Service Boom Inspection and Repair

Boom Inspection and Repair

Table of Contents: This booklet contains four individual Service Manual Codes. Codes. SM08-SM08--- 0101 --- 001.00 concerns inspection and repair of lattice lattice booms booms and jibs made of steel angle angle material material.. SM09-SM09--- 001-001--- 002.00 002.00 concerns concerns inspectio inspection n and repair repair of lattice lattice booms, flys, and jibs jibs made of tubular steel material. material. SM17--- 001001 --- 036.00 concerns inspection inspection of diamond embossed, telescopic booms. And lastly, lastly, SM17 --- 001001 --- 053.00 concerns inspection of two piece, formed, telescopic booms.

SM08 --- 001 --- 001.00 Repairing Repai ring Damaged Angle Booms And Jibs   Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Chord Material Identification . . . . . . . . . . . . . . . 2 Ordering Replacement Materials . . . . . . . . . . . 3 Lattice, Diagonals, And Picture Frame  Angle Repair . . . . . . . . . . . . . . . . . . . . . . . . . 4 Classification Of The Cases . . . . . . . . . . . . . . . 4 Case I --- Repair Of Cracks In Welds Throughout The Boom Or Jib . . . . . . . . . . 4 Case II --- Straightening Damaged Lattice, Picture Frame Angles, Diagonals,  And Braces . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Case III --- Replacement Of Lattice, Picture Frame Angles, Diagonals,  And Braces . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Appendix A  --- Angle Boom Or Jib Chord  And Lattice Corrosion, Corrosion, Pitting, Or Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Appendix B --- Care Of Electrodes . . . . . . . . . 9

SM09 --- 001 --- 002.00 Repairing Repai ring Damaged Tubular Booms, Flys, And Jibs   Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation For Repair . . . . . . . . . . . . . . . . . . . . General Instructions And Procedure Selection . . . . . . . . . . . . . . . . . . Guidelines For Straightening Of Lattice, Diagonals, And Picture Frame . . . . . . . . . . Procedure “A” --- Straightening . . . . . . . . . . . . . Procedure “B” --- Replacement Of Lattice By Lap Replacement . . . . . . . . . . . . . . . . . . Procedure “C” --- Replacement Of Lattice, Diagonals, Or Picture Frame By Complete Replacement . . . . . . . . . . . . . . .

1 2 3 3 4 4

6

SM09 --- 001 --- 002.00 (Continued)   Page Appendix A  --- Tubular Boom, Fly, And Jib Chord And Lattice Corrosion, Pitting, Or Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Appendix B --- Care Of Electrodes . . . . . . . . 15 Appendix C   ---- Ordering Replacement Replaceme nt Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Appendix D --- Weldi elding ng Curr Curren entt Tabl able . . . . . 17 Appendix E --- Training Instructions Required Require d Before Welding Tubular Jib Structures . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Appendix F  - --- Repair Of Picture Pictur e Frame Lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SM17 --- 001 --- 036.00 Hydraulic Hydraul ic Boom Inspection  (Diamond Embossed)   Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Documentation & Analysis . . . . . . . . . . . . . . . . General Inspection . . . . . . . . . . . . . . . . . . . . . . . Chord Angle Squareness . . . . . . . . . . . . . . . . . Boom Section Twist Inspection . . . . . . . . . . . . . Chord Angle Roll Inspection . . . . . . . . . . . . . . . Minor Axis Bow . . . . . . . . . . . . . . . . . . . . . . . . . . Major Axis Camber . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Boom Field Inspection Sample Form . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 2 3 3 4 5 6

SM17---001---053.00 Hydraulic Boom Inspection  (Formed)   Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Documentation & Analysis . . . . . . . . . . . . . . . . General Inspection . . . . . . . . . . . . . . . . . . . . . . . Boom Section Twist Inspection . . . . . . . . . . . . . Sidewall Flatness . . . . . . . . . . . . . . . . . . . . . . . . . Minor Axis Bow . . . . . . . . . . . . . . . . . . . . . . . . . . Major Axis Camber . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Boom Field Inspection Sample Form . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 3 4 5 6 7

Welding Instructions . . . . . . . . . . . . . . . . . . . . . . 9

Book Number 632J (0112)

Service Manual

 

SM08---001---001.00

0112

Acceptable Cosmetic Conditions Which Do Not Require Repair

1 1.

