled back and the superstructure is directly over the front,
the swing lock pin is engaged in the socket in the turntable thus preventing swing. To use the control, pull out on the
handle until the lever is released from the detent and push the lever in the desired direction until the lever is engages
in the opposite detent and release the lever.

TRANSMISSION SHIFT CONTROL LEVER

The transmission shift control lever is mounted on the steering column on the left side of the operator. The control
lever operates the transmission selector valve electrically. Positioning the lever up actuates forward and positioning
the lever down actuates reverse. When the lever is in neutral, it rests in a detent. To move the lever up or down, pull
back on the lever first. To shift the transmission to first, second, third or fourth gear, rotate the knob to 1, 2, 3 or 4.

58
PIXEF 215 CAB CONTROLS AND INDICATORS

FIGURE 7 : CABIN CONTROLS & INSTRUMENTATION

59
PIXEF 215 CAB CONTROLS AND INDICATORS

60
PIXEF 215 CAB CONTROLS AND INDICATORS

61
PIXEF 215 CAB CONTROLS AND INDICATORS

62
PIXEF 215 CAB CONTROLS AND INDICATORS

63
PIXEF 215 CAB CONTROLS AND INDICATORS

64
PIXEF 215 CAB CONTROLS AND INDICATORS

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PIXEF 215 CAB CONTROLS AND INDICATORS

FIGURE 20 : CLUSTER- DETAIL

WARNING LIGHTS

L20 LEFT TURN


L14 SUSPENSION UNLOCK
L15 NEUTRAL GEAR
L17 OUTRIGGER FULLY EXTENDED
L21 RIGHT TURN
L11 SLEW LOCKED
L13 THIRD WRAP
L10 HIGH BEAM
L18 OUTRIGGER JACK EXTENDED
L1 BATTERY/ALTERNATOR WARNING
L8 SAFE LOAD
L2 ENGINE OIL PRESSURE
L3 TRANSMISSION OIL TEMP.
L6 PARK BRAKE
L9 ILLUMINATION SIDE LIGHT
L4 LOW AIR PRESSURE
L7 OVER LOAD
L12 REAR WHEELS NOT IN CENTRE
L16 LOW BEAM

66
PIXEF 215 CAB CONTROLS AND INDICATORS

67
PIXEF 215 OPERATING PROCEDURE

SECTION 4

OPERATING PROCEDURE

68
PIXEF 215 OPERATING PROCEDURE

SECTION 4

OPERATING PROCEDURES

PRE-STARTING CHECKS

A complete walk-around visual inspection of the crane should always be made with special attention to
structural damage, loose equipment, leaks, or other conditions that would require immediate correction for safety of
operation. The following checklist items are suggested specifically for the operator's benefit to make certain
his crane is prepared for starting the day's work.

FUEL SUPPLY

Check the fuel level and make sure the cap is on tight.

ENGINE OIL

Check the oil level in the crankcase and fill to the FULL mark on the dipstick. Do not overfill.

ENGINE COOLANT

Check the coolant level in the radiator and fill to the proper level. Do not overfill and check to make sure the cap is
secure.

BATTERIES

Check that the battery cables and clamps are tight and not corroded.

SIGNAL

Check all signal and running lights for proper operation. Replace burned out lamps with those of the same number
or equivalent.

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PIXEF 215 OPERATING PROCEDURE

FOOT AND PARKING BRAKES

Check the foot and parking brakes for proper operation.

DAILY LUBRICATION

Make certain that all components requiring daily lubrication have been serviced. (Refer to Section 5, Lubrication.)

HYDRAULIC RESERVOIR AND FILTER

Check hydraulic fluid quantity level and filter condition indicator. Check breather for cleanliness and security.

TIRES

Check for severe cuts, foreign objects embedded in treads, and for correct inflation pressures. A tire
inflation chart, providing the correct air pressures, is located in the Load Chart Book in the crane cab.

WIRE ROPE

Inspect wire rope, sheaves, guards, guides, drums, flanges, and any other surfaces that may come in contact with
the rope for any condition that could cause possible damage to the rope.

HOOK BLOCK

Visually inspect for nicks, gouges, cracks, and evidence of any other damage. Replace any hook that contains
cracks or shows evidence of excessive deformation of the hook opening, including twist. Be sure the safety latch is
free and aligned.

AIR CLEANER

Check the filter condition indicator. Check filter and tubing for security.

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PIXEF 215 OPERATING PROCEDURE

COLD WEATHER OPERATION

The following recommendations are for operating TIL cranes in very low (i.e., sub-zero) temperatures. Use
particular care to ensure that cranes being operated in very cold temperatures are operated and maintained
in accordance with the procedures as provided by TIL Ltd.. Cranes should have appropriate hydraulic oil,
lubricants, and other auxiliary items required for operation in sub-zero temperatures. Individual crane functions
should be operated to ensure they are sufficiently warmed prior to performing a lift.

Operation of cranes at full rated capacities in temperatures between -18C (0F) and - 40C (-40F) or lower
should be accomplished only by competent operators who possess the skill, experience, and dexterity to ensure
smooth operation. Shock loading shall be avoided.

ENGINE OPERATION

Starting and shutdown procedures for most diesel engines generally follow the same pattern. Therefore, the
following procedures can be applied except where specific differences are noted. (Refer to the applicable
engine manufacturers manual for detailed procedures.)

STARTING PROCEDURE

Make an under-the-hood inspection for fuel, oil, and coolant leaks, worn drive belts, and trash build-up.

DANGER

DIESEL ENGINE EXHAUST CAN BE HARMFUL


TO YOUR HEALTH. ONLY OPERATE THE ENGINE
IN A WELL VENTILATED AREA OR VENT EXHAUST OUTSIDE.

DANGER

BEFORE STARTING THE ENGINE, APPLY THE


PARKING BRAKE AND ENGAGE THE SWING LOCK.

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PIXEF 215 OPERATING PROCEDURE

CAUTION

NEVER CRANK THE ENGINE FOR MORE THAN 30 SECONDS


DURING AN ATTEMPTED START. IF THE ENGINE FAILS TO START
AFTER 30 SECONDS, STOP AND ALLOW THE STARTER MOTOR TO
COOL FOR APPROXIMATELY TWO MINUTES BEFORE ATTEMPTING
ANOTHER START.

CAUTION

IF THE ENGINE FAILS TO START AFTER FOUR ATTEMPTS, CORRECT


THE MALFUNCTION BEFORE ATTEMPTING FURTHER STARTS.

DANGER

DO NOT SPRAY STARTING FLUID INTO THE AIR INLET.


THE SPRAY WILL CONTACT THE HEATER ELEMENTS
AND COULD EXPLODE CAUSING PERSONAL INJURY.

NOTE

The engine will not crank unless the


transmission shift lever is in neutral.

1. Warm Engine.

2. Turn the IGNITION switch to START and release immediately when the engine starts. Do not push or hold
the throttle down. The ECM will automatically provide the proper amount of fuel to start the engine.

3. Immediately check the engine instruments for proper indication after starting. Shut down the engine if the
oil pressure gauge does not reach the proper reading within 15 seconds.

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PIXEF 215 OPERATING PROCEDURE

IDLING THE ENGINE

Idling the engine unnecessarily for long periods of time wastes fuel and fouls injector nozzles. Unburned fuel
causes carbon formation, oil dilution, formation of lacquer or gummy deposits on the valves, pistons, and rings,
and rapid accumulation of sludge in the engine.

Note

When prolonged idling is necessary, maintain at least 800 rpm.