See Appendi Appendix x A.

Repairable Conditions Conditions Which Which Must Be Corrected Corrected 1. 2.

Non--Repairable Conditions Which Require The Section To Be Destroyed To Avoid All Possibility Of Future Use

5

1.

2

4

2.

3

6

3.

4.

5.

7

8 1. 2. 3.

Throat Throat Braces Braces Pin Connec Connectio tion n Corner Corner Bolt Bolt Plat Plate e

4. Picture Picture Frame Frame Angle 5. Chor Chords ds 6. Latt Lattic ice e

6. 7. 8.

Broken, bent, kinked, kinked, or missi missing ng lattice lattice,, picture frame angles, diagonals, or braces. Cracks in welds welds or braces braces other than than chord chord members, or boom or jib lugs.

Corner Corner Gusset Gusset Plate Plate Diagon Diagonal al

7.

Any cracks cracks in in main main chord members members or boom or jib lugs. Unacceptabl Unacceptable e dents or pitting pitting in in or corrosion corrosion on the chord members. members. (See  Appendix A.)* Overall straightness straightness of each each of the chords chords is is not within 3/16 inch ( 4.8mm ( 4.8mm)) per free span (distance between lattice), or 1/4 inch (6.4mm) 6.4mm) over length of section. Any prior prior repairs repairs on the the chord members members or boom or jib lugs (other than authorized lattice replacement). Cracks which continue continue into the chord chord in welds joining parts to chord members. Chord members members which have had had brackets, brackets, rigging parts, walkways, etc. welded on which are not original equipment. Obvious deformation deformation of the section. section.

* Consultatio Consultation n with LBCE LBCE is required required in this this area.

Figure 1 Typical Angle Boom Sections Sections

Repairing Damaged Angle Booms And Jibs Introduction This procedure provides information for identification, inspection, and repair of angle boom and jib sections manufactured by Link---Belt Construction Equipment (LBCE), which have only specific types of damage. These These instr instruct uctio ions ns are not not intend intended ed torepair torepair live live masts. masts. The scope scope of repair repairabl able e damage damage to attach attachmen ments ts is limlimited to only those components mentioned in Figure 1 under  Repairable Conditions Which Must Be Corrected . It is important important to note note that LBCE will will not assume respo responsi nsibi bilility ty for for repair repairs s made made by anyon anyone, e, other other than than a certified Link---Belt representative, using the procedures and restrictions outlined here. The suggestions made or procedures given are for informa formatio tion n only only and are based based on LBCE’s LBCE’s knowle knowledg dge e of  the produc product. t. The repairperso repairpersonne nnell must must assume assume theresponsi sponsibi bilility ty as to the workm workmans anshi hip p andthe ownermust ownermust bear the final responsibility responsibility as to its use. Prior to starting any repair work, all information contained in these procedur procedures, es, must be read and thorough thoroughly ly understoo understood. d.

 All inspection and repair work is to be performed by qualified qualified personnel. All work prescribed prescribed in these procedures is to be done on a non---working boom or jib, and whenever possible, possible, as single single sections. Boom or or  jib sections must be positioned positioned in such a manner that the work can be done in a safe and ready fashion. Note: Note: In an emergency emergency situati situation, on, repairs repairs can be done with the attachment attachment installed. installed. However, However, extreme care must be taken to fully support it, relieve any stress and remove all load from the damaged attach attachment ment.. In this this situat situation ion,, only one lattic lattice e can be replaced at a time.

Thearea of the boom boom or jib sectio section n being being repair repaired ed must must be free of moisture prior to any repair work which requires welding, gouging, gouging, or cutting. The use of low --hydrogen electrodes is required in many portions of  these procedures. See Appendix B for for care of low hydrogen electrodes. Materials used to manufacture booms and jibs, and the performance of these structures, requires special repair procedures as outlined in these instructions.

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SM08---001---001.00 Serial Number

Part Number

Service Manual

0112

L 0595 059573 73 18M3610 00 0000 0000 000 0000

D

Material Designation

Style 1

Part Number

18M1234 L 0702123 Serial Number

Style 2 Figure 2 Typical I.D. Plates

Chord Material Identification Before Before repair repairs s are starte started, d, it may be necess necessary ary to idenidentify the boom chord material if certain types of cutting and goug gouging ing equipme equipment nt are used. used. See Tabl Table e B. If  coated coated --- electrod electrode e (gouging (gouging w/o air) equipmen equipmentt is used used tocut and and goug gouge e on the the maincho mainchord rd thenit thenit willbe willbe necessary to establish what type of material was used in the main chords chords of the boom boom or jib. There There are two styles of identification (I.D.) plates. The Style 1 plate which contains the material designation and Style 2 plate plate which which does does not not indi indicat cate e the materi material al desig designat natio ion. n. See Figure 2. The Style Style 1 I.D. I.D. plate has a large large alphab alphabeti etical cal desig designanation tion stampe stamped d on it. Using Using these these letter letters, s, refer refer to Table able A for material identification. If a Style 2 identification plate is used, and the repair technique requires that the material be known, seek assist assistanc ance e from from LBCE LBCE Servic Service e Depart Departmen mentt for for materi material al identification.

DANGER Use only Link-Link-- Belt approved materials. materials. Any deviation deviation from these materials could result in seri seriou ous s pers person onal al inju injury ry,, deat death, h, or majo majorr equipment damage. damage. In the event event the boom or jib jib secti section on I.D I.D. plate plate is missi missing ng or unr unread eadabl able, e, repair repair of that that section section is not recommende recommended d until unt il it can be posit positiv ively ely ident identif ifie ied. d. Seek Seek assista assistance nce from LBCE LBCE Servic Service e Departm Department ent for proper methods methods of identifica identification. tion.

If the factor factory y I.D. I.D. tag and other other infor informat matio ional nal or cautio cautionnary ary tags tags are are on the the latti lattice ce bein being g repl replac aced ed,, it will will be necnecessary essary to replac replace e them. them. The The I.D. I.D. plate plate can be remov removed ed by carefu carefulllly y cuttin cutting g throu through gh the tack tack welds welds and reloc relocatating it on the replacement replacement lattice. Any Warning Warning or Caution tion label labels s will will have have to be order ordered ed from from a LBCE LBCE distr distrib ibuutor. The repair procedures for both types of material are similar, except, different types of cutting and grooving equipment are needed. needed. The welding procedure procedure is the same for all booms and jibs. For For any additio additional nal informati information on regardin regarding g chords chords or weldi welding ng of vario various us additi addition ons s to the chords chords,, pleas please e conconsult a LBCE distributor distributor. Be ready to provide identificaidentification plate informati information, on, amount amount and locatio location n of damage, damage, location and object to be welded, etc.

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Service Manual

 

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0112

Strength (Minimum Yield)

Type Of Angle Chord Material

Stamping

lbf /in2

N/ mm 2

(1) “D”

Quenched And Tempered High Strength    Alloy or Carbon Steel

100,000

690

(2) “TT”

Low Alloy High Strength Steel

50,000

345

Table A Material Identification

Recommended Processes

 

Usage

 

Material Type

 

Notes

Oxygen Acetylene Cutting Torch (Cutting)

For Cutting Lattice At Chord Angles As Stated In Case III

TT and D

See Case III

 Arc Arc --- Air (Gouging)

Gouging Of All Welds

TT and D

See Table C

Plasma Torch (Cutting & Gouging)

For Cutting Lattice At Chord Angles And Gouging Off Weld Material

TT and D

See Case I And Case III

Coated---Electrode (Gouging W/O Air)

Gouging Of All Welds

TT Only

See Table C

Grinders, Chisels, Saws

Removal, Cutting and Veeing Veeing of of Lattices, Lattices, Lattice Welds and Welds in General

TT and D

Table B Recommended Recommended Processes Processes With Skilled Operator’s Using Good Technique Techniques s To Keep Excessive Heat Out Of The Chord Material

Ordering Replacement Materials Proper Proper identifi identificatio cation n of replaceme replacement nt material materials s is crucial crucial to ensure the structural integrity of the attachment, as well as ease the assembly and and welding welding process. process. No variation of material type or nominal cross section dimensions is allowed.