RACING THE ENGINE

NEVER race the engine during the warm-up period. NEVER operate the engine beyond governed speed (as might
occur in downhill operation or downshifting). Engine bearings, pistons, and valves may be damaged if these
precautions are not taken.

SHUTDOWN PROCEDURE

1. Allow the engine to operate at fast idle for about five minutes to avoid high Internal heat rise and
allow for heat dissipation.

2. Turn the ignition switch to OFF (0).

BATTERY DISCONNECT

The crane is equipped with a battery disconnect. To operate disconnect, push in on the disconnect handle and twist
the handle out of the receptacle. When the handle is out, the battery ground is disconnected. To connect the battery
ground, insert the handle, push and twist it into place.

73
PIXEF 215 OPERATING PROCEDURE

CRANE TRAVEL OPERATION

TRAVELING - GENERAL
CAUTION

ENSURE THE CRANE FUNCTION SWITCH


IS TURNED TO OFF FOR EXTENDED
TRAVELING, COLD WEATHER STARTING,
OR ENGINE CHECKS.

DANGER

DO NOT TRAVEL WITH AN EMPTY HOOK


IN A POSITION WHERE IT CAN SWING FREELY.

DANGER

DO NOT DRIVE THE CRANE WITH THE BOOM OFF CENTER


BECAUSE AUTOMATIC OSCILLATION LOCKOUT WILL
OCCUR, MAKING THE CRANE SUBJECT TO TIPPING
ON UNEVEN SURFACES.

DANGER

AVOID HOLES, ROCKS, EXTREMELY SOFT SURFACES,


AND ANY OTHER OBSTACLES WHICH MIGHT SUBJECT
THE CRANE TO UNDUE STRESSES OR POSSIBLE OVERTURN.

CAUTION

DO NOT DRIVE THE CRANE WITH THE


LIFT CYLINDER BOTTOMED. POSITION
THE BOOM SLIGHTLY ABOVE HORIZONTAL.

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PIXEF 215 OPERATING PROCEDURE

DANGER

ON OPEN GROUND, TOW OR PULL ONLY ON THE


TOW / TIE-DOWN LUGS OR WITH THE OPTIONAL PINTLE HOOK.

CAUTION

SHOULD THE CRANE BECOME MIRED DOWN, USE A


TOW TRUCK OR TRACTOR TO FREE THE VEHICLE. SEVERE DAMAGE
TO THE TRANSMISSION OR AXLES MAY OCCUR IF THE OPERATOR
ATTEMPTS TO FREE THE CRANE UNASSISTED.

CAUTION

IF THE CRANE IS MIRED DOWN, USE THE


TOW/TIE-DOWN LUGS TO PULL OR TOW.

There are two tow/tie-down lugs installed on each end of the crane. Use both lugs to tow or pull the crane.

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PIXEF 215 OPERATING PROCEDURE

TRAVELING WITH BOOM EXTENSION ERECTED

Travel with boom extension erected is permissible under the following conditions.

1. Boom extension shall be erected at minimum offset with stinger section (if applicable) pinned in fully
retracted position.

2. Jobsite travel only on firm, level surface.

3. Main boom shall be fully retracted.

4. Main boom angle: 0 degrees minimum, 20 degrees maximum.

5. Maximum travel speed: 5 km/h (2.5 mph).

6 Boom over the front, lock pin (in cab) in down position.

7. Hook block may be reeved over main boom nose, hanging 0.9 m (3 feet) below nose sheaves.

8. Headache ball may be reeved over boom extension, hanging 0.9 m (3 feet) below sheave.

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PIXEF 215 OPERATING PROCEDURE

MOVING THE CRANE

The following superstructure conditions should be strictly adhered to before moving the crane. Procedures for
accomplishing the following can be found in the various sections of this manual.

1. Fully retract the boom.

2. Ensure the swing away jib is properly stowed and secured.

3. Swing the boom to over and lower it to slightly above horizontal.

4. Turn the SWING BRAKE switch on the front console to ON and engage the swing lock pin by
pushing down on the handle.

5. Remove the hook block and/or headache ball from the hoist cable(s) and stow securely before traveling or
make sure the hook block or headache ball is properly secured to the tie down provided for that
purpose.

6. Fully retract the outrigger stabilizers and remove the floats.

7. Properly store the floats.

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PIXEF 215 OPERATING PROCEDURE

TRAVELING - FORWARD

DANGER

ENGAGE THE SWING LOCK PIN


FOR EXTENDED TRAVEL.

1. Put the transmission control lever in the first (F-1) gear position and release the parking brake. Depress
the foot throttle until maximum first gear speed is attained and shift into the second (F-2) gear position.

2. When the maximum second gear speed is attained, shift from second to third (F-3) gear and accelerate to
the desired speed.

CAUTION

DO NOT DOWNSHIFT TO A LOWER GEAR IF THE ROAD


SPEED IS GREATER THEN THE MAXIMUM SPEED OF THE
LOWER GEAR.

TRAVELING - REVERSE

Traveling in reverse is accomplished the same way as traveling forward, except for shifting the transmission
control lever to the applicable reverse (R-1, R-2, or R-3) position. (Refer to TRAVELING - FORWARD.)

CAUTION

APPLY SERVICE BRAKES AND BRING CRANE TO


A COMPLETE STOP BEFORE SHIFTING TRANSMISSION
INTO REVERSE.

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PIXEF 215 OPERATING PROCEDURE

CAUTION

DO NOT OPERATE THE CRANE IF THE


AXLE OSCILLATION LOCKOUT SYSTEM
IS NOT FUNCTIONING PROPERLY.

1. If the axle oscillation lockout valve is not functioning properly, the crane will not re-level itself. If the rear
axle does not lock or unlock properly, evaluate the lockout system and repair as necessary.

GENERAL CRANE OPERATION

NOTE

Always operate the control levers


With slow, even pressure.

PRELOAD CHECK

After the crane has been readied for service, an operational check of all crane functions (with no load applied)
should be performed. The Preload Check is as follows:

CAUTION

OPERATE ENGINE AT OR NEAR GOVERNED RPM


DURING PRELOAD CHECK OF CRANE FUNCTIONS.

NOTE

Carefully read and become familiar with all crane


Operating instructions before attempting a preload
Check or operating the crane under load.

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PIXEF 215 OPERATING PROCEDURE

1. Extend and set outriggers.

2. Telescope the boom in and out.

3. Raise and lower the cable a few times at various boom lengths. Ensure there is no kinking.

USING YOUR LOAD CHART

NOTE

One of the most important tools of every TIL crane


is the load chart found in the crane operator's cab

The load chart contains a large amount of information, which must be thoroughly understood by the operator.

The load chart contains four outrigger capacity charts: fully, mid, and retracted outriggers main boom and
boom extension with full outriggers. In addition, the load chart contains three on-rubber capacity charts:
over front stationary, 360 stationary, and pick and carry over front.

FIGURE 22: TERMS TO KNOW

The capacity charts are divided into structural strength and stability limits. This is shown by the bold line across the
chart. Capacities above the line are structural strength limits and capacities below the line are stability limits.

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PIXEF 215 OPERATING PROCEDURE

The left column is the load radius, which is the distance from the center of crane rotation to the load center
of gravity. The top row lists various boom lengths ranging from fully retracted to fully extended with the swing
away jib. The number at the intersection of the left column and top row is the total load capacity for that load radius
and boom length.

Another important section is the range diagram. The range diagram shows the operating radius and tip height that
can be achieved at a given boom length and angle. If the operator knows the radius and tip height required for a
specific lift, the angle and boom length can be quickly determined from the range diagram. Or, if the boom length
and angle are known, the tip height and operating radius can be quickly determined.