DANGER Use only Link-Link-- Belt approved materials. materials. Any dev deviat iation ion from from nomi nomina nall cross ross sec section ion dimensions or material types could result in serious personal injury, death, and/or major equipment damage. damage. In the event the boom or jib jib secti section on I.D. I.D. plate plate is missi missing ng or un unrea reada dable ble,, repair repair of that that section section is not recommended recommended until unt il it can can be posit positiv ively ely ident identif ifie ied. d. Seek Seek assistan assistance ce from LBCE LBCE Service Service Departme Department nt for proper methods of identificat identification. ion.

Use the foll follow owin ing g Steps Steps to colle collect ct the necess necessaryinfo aryinformrmation needed to order attachment repair material from Link-Belt.

Length1

Thickness

Length 2 Figure 3 Nominal Cross--Sectional Dimensions

1. Locate Locate the I.D. I.D. plate plate and recor record d the serial serial number number,, part number, and chord material type, if shown. Refer to Figure 2. a. If I.D. plate plate Style Style 1 is used, refer refer to Table Table A for for material specification requirements. b. If I.D. I.D. plate Style Style 2 is used, used, seek seek assista assistance nce from LBCE Service Service Department Department for material material specifications. 2. Accurately measure and record the nominal nominal cross section section dimensio dimensions ns of the lattice, lattice, diagon diagonal, al, picture picture frame, frame, or brace brace to be replac replaced ed or repair repaired. ed. Refe Referr to Figure 3.

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SM08---001---001.00

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Lattice, Diagonals, And Picture Frame Angle Repair Lattice, diagonals, and picture frame angles must be kept in good condition to hold the chords in proper alignme alignment. nt. Bent lattice lattice cause deflectio deflection n of the main chord chord anglesso anglesso they they are no longe longerr “in “in line” line”,, thus thus reducreducing and partially destroying the load carrying capacity of the boom.  A good percentage of damaged lattice can be straightened by conventio conventional nal methods. methods. If the damage to the lattice is beyond repair by straightening, such as a severe twist or kink, it must be replaced. The maximum allowable uniform curvature, where no repair is necessary on lattice, diagonals, and picture 1mm m per per 40cm 40cm), or fram frame e angl angles es,, is 1/32 1/32 inch inch per per foot foot (1m less.  A lattice, diagonal, diagonal, or picture frame angle with a uniform curvature, greater than the maximum allowable mentioned, but but less than the ratio of 1 inch inch across 36 inche inches s (1cm across 36cm), may be straighten straightened. ed. Curvaturein vaturein excess excess of this this ratio ratio requir requires es compl complete ete replac replaceement of the lattice, diagonal, or picture frame angle.

DANGER Use only Link-Link-- Belt approved materials. materials. Any deviation deviation from these materials could result in seriou serious s person personal al inju injury ry,, deat death, h, or major major equipment damage.

The straightening, removal, and replacement of damaged components and repair of welds can be separated into three cases. A thorough examination examination of the boom or jib must be made to determine which case is to be used for repair of the boom or jib.

Classification Of The Cases Case I

Repair of cracks in welds throughout throughout the boom or jib.

Case II

Straightening Straightening damaged lattice, picture frame angles, diagonals, and braces.

lattice, picture frame Case III Replacement of lattice, angles, diagonals, and braces.

Case I Repa Repair ir of crac cracks ks in weld welds s throu through ghou outt the boom boom or jib. The The most most comm common on crac cracks ks in a weld weld join jointt are are at the the end end of welds. Less common are cracks cracks along the edge of  the weld. weld. Refer Refer to Figure Figure 4. 4 of 10

Service Manual The following are some helpful weld inspection hints. The most common weld inspection process is visual examination with the aid of a portable light. The equipment listed below, can be used to clear any doubt. 3. Magnetic Magnetic Particl Particle e a. Wet b. Dry 4. Penet Penetran rantt Dye a. Visi Visibl ble e b. Flor Floresc escent ent The indicati indication on of cracks when using using the visual visual method method would be: 1. Chipped Chipped,, flaked, flaked, or or blistere blistered d paint. paint. 2. Rust lines lines staini staining ng the the paint paint.. 3. Bent, twisted, twisted, or broken broken parts parts in the area. area.

 A procedure should be established for boom inspection. The section should should be placed so that that a good ininspec specti tion on can can be made made of each each side side of the the boom boom.. Ther There e shouldbe shouldbe equip equipmen mentt avail availabl able e to turn turn or roll roll thesection thesection from side to side so that a good inspection can be made. Each lattice lattice weld should should be examined examined,, along with all other areas areas of the boom section. section. The cracked welds should be marked, and only after marking all place places, s, shou should ld the repair repair be started started.. An order orderly ly proceprocedure should also be followed in the repair of cracked welds. Procedure Procedure For Removing, Veeing, Or Grooving Cracked Welds

1. Cracks Cracks in lattice lattice welds welds only: only: a. Remove Remove entire entire weld. weld. b. Replace Replace entire entire weld. weld. 2. Cracks Cracks other other than lattice lattice welds: welds: a. Cracks Cracks in welds welds where where the the weld length length is less less than 2 inches ( 50.8mm) long. 1. Remove Remove entire entire weld. weld. 2. Replace Replace entire entire weld. weld. b. Crac Cracks ks inwelds inwelds wher where e the the weldlen weldlengt gth h isgreatisgreat50.8mm er than 2 inches ( ) long and the crack is less than one half the length of the weld. 1. Vee Vee or groove groove out the weld weld deposit deposit the the 6.4mm length of the crack plus 1/4 inch ( ) beyond the crack length. 2. Replace Replace remov removed ed sectio section n of weld. weld. c. Crac Cracks ks inwelds inwelds wher where e the the weldlen weldlengt gth h isgreatisgreater than 2 inches (50.8mm) long and the crack is greater than one half the length of the weld. 1. Remove Remove the entire entire weld. weld. 2. Replace Replace the entire entire weld. weld.

Service Manual Diameter Of Electrode inches

mm

0.156

4

0.188

4.8

 

SM08---001---001.00

0112

Air Pressure psi    

Speed Of Travel  

kPa

ft/min

 

Amperage Range

m/min

80---100

 

552 --- 690

 

10---20

 

3 --- 6 3-

 

90---150

80---100

 

552 --- 690

 

10---20

 

3 --- 6 3-

 

150---200

Table C Data For Arc--Air And Coated--Electrode Gouging

Cut Welds Here

Cut Lattice Bends Here

Edge Of Weld Cut Cut Weld Welds s Here Here

End Of Weld Weld

Figure 4 Weld Removal Example

Figure 6 Cutting Cutt ing Lattice And Weld Removal Example

Cut Welds Here

Table B shows the recommended processes for cutting, veeing, and gouging of lattice, and all welds on a boom or jib. When using the arc---air process: 1. Use only only those those paramete parameters rs listed. listed. 2. Use qualifi qualified ed personnel personnel.. Cut Lattice Bends Here

Figure 5 Cutting Lattice And Weld Removal Example

3. Cracks Cracks in a plug plug or deep deep groo groove ve weld. weld. a. The The leng length th of the the crac crack k is to be vee’d vee’d or grooved out plus 1/4 inch (6.4mm) beyond its length and as deep as the crack penetrates into the weld. weld. The vee or groo groove ve is to have a minimum face opening of 1/4 inch (6.4mm) wide, or one half times its depth. b. Replace Replace remov removed ed section section of weld. weld.