A lifting diagram is included to describe over side, over rear, and over front lifting areas. The lifting area diagram
shows that the locations of the outrigger stabilizer cylinders in the full extended position are used to mark the
boundaries of the lifting areas.

A boom extension capacity chart and notes are included to list the capacities for the extension length, load radius,
and boom angle.

Another section contains the notes for lifting capacities. Be sure to read and understand all the notes concerning
lifting capacities.

The load chart also gives weight reductions for TIL load handling devices such as hook blocks, headache balls,
boom extensions, etc., which must be taken into consideration as part of the load. Remember, the weight of any
other load handling devices such as chains, slings, or spreader bars must be added to the weight of the load.

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PIXEF 215 OPERATING PROCEDURE

CRANE FUNCTIONS

DANGER

DEATH OR SERIOUS INJURY COULD RESULT


FROM IMPROPER CRANE SETUP ON OUTRIGGERS.

DANGER

THE OUTRIGGERS MUST BE PROPERLY EXTENDED


AND SET AND THE CRANE LEVEL BEFORE ANY
OTHER OPERATION OF THE CRANE ON OUTRIGGERS
IS ATTEMPTED.

SETTING THE OUTRIGGERS

1. Position the outrigger floats directly out from each outrigger to where the outriggers will be properly
extended.

SWINGING THE BOOM

DANGER

DEATH OR SERIOUS INJURY COULD RESULT FROM BEING


CRUSHED BY MOVING MACHINERY. BEFORE ACTIVATING SWING,
SOUND THE STEERING WHEEL HORN AND VERIFY THAT ALL
PERSONNEL ARE CLEAR OF ROTATING AND MOVING PARTS.

DANGER

KEEP THE AREAS IN THE SWING PATH OF THE HOOK,


LOAD AND TAIL CLEAR OF ALL OBSTRUCTIONS
AND PERSONNEL.

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PIXEF 215 OPERATING PROCEDURE

CAUTION

DISENGAGE THE SWING BRAKE AND THE SWING LOCK


PIN OR 360 SWING LOCK BEFORE ATTEMPTING TO SWING.

NOTE

Automatic rear axle oscillation lockout will activate


when the boom swings right or left of the crane centerline.

ELEVATING AND LOWERING THE BOOM

Elevating the Boom

DANGER

KEEP THE AREA ABOVE AND BELOW THE BOOM


CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL
WHEN ELEVATING THE BOOM

To elevate the boom, pull the BOOM (lift) control lever back, toward the operator, and hold until the boom reaches
the desired elevation level.

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PIXEF 215 OPERATING PROCEDURE

Lowering the Boom

DANGER

KEEP THE AREA BENEATH THE BOOM CLEAR OF ALL


OBSTRUCTIONS AND PERSONNEL WHEN LOWERING
THE BOOM.

DANGER

LONG CANTILEVER BOOMS CAN CREATE A TIPPING


CONDITION, EVEN WHEN UNLOADED AND IN AN EXTENDED,
LOWERED POSITION.

CAUTION

WHEN LOWERING THE BOOM, SIMULTANEOUSLY LET


OUT THE CABLE TO PREVENT TWO-BLOCKING THE
BOOM NOSE AND HOOK BLOCK.

CAUTION

THE CLOSER THE LOAD IS CARRIED TO THE BOOM


NOSE, THE MORE IMPORTANT IT BECOMES TO
SIMULTANEOUSLY LET OUT THE CABLE AS THE
BOOM IS LOWERED.

To lower the boom push the BOOM control lever forward, away from the operator, and hold until the boom is
lowered to the desired position.

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PIXEF 215 OPERATING PROCEDURE

TELESCOPING THE BOOM

Extending the Boom

DANGER

WHEN EXTENDING THE BOOM, SIMULTANEOUSLY


LET OUT THE CABLE TO PREVENT TWO-BLOCKING
THE BOOM NOSE AND HOOK BLOCK.

DANGER

CHECK THE LOAD CHART FOR THE MAXIMUM LOAD


AT A GIVEN RADIUS, BOOM ANGLE, AND LENGTH
BEFORE EXTENDING THE BOOM WITH A LOAD.

NOTE

When the crane is equipped with an auxiliary hoist,


the telescope function is controlled by a foot pedal.

To extend the boom, push the TELESCOPE control lever forward, away from the operator, and hold until the
boom extends to the desired length.

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PIXEF 215 OPERATING PROCEDURE

Retracting the Boom

DANGER

WHEN RETRACTING THE BOOM, THE LOAD WILL LOWER


UNLESS THE CABLE IS TAKEN IN AT THE SAME TIME.

To retract the boom, pull the TELESCOPE control lever back, toward the operator, and hold until the boom retracts
to the desired length.

LOWERING AND RAISING THE CABLE

DANGER

KEEP THE AREA BENEATH THE LOAD CLEAR OF


ALL OBSTRUCTIONS AND PERSONNEL WHEN
LOWERING OR RAISING THE CABLE (LOAD).

DANGER

DO NOT JERK THE CONTROL LEVER WHEN STARTING


OR STOPPING THE HOIST. JERKING THE LEVER CAUSES
THE LOAD TO BOUNCE, WHICH COULD RESULT IN
POSSIBLE DAMAGE TO THE CRANE.

NOTE

When the load is stopped at the desired height, the


automatic brake will engage and hold the load
as long as the control lever remains in neutral.

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PIXEF 215 OPERATING PROCEDURE

Lowering the Cable

Push the MAIN or AUX hoist control lever forward, away from the operator, and hold until the hook or load is lowered
to the desired height.

Raising the Cable

Pull the MAIN or AUX hoist control lever back, toward the operator, and hold until the hook or load is raised to the
desired height.

OPERATIONAL AIDS

DANGER

ELECTRONIC EQUIPMENT ON THIS CRANE IS INTENDED


AS AN AID TO THE OPERATOR. UNDER NO CONDITION
SHOULD IT BE RELIED UPON TO REPLACE THE USE OF
CAPACITY CHARTS AND OPERATING INSTRUCTIONS.
SOLE RELIANCE UPON THESE ELECTRONIC AIDS
IN PLACE OF GOOD OPERATING PRACTICES CAN
CAUSE AN ACCIDENT.

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PIXEF 215 OPERATING PROCEDURE

LOAD MOMENT INDICATOR (LMI) SYSTEM

The Load Moment Indicator (LMI) is an electro-mechanical sensing system designed to alert the crane operator of
impending capacity when the system has been properly preset by the operator. The control panel is mounted in
the dashboard of the operator's cab. When an overload condition is sensed, the system provides the operator with a
visual and audible warning, and locks out the control levers to prevent lowering the boom, extending the
boom, or raising the main or auxiliary hoist cables. In addition to the audible warning in the cab, an audible warning
alarm is also mounted in the vicinity of the boom floodlights to warn all personnel that a lockout has occurred.

Three additional features are included within the LMI system:

Swing Angle Set Limitation

Work Area Definition

Anti-two Block Device

Swing Angle Set Limitation allows left and right swing angle to be preset. When the preset angle is reached, the
system will provide an audible warning.

Work Area Definition allows the crane operator to describe the crane's working area by setting up "virtual walls".
They are referred to as virtual walls because they exist in the system and are not real walls. The virtual walls
represent obstacles (i.e. buildings, towers, poles, etc.) in the crane's working range. They are set by defining points
along the outer limits of the working area with the tip of the boom. Once the working area has been defined, the
system will provide a visual and an audible warning if the boom approaches a virtual wall.