The maximum maximum allowable allowable gouging gouging depth depth into into the the base metal is 1/32 inch (0.8mm). The gouges gouges must must be filled with weld during the repair procedure. without air (i.e. Use of electrod electrodes es for gougin gouging g without (i.e. Eutectics Eutectics  Astrode) is allowable allowable only on type “TT” “T T” material. In Table C, the parameters for gouging out welds  with the the arc--air  process  process are listed. listed. This data data is given given so that the process may be used on both type “D” and “TT” materials materials.. This process process is to be be used by qualifi qualified ed personnel, skilled in the arc---air process. Note: It is important that that the speed of travel shown shown in Table C is adhered to. In Summary Of Case I 1. Positi Position on the sectio section n properl properly y. 2. Inspec Inspectt and mark mark areas areas for repair repair in an orderl orderly y fashion. 3. Repair Repair the welds welds using using a recommen recommended ded proces process s which is proper for that material.

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SM08---001---001.00 1

0112

Service Manual

2

45

Figure 8 Preparing Angle Stub

3 1. Damaged Damaged Picture Picture Frame Frame Angle Angle 2. Remove Removed d Port Portion ion 3. Stub Stubs s

Figure 7 Removing Damaged Picture Frame Angle

Case II Straightening damaged lattice, picture frame angles, diagonals, and braces. Straightening Straightening may be performed performed on bent lattice, picpicture frame angles, angles, diagonals, diagonals, and braces using convention ventional al methods methods such as hammerin hammering g andbumping andbumping dollies, anvils, prying with bars, twisting with adjustable able wrenches, wrenches, etc. If heating heating is used in the straigh straighttening process the maximum allowable allowable temperature 593° C ). Temperatur is 1,100 1,100°° F (593° emperature e should should be controlled with the use of temperature crayons, thermometers, etc.

Case III Replacement of lattice, picture frame angles, diagonals, and braces. Replacement of lattice, diagonals, and braces

If the the chor chord d angl angle e is bowe bowed d in the the area area of the the dama damage ged d latti lattice, ce, dia diago gonal nal,, or brace, brace, itit may be due to the bend bend in the lattic lattice, e, diago diagonal nal,, or brace. brace. The chord chord may return return to its origina originall positio position n when the lattice, lattice, diagonal diagonal,, or brace is removed. If the chord does not straighten straighten up when the lattice, diagonal, or brace is removed, repair is not recommended. Thelattice, Thelattice, diago diagonal nals, s, or braces braces must must be remov removedfrom edfrom the chord by cutting out the welds at the chords or cross cross braces. In single piece piece replacement, replacement, the ends  joining the chords must be cut as shown in either Figure Figure 5, Figure Figure 6, or Figure Figure 7., 7., using using an oxygenoxygen---acetylene torch with cutting parameters listed in Table B. If more more than than a singl single e piece piece replac replaceme ement nt of adjace adjacent nt pieces pieces is required, required, then each bent section section of the piece piece which which is welded welded to the the chord chord must be removed removed by cutting through these welds.

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Note: A replacement lattice may either be a single piece, or bent adjacent pieces.

Caution should be used in maintaining alignment of  chord chord angle angles. s. This This canbe done done by clampi clamping ng a brace brace to the chords to keep them in line prior prior to welding. welding. If the diago diagonal nal braci bracing ng of the angle angle of the pictu picture re frame frame is being replaced, the section should be pinned up with another section in good condition, to hold the picture frame (boom box) square while making repairs. The replacement angle components for lattice, diagonals nals,, or brac braces es must must have have the the same same nomi nomina nall cros cross s secsection tion dime dimens nsio ions ns as the the orig origin inal al parts parts.. Refe Referr to Figu Figure re 3. The repla replacem cement ent compon component ents s must must also also have the same material and strength specifications as the original part. Replacement Of Picture Frame Angles

Cut out the damaged picture frame angle 1---2 inches (25.4---50.8mm ) above the corner corner gusset gusset plate, and/or and/or the corner bolt plate (See Figure 7). Note: Note: On some some booms, booms, there there may be plates plates or angles welded to the picture frame angle that will have to be cut loose to allow replacement of the damaged angle. If the plate or angle welded welded to the picture frame is also damaged, straighten or replace it.