CAUTION

WHEN DEFINING VIRTUAL WALL(S), ALWAYS ALLOW


A SAFE WORKING DISTANCE TO ANY OBSTACLES.
NEVER WORK OUTSIDE A SAFE WORKING AREA
AS DEFINED BY COMMON PRACTICE, STANDARDS,
AND MANUALS.

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PIXEF 215 OPERATING PROCEDURE

WARNING

THERE ARE NO CUTOUTS ASSOCIATED WITH THE


SWING ANGLE SET LIMITATION OR THE WORK
AREA DEFINITION FEATURES.

An Anti-two Block Device is also incorporated into the system to prevent the hook block or headache ball from
coming into contact with the boom nose or boom extension. This condition will also cause a lockout of hoist up,
boom down, and telescope out, and also provide a visual and an audible alarm. Refer to the LMI Operator's
Handbook for more detailed information on the function of the LMI system.

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PIXEF 215 OPERATING PROCEDURE

STOWING AND PARKING

DANGER

NEVER PARK THE CRANE NEAR HOLES,


OR ON ROCKY OR EXTREMELY SOFT
SURFACES. THIS MAY CAUSE THE
CRANE TO OVERTURN, RESULTING IN
INJURY TO PERSONNEL.

When parking the crane, do the following:

1. Park the crane on a stable surface.

2. Remove the load from the hook.

3. Stow the swing away boom extension, if erected.

4. Fully retract the boom and position it in the normal travel position.

5. Engage the swing brake and/or swing lock pin.

6. Retract all stabilizer cylinders and outrigger beams.

7. Apply the parking brake.

8. Put all operating controls in the neutral position.

9. Position the CRANE POWER switch to OFF.

10. Shut down the engine following the proper procedures specified in this Handbook and the applicable Engine
Manual.

11. Remove the keys.

12. Close and lock all windows, covers, and doors.

90
PIXEF 215 LUBRICATION

SECTION 5

LUBRICATION

91
PIXEF 215 LUBRICATION

SECTION 5

LUBRICATION

GENERAL

Following the designated lubrication procedures is important in ensuring maximum crane lifetime and utilization. The
procedures and lubrication charts in this section include information on the types of lubricants used, the location of
the lubrication points, the frequency of lubrication, and other information.

LUBRICATION POINTS

The service intervals specified are for normal operation where moderate temperature, humidity, and atmospheric
conditions prevail. In areas of extreme conditions, the service periods and lubrication specifications should be
altered to meet existing conditions. For information on extreme condition lubrication, contact your local service
representative or TIL Ltd. Customer Support.

A regular frequency of lubrication must be established for all lubrication points. Normally, this is based on
component operating time. The most efficient method of keeping track of lubrication requirements is to maintain a
job log indicating crane usage. The log must use the readings from the engine hour meter to ensure coverage of
lubrication points that will receive attention based on the hourmeter readings. Other lubrication requirements must
be made on a time basis, i.e. weekly, monthly, etc.

All oil level are to be checked with the crane parked on a level surface in the transport position, and while the oil is
cold, unless otherwise specified.

On plug type check points, the oil level are to be at the bottom edge of the check port.

On all crane with a sight glass on the left side of the hoist, the fill level should be to the center of the sight glass.

All grease fittings are SAE STANDARD unless otherwise indicated. Grease non-sealed fittings until grease is seen
extruding from the fitting. One pump on a standard 0.45 kg (1 lb) grease gun equals 28 grams (1 oz) of EP-MPG.

Over lubrication on non-sealed fittings will not harm the fittings or components, but under lubrication will definitely
lead to a shorter lifetime.

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PIXEF 215 LUBRICATION

On sealed U-joints, care must be exercised to prevent rupturing the seals. Fill only until expansion of the seals first
becomes visible.

Unless otherwise indicated, items not equipped with grease fittings, such as linkage, pins, levers, etc. should be
lubricated with oil once a week. Motor oil, applied sparingly, will provide the necessary lubrication and help prevent
the formation of rust. An anti-Seize compound may be used if rust has not formed, otherwise the components must
be cleaned first.

Grease fittings that are worn and will not hold the grease gun, or those that have a stuck check ball, must be
replaced. Where wear pads are used, cycle the components and lubrication to ensure coverage of the entire wear
area.

Each lubrication point to the crane is numbered, which corresponds to the index number shown on Lubrication
Chart. The descriptions of the lubrication points given the lube type, lube interval, lube amount & application.

93
PIXEF 215 LUBRICATION

Recommended Lubricants
Sl. Type of
No. Lubricant
Balmer Indian Oil Bharat Hindusthan
Lawrie Petroleum Petroleum

1 Hydraulic Oil Protomac H68 Servosystem 68 Hydrol - 68 Enclo - 68

2 Engine Oil Protomac Servo Premium Actuma Ultra HP Engine Oil


PMG 20W40 20W/40 Super 20/40W Super 20/40W

Protomac HP Servogear Spirol 140-EP HP Gear Oil


3 Gear Oil 140
HP-140 EP-140

4 Grease Liprex EP1 Servogrease-MP Bharat HP-MP Grease


Univex "A"

Liprex EP2 Servocoat 140 Camex Hytak-2


Open Gear
5 Compound Compound "F"

6 Transmission Oil Protomac SAE Servo Premium Actuma Ultra


SAE GRADE HP Engine Oil
GRADE 15W-40 SAE GRADE SAE GRADE
15W-40 15W-40 15W-40
7 Brake Fluid

94
PIXEF 215 LUBRICATION

FIGURE 23: LUBRICATION CHART

95
PIXEF 215 LUBRICATION

1. Hook Block Swivel Bearing

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 250 hours or 3 months
Lube Amount - Until grease extrudes
Application - 1 grease fitting

2. Hook Block Sheaves

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 250 hours or 3 months
Lube Amount - Until grease extrudes

3. Side Wear Pads

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 250 hours or 3 months
Lube Amount - Thoroughly coat the area the wear pad moves on.
Application - By brush: with boom in extended position.

4. Boom Section Upper Wear Pads

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 50 hours or 1 week
Lube Amount - Thoroughly coat the area the wear pad moves on.
Application - By brush: 6 places; with boom in extended position.

5. Boom Section Lower Wear Pads

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 50 hours or 1 week
Lube Amount - Thoroughly coat the area the wear pad moves on.
Application - By brush; extend boom for entry through access holes

96
PIXEF 215 LUBRICATION

6. Boom Pivot Shaft

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 250 hours or 3 months
Lube Amount - Until grease extrudes
Application - 2 grease fittings, one on each side

7. Upper Boom Nose Sheave

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 250 hours or 3 months
Lube Amount - Until grease extrudes
Application - 1 grease fitting per sheave

8. Lower Boom Nose Sheave

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 250 hours or 3 months
Lube Amount - Until grease extrudes
Application - 1 grease fitting per sheave

9. Upper Lift Cylinder Pivot Pin

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 500 hours or every 3 months
Lube Amount - Until grease extrudes
Application - 1 grease fitting

10. Lower Lift Cylinder Pivot Pins

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 500 hours or 3 months
Lube Amount - Until grease extrudes
Application - 2 grease fittings

97
PIXEF 215 LUBRICATION

11. Main Hoist

Lube Type - EP Gear Lubricant - Protomac HP - 140


Lube Interval - Every 1000 hours or 12 months
Lube Amount - Capacity 2.8 liters
Application - Fill until level with the check plug opening.

12. Slew Gear Box

Lube Type - PROTOMAC HP 140 (SPL)


Lube Interval - Check and fill every 50 hours. Drain and fill after first 250 hours and every 500 hours or 12
months thereafter.
Lube Amount -
Capacity - 3.4 liters
Application - Fill until oil appears in sight gauge.

13. Turntable Gear and Drive Pinion

Lube Type - Open Gear Compound - Liprex EP2


Lube Interval - 500 hours or 6 months
Lube Amount - Coat all teeth
Application - Spray on

14. Turntable Bearing

Lube Type - EP-MPG - Liprex EP1


Lube Interval - 500 hours or 6 months
Lube Amount - Until grease extrudes the whole circumference of the bearing.
Application - 2 grease fittings at the front of the turntable. Rotate the turntable 90 and apply grease to
fittings. Continue rotating 90 and grease the fittings until the whole bearing is greased.

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PIXEF 215 LUBRICATION

15. Differentials

Lube Type - EP Gear Lubricant - Protomac HP - 140


Lube Amount -
Capacity - 16 liters
Lube Interval - Check lubricant level every 500 hours or 3 months and refill as necessary. Drain and refill
every 4000 hours or 2 years.

16. Planetary Hubs and Wheel Bearings

Lube Type - EP Gear Lubricant - Potomac HP 140


Lube Amount -
Capacity - 3 liters
Lube Interval - Check fluid level every 500 hours or 3 months and refill as necessary. Drain and refill every
4000 hours or 2 years.

17. Drive Line - Slip and U-Joints

Lube Type - EP-MPG


Lube Interval - 500 hours or every 3 months
Lube Amount - Until grease extrudes
Application - 6 grease fittings

18. Outrigger Beams

Lube Type - EP-OGL


Lube Interval - 500 hours or 6 months
Lube Amount - Spray lubricant on bottom of outrigger beams.
Application - Spray on

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PIXEF 215 LUBRICATION

19. Steering Cylinder Pivot Pins

Lube Type - EP-MPG


Lube Interval - 500 hours or 3 months
Lube Amount - Until grease extrudes
Application - 8 grease fittings

20. Upper and Lower King Pins

Lube Type - EP-MPG


Lube Interval - 500 hours or 3 months
Lube Amount - Until grease extrudes
Application - 8 grease fittings

21. Lockout Cylinder Pivot Pins

Lube Type - EP-MPG


Lube Interval - 500 hours or 3 months
Lube Amount - Until grease extrudes
Application - 4 fittings

22. Hydraulic Reservoir

Lube Type - HYDO - Potomac H 68


Lube Interval - Check fluid level every 10 hours or daily, using sight gauge on side of tank, with boom down
and all outrigger cylinders retracted; drain and refill as necessary.
Lube Amount - 160 liters to FULL mark on sight gauge.
Application - Fill through breather/fill cap on top of tank.

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PIXEF 215 LUBRICATION

23. Throttle Master Cylinder

Lube Type - BF
Lube Interval - Check fluid level every 500 hours or 3 months and fill as required
Application - Fill cap on reservoir.

24. Transmission, Torque Converter and Transmission Filter

Lube Type - PROTOMAC SAE GRADE 15W-40


Lube Amount -
Capacity - 15 liters
Lube Interval - Check fluid level every 10 hours or daily with the engine running at 800 rpm and the oil at
82 to 93 C (180 to 200 F); Drain and refill every 1000 hours or 6 months with the oil at 65
to 93 C (150 to 200 F); change transmission filter after the first 50 and 100 hours of
service, then every 500 hours thereafter.

To add fluid:

1. Fill to FULL mark on dipstick.

2. Run engine at 800 rpm to prime torque converter and lines.

3. Check oil level with engine running at 800 rpm and oil at 82 to 93 C (180 to 200 F). Add oil to bring
oil level to FULL mark on dipstick.

25. Engine Cooling System

Lube Type - AFC


Capacity - 8.5 Liter
Lube Interval - Check coolant level every 10 hours or daily; drain and refill cooling system in accordance
with Engine Service Manual.
coolant Amount- Capacity - 14 liters.
Application - Fill radiator with EURO COOL Premix to bottom of the surge tank filler neck. Run engine
through two (2) thermal cycles. Check coolant level and refill as required

26. Engine - See Separate Engine Manual

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

SECTION 6

MAINTENANCE / SERVICING INSTRUCTION

102
PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

GENERAL

1 a) Start the engine. Starting of the engine under different environmental conditions, should follow the
procedures as indicated in the manual .

a) The crane operations viz. derricking, telescoping hoisting, and slewing should be performed in both
directions several times. This will ensure proper lubrication and greasing of all required surfaces. It
will serve as a check on the proper functioning of various sub-systems.

b) If the machine is keep under storage indoors, special attention must be paid to ventilation.

c) The heater in the operators cabin must be set into operation for approx. 15 minutes when required.

d) Check all the wire cables to ensure against loss of insulation and corrosion.

e) Spray paint all surfaces having a tendency to rust, with anti-corrosive. The anti-corrosive should form
a thick film over such surfaces.

f) All recommended storage procedures are to be carried out once again, prior to storage of the
machine.

2 The inspections are separated into the following frequency classifications :

a) Daily Inspections - These items should be visually inspected each day by the operator prior to
using the unit.

b) Weekly Inspections - These items should be visually inspected weekly by the operator

c) Monthly Inspections - These inspections are to be performed monthly by the personnel


responsible for maintenance and service of the crane.

d) Periodic Inspections - This inspection is a thorough inspection conducted at least months and
includes all items listed under Daily, Weekly and Monthly inspection in
addition to those items listed under periodic inspection.

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

3) DAILY INSPECTIONS:

Check the following items:

i) Hydraulic oil level.

ii) Engine oil level.

iii) Diesel in fuel in tank.

iv) Transmission oil level.

v) Axle oil level.

vi) Brake oil level.

vii) Loose parts or damage to structures or weld.

viii) Operation of lights, safety equipment and gauges.

ix) Condition of tires and suspension.

x) Condition of load line and end attachment for corrosion, severe kinking, crushing, cutting or slippage
of cable clamps or wedge socket.

xi) Free turning of sheaves.

xii) Lubrication of points required by Lubrication Chart.

xiii) Evidence of oil leak from hoses or gearboxes.

xiv) Controls including foot throttle for malfunction or misadjustment.

xv) Truck hand brake operation.

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

xvi) All securing hardware such as cotter pins, snap rings, hairpins, pin keepers and cap screws for
proper installation.

xvii) Condition and operation of anti-two block system including : switch, power cord, and weight and
chain at boom tip.

xviii) All safety covers for proper installation.

xix) Presence and proper operation of load hook safety latch.

4) WEEKLY INSPECTIONS:

Check the following items:

i) Battery water level.

ii) Tire Pressure.

iii) Lubrication of points required by Lubrication Chart.

iv) Boom derrick and outrigger / jack holding valves for proper operation.

v) Torque mounting bolts during first month of operation of machine and then during periodic
inspections thereafter.

vi) Hoist brake for proper operation at winch capacity load.

vii) Torque boom wear pad retaining bolts during first month of operation, then monthly thereafter.

5) MONTHLY INSPECTIONS:

Check the following items :

i) All cylinder and valves for signs of leaks.

ii) Lubrication of points required by Lubrication Chart.