Chamfe Chamferr the remaini remaining ng stubs stubs at a 45° angle angle (See Figure 8). Pin or bolt bolt the section to another another section in good good condition condition to check check for squareness. squareness. It may be necess necessary ary to jack the damag damaged ed sectio section n around around to achieve achieve alignment. alignment. Clamp Clamp angles or flat bars across the boom boom to hold hold alig alignme nment, nt, then then disco disconn nnect ect the other other section. section. Recheck the squareness squareness of the boom boom section section to make make sure sure it rema remain ined ed squa square re afte afterr remo remova vall from from the the other section.

Service Manual

 

SM08---001---001.00

0112

1

2

2 90

1

3

1. Guid Guide e 2. Clam Clamps ps

1.

Check back side for comple complete te penetration. penetration. If not, grind. grind. 2. Root Root Pass Pass Weld Weld

Figure 9 Clamping On Guide Angle

Figure 10 Weld Procedure

3.

0-0--- 1/16 inch inch (0 (0 --- 1.6mm) 1.6mm) Maximum Gap

Clamp an angle or flat bar across the stubs where the pictu picture re frame frame angle angle is being being replac replaced. ed. This This angle angle or flat flat bar will be used as a fixture to hold in the replacement lattice (See Figure 9). Cut the replacement replacement angle 0 to 1/8 inch (0 --- 3.2mm ) shorter than the distance measured between the stubs to provide a weld root opening ing at each each end. end. Cham Chamfe ferr the the ends ends of the the repl replac acem emen entt angl angle e to a 45° angl angle e to matc match h the the cham chamfe ferr on the the stub stubs s so that an included included “V” angle of 90° for a butt joint is formed. Clamp the replacement replacement angle in place, place, allowing ing for for a 0-0---1/16 -1/16 inch( inch( 0 --- 1.6mm ) root root openi opening ng on each each end. end. Tack the replac replaceme ement nt angle angle in place place,, and remov remove e the flat bar or angle used for a fixture.

In Brief Summary Of Case III: 1. Remove Remove entire entire length length or lengths lengths of of damaged damaged lattice, diagonals, or braces by: a. Cutti Cutting ng through through the welds welds on the chords chords or support braces. b. Cutting Cutting throug through h the center center of the bent bent portion portion of the the latt lattic ice e at the the chor chord d as show shown n in Figu Figure re 5, Figure 6, and Figure 7. 2. Maintain Maintain chord chord alig alignment nment.. 3. Repla Replace ce lattice, lattice, diagon diagonals als,, and braces braces in same locations as they were removed. 4. Use only only those those lattice, lattice, diagona diagonal, l, and brace angle angle sizes and materials as were originally used.

Recheck the squareness of the section by pinning or bolting bolting to another another section in good good condition condition.. If the squareness squareness is acceptable acceptable,, remove remove the section section and prepare for welding.

 Any given job may require adjustment of current setting for welding. welding. Therefor Therefore, e, refer to the welding welding rod manufacturer’s recommended current ranges.

Weld Weld theroot pass, pass, one one side side only only,, on both both ends. ends. Check Check the back back side side of the root root pass pass for compl complete ete weld weld penepenetratio tration n (See (See Figur Figure e 10). 10). If there there is a lack lack of of penetr penetrati ation on,, grind grind or air-air---arc the root root side side to sound sound metal. metal. Weld Weld the back side, then fill in the groove.

Prior to welding, the area should be properly cleaned. This may include grinding free the paint, cutting slag, etc. While grinding, grinding, avoid under-under--- cutting or gouging into the base metal.

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SM08---001---001.00 Appendix A Angle Boom Or Jib Chord And Lattice Corrosion, Pitting, Or Dents The information contained in this appendix is to be used when considering chord and lattice corrosion, pitting, pitting, or dents. These These guidelin guidelines es state what is acceptable based on structural strength.