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

iii) Load hook for cracks degree twist.

iv) All structural members (boom, sub frame, superstructure and outriggers) for bends, cracks or broken
members.

v) All welds for breaks or cracks.

vi) All pins for proper installation.

vii) All control, safety and capacity placards for readability and secure attachment.

viii) Tightness of all boom wear pad retaining bolts.

ix) Sheaves and rope drums for wear and cracks.

x) Unspool hoist rope and check according to rope maintenance procedure.

6) PERIODIC INSPECTIONS:

Check the following items:

i) All items listed under daily, weekly and monthly inspections.

ii) Loose bolts and fasteners in all areas. Torque pin retainer bolts.

iii) All pins, bearings, shafts, and gears for wear cracks or distortion to include all pivot, outriggers and
sheave pins, and bearings.

iv) Hydraulic system for proper operating pressure.

v) Lift and outrigger / jack cylinders for drift caused by oil leaking around piston.

vi) Cylinders for :

a) Damaged rods
b) Dented barrels
c) Drift from oil leaking by piston
d) Leaks at rod seals, welds or holding valves.

106
PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

vii) Hydraulic hose and tubing for evidence of damage such as blistering, crushing or abrasion.

viii) Inspect all electrical wires and connections for worn, cut or deteriorated insulation and bare wire.
Replace or repair if equipped.

ix) Slew bearing and gearbox mount bolts for proper torque.

There is now an increasing awareness of, and demand for, correct torque figures to be used when tightening nuts,
bolts and screws. Accordingly we have issued the following figures which correspond to the maximum clamping
force for each size and grade of bolts.

Clearly there will be many instances where the stress imposed on bolts is far below the maximum allowed and
therefore the maximum torque figure given would not be necessary, however if in doubt the maximum figures quoted
bellow should be used.

It should be clearly understood that there is a vast difference between the effects of tightening bolts with dry
(unlubricated) threads as compared with threads which have been lubricated. If bolts are lubricated and then
tightened using the dry thread torque figure, failure from overstressing could result.

There are instances where special care should be taken i.e., wheel studs and slew ring bots and the correct
procedure for these deviations follow the general tables.

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

METRIC THREAD FORM RECOMMENDED TIGHTENING TORQUES lbf. Ft, / kgf. m.

THREAD SIZE GRADE TIGHTENING TORQUE


lbf. Ft. Kg. m
M4 8.8 2.25 0.31
10.9 3.20 0.44
12.9 3.85 0.53
M5 8.8 4.60 0.64
10.9 6.50 0.90
12.9 7.75 1.08
M6 8.8 7.80 1.09
10.9 11.00 1.50
12.9 13.20 1.80
M8 8.8 19.00 2.60
10.9 26.70 3.70
12.9 32.00 4.40
M10 8.8 38.00 5.20
10.9 53.00 7.30
12.9 63.00 8.80
M12 8.8 66.20 9.10
10.9 92.00 12.80
12.0 111.00 15.30
M16 8.8 163.00 22.50
10.9 230.00 32.00
12.9 275.00 38.00
M20 8.8 320.00 44.00
10.9 450.00 62.00
12.9 540.00 74.00
M22 8.8 430.00 60.00
10.9 610.00 84.00
12.9

M24 8.8 550.00 76.00


10.9 775.00 110.00
12.9 925.00 130.00
M30 8.8 1100.00 151.00
10.9 1525.00 215.00
12.9 1850.00 355.00
M36 8.8 1900.00 264.00
10.9 2700.00 371.00
12.9 3200.00 446.00
M48 8.8 4550.00 633.00
10.9 6400.00 890.00
12.9 7700.00 1070.00

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

IMPERIAL THREAD FORMS RECOMMENDED TIGHTENING


TORQUE lbf. ft. / kgf. m.

THREAD SIZE GRADE TIGHTENING TORQUE


U.N.F. U.N.C.
lbf. ft. Lbf. Ft.
7/16 R 45.0 41.0
S 50.0 46.0
T 58.0 54.0
X 83.0 74.0
1/2 R 67.0 61.0
S 75.0 69.0
T 87.0 80.0
X 125.0 114.0
5/8 R 136.0 127.0
S 151.0 141.0
T 175.0 163.0
X 250.2 233.0
3/4 R 235.0 223.0
S 263.0 257.0
T 312.0 290.0
X 425.0 416.0
7/8 R 378.0 360.0
S 424.0 400.0
T 490.0 466.0
X 740.0 675.0
1 R 570.0 540.0
S 640.0 605.0
T 770.0 705.0
X 1100.0 1010.0

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

Wheel Studs

Correct tightening of wheel nuts at regular intervals is an essential requirement if expensive repairs are to be
avoided

Problems will invariably occur if wheel nuts are tightened to a torque significantly above or below the recommended
figure

Under tightening wheel nuts inevitably results in a fairly rapid loosening with damage to studs, nuts and wheel disc
locations ultimately the wheel studs may shear and the wheel/s become detached

Over tightening can be equally dangerous in as much as the device incorporated to prevent rotation of the stud i e.,
serrations or dowels, may be destroyed.

Subsequent loosening of the stud retaining nut may result particularly on axles where the left hand side hubs are
fitted with left hand thread wheel nuts and right hand thread locknuts

Over stressing of the studs is also an obvious danger where nuts have been over tightened

Once wheel nuts have been found loose it is recommended that the studs and the location areas of the wheel disc/s
are checked for signs of damage If noticeable deformation is present it is unlikely that the wheel can be adequately
secured even when tightened to the correct torque

When tightening wheel nuts, the progressive pattern illustrated in figure 24 should be adopted Never hilly tighten one
nuts whilst others are fully loosened Checks should be made during the tightening process to ensure that the nuts
are fitting snugly in their locations in the wheel disc This is particularly important with twin wheel where the location
of the innermost wheel must also be checked

Note : Wheel stud and nut threads should be clean and dry.

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

FIGURE 24 : WHEEL STUDS

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

Slewing Rings

It must be borne in mind that the stewing ring and its mounting bolts are the only connection between the
superstructure and chassis and accordingly adequate attention to this assembly is essential.

Generally speaking, once the slew ring bolts have been correctly tightened at the Factory, it should only be
necessary for inspection annually. However as a crane by the very nature of its work is liable to be overloaded either
knowingly or unwittingly (e g , slipping slings, dual fills, wind conditions etc.) our recommendations are that more
frequent inspections should be carried out particularly where such over loading is known to have occurred.

Every 3 months, all slew ring securing bolts, ring to chassis and ring to superstructure, should be checked to ensure
that all are in place and that there are no obvious signs of loosening

All bolts should be checked at the annual inspection using torque measuring equipment to ensure that they are
tightened to the correct degree of pre-stress If one or more bolts are found to be tightened to less than 80 % of the
prescribed pre-stress, the loose bolt or bolts should be replaced, as should the two adjacent bolts If 20% of the total
number of bolts in a single ring are found to be tightened to less that 80 % of the prescribed pre-stress, all bolts
should be replaced. Replacement bolts should always be tightened progressively in the sequence shown in figure
25.

FIGURE 25: SLEW RING

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PIXEF 215 MAINTENANCE / SERVICING INSTRUCTION

WIRE ROPE MAINTENANCE

a. INSPECTION
Three scheduled inspections: daily, monthly and quarterly, should be made of all rope in daily service. These
scheduled inspections vary in the degree of thoroughness as outlined below and should be made at the
intervals recommended or sooner should the general appearance or use cycle of a particular rope indicate
the need for more frequent or more thorough inspection. All rope which has been idle for a period of a month
or more due to a shutdown or storage of a machine on which it is installed, shall be given a thorough
inspection before it is placed in service. This inspection should cover all types of deterioration including:

I. Distortion of the rope such as kinking, crushing, unstranding, birdcaging, main strand displacement
or core protrusion. Loss of rope diameter in a short rope length or unevenness of outer strand should
provide evidence the rope or ropes be replaced.

II. General corrosion.

III. Broken or cut strands.

IV. Number, distribution and type of visible broken wires

V. Core failure in rotation resistant ropes.

Only surface or rope should be inspected. Never attempt to open the rope.

All running rope in continuous service should be inspected once each working day. This inspection is made
before the rope is used for the first time on any particular day. It should cover the eye and that portion of the
rope used most extensively in daily operation. The eye should be inspected thoroughly for abrasion,
corrosion, broken wires and loose or broken servings. Inspect the remainder of the rope length normally
used for daily operations for points showing kinks, sharp bends, or any other evidences of damage or
excessive wear.

During the monthly inspections, the entire length of wire rope should be examined. A thorough inspection
should be made of the eye and the length of rope normally used in daily operations. Examine the remainder
of the rope for kinked, crushed or otherwise damaged points.

The periodic inspection requires a thorough inspection of the entire rope length. This inspection will usually
indicate greater wear at the eye end of the rope. Therefore, if the rope is in good condition and is to remain
in service, it should be reversed on the drum so that the wear will more nearly equalize along the entire
length.

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ROPE REPLACEMENT

It is extremely difficult to determine the exact time for replacement of wire rope since many variable factors are
involved. Proper determination of the condition of a wire rope depends upon the good judgement of an experienced
person in evaluating the remaining strength in a used rope after allowance for deterioration disclosed by inspection.
The following reasons are sufficient justification for consideration of rope replacement.

I Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay.

Rope is unsafe for further use if there are either three broken wires in one strand (Brakes 2, 3, 4) or a total of
six broken wires in all strands in any one rope lay. (Fig.12)

II Wear of onethird the original diameter of outside individual wires.

Worm rope, usually indicated by flat spots on the outer wires as shown is unsafe for further use when less
than two--thirds the thickness of the outer wire remains.

III Necking down of the rope, which would indicate for failure.

IV Kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure.

V Evidence of heat damage from any cause.

VI Reductions from nominal diameter of more than 1/32 inch.

VII One outer wire broken at the point of contact with the core of the rope which has worked its way out of the
rope structure and protrudes or loops out from the rope structure. Additional inspection of this section is
required.

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FIGURE 26: WIRE ROPE CONDITION

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MAINTENANCE & SERVICING OF BOOM ASSEMBLY

BEARING PAD ADJUSTMENT

Adjustable bearing pad assemblies with renewable nylatron pads are located at various points in the telescope
boom assembly. The bearing pad assemblies combine the functions of providing bearing surfaces for the
telescoping boom sections plus the means of adjusting the individual boom section for correct alignment in the
vertical and horizontal planes both during initial assembly and for re-adjustment due to normal wear in service.

Typical examples of the bearing pad assemblies employed to provide these functions are shown in the figures
below.

Warning: The outriggers must be fully extended and the crane properly jacked up and parking brake engaged
before undertaking any check or adjustment described in the following system.

a. Boom Assembly

A correctly shimmed boom should have between 1 mm and 3 mm clearance between the top of rear upper
pads and the next boom section. If outside of this tolerance, shimming should be adjusted as necessary.
Shims are available in two thickness 3 mm & 1.5 mm.

b. Location of Adjustable Side Pads - Refer to figure 27

1. Upper Front Pads - No. 2 Boom


2. Upper Front Pads - No. 1 Boom
3. Lower Front Pads - No. 1 Boom
4. Lower Front Pads - No. 2 Boom
5. Side Rear Pads - No. 2 Boom

c. Location of Non-Adjustable Side Pads - Refer to figure 27

6. Lower Front Pads - No. 2 Boom


7. Lower Front Pads - No. 1 Boom
8. Top Rear Pads - No. 3 Boom
9. Top Rear Pads - No. 2 Boom
10. Side Rear Pads - No. 3 Boom

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d. Bearing Pad Adjustment

It is recommended that adjustable side pads are inspected for wear and adjusted as necessary every three
months. Lubrication should be undertaken at the regular intervals stipulated in the Lubrication Schedule in
this manual.

e. Side Pad Wear Limits

The permissible amount of wear for the circular side pads is determined by the thickness of an individual
pad. Since the rear side pads can be properly checked for wear only when the boom is dismantled, the wear
rate of the front side pads, which can be determined by taking measurement inside the pad boss, should be
used as a general guide for assessing the wear of the rear pads i.e. the wear rate will be approximately
similar.

In consequence, it will become necessary to renew a pad or pads when the maximum wear dimension given
in the table below is obtained.

Boss Maximum Wear


Thickness Dimension X

1 - 25.4 mm 1/4 - 6.35 mm


1 1/4 - 31.7 mm 3/8 - 9.52 mm
1.29/32 - 49.2 mm. 3/4 - 19.05 mm
2 1/4 - 57.2 mm 3/4 - 19.05 mm
2 1/2 - 63.5 mm 1 - 25.4 mm

Dimension X from edge of boss to rear face of pad

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f. Bottom Front Pads - Refer to figure 27

The bottom pads (6) and (7) re fitted between shear stops (11) and are non-adjustable. These pads can be
visually inspected for wear with the boom partially extended and either lifted or derricked down onto a
suitable support. The pads are 30 mm (1 3/16) and 65 mm (2 3/8) thick respectively when new and renewal
should occur when wear reduces the thickness by 8 mm (5/16).

The pads are secured by self-locking screws and flat washers. When renewing a pad it is important to
ensure that the screws are fully tightended and then backed off by the 1/4 turn to allow the pad to slide
between the shear stops. These will ensure that there is no load on the screws.

Access to rear bearing pads at FRONT of No. 1 boom (1) is shown at hole (2). To check adjustment,
telescope boom OUT until pads are aligned with the access hole (2) at each side of boom.

g. Top Rear Pads - Refer to figure 27

The top pads (8) and (9) are fitted between shear stops (12) and in common with the front pads (6) and (7)
are non-adjustable. Since these pads can be properly checked for wear only when the boom is dismantled,
the wear rate of front pads (6) and (7) should be used as a guide for general assessment of rear pad wear.

Both pads are 30 mm (1.3/16) thick. The wear rate and fitting precautions described in previous notes for
pads (6) and (7) are applicable to these pads.

h. Rear Side Pads - Refer to figure 27

The side pads (10) are adjusted by shims to centralize No. 3 boom within No. 2 boom. The pads should be
inspected at overhaul periods (or whenever the boom dismantled) and renewed if necessary.

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i. Side Pad Locking Plates

Note that when adjusting the rear side pads shown in Fig.28. a pad must be turned as necessary at the
desired adjustment point until the spring-loaded locking plate engages correctly. Also note, when screwing a
rear pad outwards (with the pad on the opposite side backed off), the rear of the boom section will be moved
towards the boom centre line.

When adjusting the front side bearing pads shown in Fig. 29 it is important to ensure that the locking plate is
located correctly on completion. To do so it will be necessary to align the pads and the slot in the pad boss
at a position nearest to the desired adjustment point so that the locking plate can be inserted and secured.

To check and Adjust the Side Pads

j. Rear Pads

1. With the crane properly jacked up, boom fully retracted, A parking brake engaged, visually check the
location of the individual boom sections in relation to each other, i.e. central location with equal side
spacing between boom sections as required.

2. This can be ascertained at the rear pads for example by measuring the distance between Nos. 1 and
2 booms using the inner face of No. 1 boom as a datum line. Both sides of the boom must be
measured.

3. Telescope boom OUT until rear pads are aligned with access holes (2) in No. 1 boom and check
measurements in a similar manner a (2) above - see figure 27.

4. If the measurement obtained are different, No. 2 boom must be centralised by adjusting the rear
pads. To do so, screw the required pad outwards to move the boom section in the desired direction
after backing off the pad on the opposite side see figure 29.

5. Set the final of each rear pad by screwing out until bottomed against No. 2 boom and then off by a
half turn to provide turning clearance between the boom sections.

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FIGURE 27: LOCATION OF BEARING PADS

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FIGURE 28: BOOM PAD ADJUSTMENT

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FIGURE 29: BOOM PAD ADJUSTMENT

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FIGURE 30: BOOM ALIGNMENT

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FIGURE 31: BOOM PAD ADJUSTMENT

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FIGURE 32: FRONT BEARING PADS

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k. Front Pads

1. The front pads on each boom section are now set in the same manner after taking measurement
from a similar datum line to ensure that the sections are centrally located in relation to each other.

2. As with the rear pads, measurements are taken with the boom fully retracted and repeated with the
boom telescoped OUT. A comparison of the measurements obtained will readily indicate any re-
adjustments that may be necessary.

3. Set the final position of each front pad by screwing in until bottomed and then backing off by half a
turn to provide running clearance between the boom sections see figure 32.

4. With all boom sections adjusted, the boom must be checked for overall alignment. With the crane
blocked up and a suitable weight on the hook, derrick in to near minimum radius then telescope
boom fully out.

5. From a position at the rear of the crane, check the boom for alignment as shown in figure 30. If any
obvious deviation from the boom centre line is evident, it will be necessary to correct this by re-
adjusting the rear pads to suit ensuring that the correct running clearance is maintained.

IMPORTANT NOTE: The maximum permissible lateral deviation of the load from the boom centre line, when lifting
loads of up to maximum safe working load, should not exceed 1 % of the total boom length. A typical example would
be on a machine having a 15 m main boom plus a 5 m lattice extension then the maximum deviation should not
exceed 15 + 5 = 0.2 m

EXAMPLE: If measurement taken show that No. 2 boom is off crane to LEFT of boom centre line viewed from rear
adjust pads s under ;

Figure 28 REAR BEARING PADS

Pads (1) fitted to No. 2 Boom

Insert tool (2) into square socket of right hand pad (1) and press inwards to release locking plate (3). Turn pad anti-
clockwise (4) to move No. 2 boom section towards boom centre line.

Pad on opposite side of boom must be backed off by turning clockwise (5) before making adjustment.

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Adjust pads as shown at top left to ensure that boom sections are central with equal side spacing between boom
sections as shown at dimension Y above.

Remove the two bolts (1) and locking plate (2)

Use tool (3) as shown to turn bearing pad (4) in or out as required. When the correct adjustment is obtained, refit
locking plate with one end in slot (5) and secure with bolts.

Dimension X above - edge of boss to rear face of pad

Adjust bearing pads to ensure that boom sections are central with equal side facing between boom sections as
shown at dimension Y above.

HYDRAULIC SYSTEM

The hydraulic system does not need a special maintenance since always that the hydraulic oil keeps its
characteristics and the filters keep the circuit clean from dirtiness, the problem will be minimal. Basically the
maintenance operations are reduced to:

a) Daily visual checking in order to discover possible leakages (for that it is important that the is regularly
cleaned) especially the connections and also to prevent hoses and hoses breaks.

b) Check the hydraulic oil level in the tank, this checking must be done with all the cylinders withdrawn.

In this position the level must be halfway of the level indicator. It is very important that the oil level is always
the maximum possible since a bigger quantity of oil would mean a lower working temperature. If the level is
low, refill using the same oil type that the crane has.

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Return line filter

a) The return filter is located on top of the tank. The red poppet extends when the filter element is clogged.

b) The poppet is operated by the pressure difference across the filter. When the hydraulic oil is cold the
pressure may be great enough to push the poppet out. If the poppet extends, push it in when the hydraulic
oil is at normal operating temperature. If the poppet stays in, the condition of the filter element is satisfactory.
If the poppet comes out after being pushed in, the filter element needs to be renewed.

c) To renew the element remove the filter from the tank and unscrew the filter bowl. Fit new element and seal.
Screw on the bowl and tighten. Refit the filter to the tank.

Periodic Maintenance Schedule

Daily When commissioning a new crane unknown quantities can be present therefore the
filter should be checked daily.

Weekly or 50 Hours There after the inspection period can be increased to weekly or 50 hours.

3 Months or 600 Hours Based on field experience it is recommended that elements are replaced after 600
hours

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Oil Change

Oil change depends on several factors, among which the aging and pollution degree are the most important ones. It
is recommended to change the oil every 4000 hours, but it is better to check periodically the oil quality and test it.
The test will say for how long the oil can be used.

When changing the oil, the tank and if possible, the whole circuit must be cleaned.

It must be proceeded as follow:

Put all the cylinders in closed position

Drain the tank (draining plug at the bottom)

Dismount the inspection cover and clean the tank.

Replace the suction and return filters,.

Release one end of return line in order to drain the circuit.

Mount the tank inspection cover.

Fill the tank up with oil.

Carry out the extension operation of all the cylinders in order to drain the old oil.

Connect again the return line.

Refill with oil up to the maximum level.

Bleeding the Hydraulic System

Ensure that the hydraulic tank is filled with oil to the correct level.

With the oil fully warmed up operate each hydraulic service several times to the full extent of travel in each
direction.

Check the hydraulic oil level and replenish if necessary.

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Slewing Ring

It must be borne in mind that the slewing ring and its mounting bolts are the only connection between superstructure
and chassis and accordingly adequate attention to this assembly is essential.

Generally, once the slew ring bolts have been correctly tightened at the Factory, it should only be necessary for
inspection annually. However as a crane by the very nature of its work is liable to be overloaded either knowingly or
unwittingly (e.g. slipping slings, dual lifts, wind conditions etc.) our recommendations are that more frequent
inspections should be carried out particularly where such overloading is know to have occurred.

Every 3 months, all slew ring securing bolts, ring to chassis and ring to superstructure, should be checked to ensure
that all are in place and that there are no obvious signs of loosening.

All bolts should be checked at the annual inspection using torque measuring equipment to ensure that they are
tightened to the correct degree of pre-stress. If one or more bolts are found to be tightened to less than 80 % of the
prescribed pre-stress, the loose bolt or bolts should be replaced, as should the two adjacent bolts. If 20 % of the
total number of bolts in a single ring are found to be tightened to less than 80 % of the prescribed pre-stress, all bolts
should be replaced. Replacement bolts should always be tightened progressively in the sequence shown in figure
25.

Whenever the slewing ring is being renewed, all bolts should be renewed at the same time. Where the
superstructure is being removed for any reason other than slew ring removal, the torque setting of the bolts should
be checked before removal. If correctly tightened bolts can be reused, however if bolts are found to be incorrectly
tightened they should be renewed following the recommendations in the previous paragraph.

On most TIL Cranes and on all current models, slew ring bolts are manufactured from high tensile steel. Only bolts
of the correct grade of steel should be used in conjunction with hardened washers where fitted.

When fitting new bolts or replacing bolts, the correct relationship between applied torque on the bolt and the degree
of pre-stress required can only be achieved by ensuring that the bolt and hole threads are clean and lubricated
lightly with B.P. Multi-Gear 80W / 90 oil or equivalent.

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