Corrosion Or Pitting: LBCE will allow corrosion corrosion or pitting up to a depth of  7.5% of the nominal angle leg thickness without replacin placing g the lattice lattice or condemn condemning ing the chord chord and therefo therefore re the boom boom section. section. This This will will be allowe allowed d proprovided vided that the amount, amount, size, size, and locati location on of the damage is not deemed excessive by a qualified LBCE represen representati tative. ve. For For example: example: An angle leg with a thickness of 3/8 inch ( 9.5mm), would have an allowable pit depth of 0.028 inch ( 0.7mm).  As an alternative to measuring the depth of the damage, the actual actual angle angle leg thicknes thickness s may be measured. measured. The angle leg thickness must be at least 92.5% of the nominal thickness.

Dents: LBCEwillallowupto1/8inch(3.2mm )ofdentdepth foranglebooms foranglebooms or jibs jibs in chordsor chordsor latticeprov latticeprovide ided d all criteria listed listed in Figure Figure 1 is maintained. A dent by definition does not reduce angle leg thickness.

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The dent depth given will only be allowed if the angle angle legthickness legthickness hasnot been been reducedby reducedby gouggouging or other means. Follow Follow the thickness requirements listed for corrosion or pitting if the angle leg thicknes thickness s hasbeen affecte affected. d. Thedent depth depth listed listed will be allowed allowed provided provided that the number, number, size, and locatio location n of thedent(s)is/arenot deemedexces deemedexcessiv sive e by a qualified LBCE representative.

Cause For Rejection:  Any main chord or lattice damage which exceeds the cosmetic guidelines stated above requires the section be taken out of service immediately.

Repair:  All damaged areas that fall into the acceptable category as outli outlinedabov nedabove e are to be treate treated d as cosme cosmeticdamticdamage only only.. It is not not recom recommen mended ded that that they they be repai repaired red..  All lattice damage which exceeds the limitations limitations stated above requires the lattice be replaced.

DANGER Angle boom or jib chord members are not to be repaired unless approved by LBCE. Any authorized repairs must be performed by a LBCE LBCE weld weld spec specia iali list st.. Impr Improp oper er repair repair procedures could result in serious personal inju injury ry,, deat death, h, and/ and/or or majo majorr equi equipm pmen entt damage.

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Appendix B Care Of Electrodes The low-low--- hydroge hydrogen n characteri characteristics stics of the electrod electrode e should should not be taken for granted. granted. Hydroge Hydrogen n is an unwanted chemical element in welding many types of  steels, steels, includin including g all the heat-heat--- treated treated steels. steels. Normally Normally,, the higher-higher--- strength alloy-alloy--- steel low-low--- hydrogen electrodes trodes are packaged packaged in hermetical hermetically ly sealed sealed containe containers rs and have less the 0.2% moisture moisture in the coating. coating. Such electr electrod odes es are suitab suitable le for for immedi immediate ate use provi provided ded the container has not been damaged and the electrodes have not been exposed to the air. Some Some electrod electrodes, es, however however,, are packaged packaged in cardboard board containe containers rs with “moistur “moisturee---- proof proof wrapping” wrapping” which may or may not provide adequate protection. To minimi minimize ze weld weld cracki cracking, ng, the foll follow owing ing steps steps are recommended for the conditioning and handling of low--hydrogen electrodes: 1. As soon soon as the electro electrode de contain container er is opene opened, d, the electrodes should be removed and placed into a baking oven. 2. Electro Electrodes des should should be baked accordi according ng to the manuf manufact acture urer’s r’s instr instruct uctio ions ns (usual (usually ly 800° 800° F ( 427 ° C) for for one one hour hour). ). The The elect electro rode des s shoul should d be putintotheovenat500° F( 260 ° C ) maximu maximum m and heated up to 800° F ( 427 ° C ) with the electrodes placed placed no more than three three layers layers deep deep on a tray. tray. Note: Note: This This baking may be omitted omitted only if the the user is certain that the electrode coating, as ready for use, contains less than 0.2 percent moisture.

3. Whether Whether baked baked or not, not, the electrode electrodes s should should be immediately transferred to a storage or holding oven at 250° 25° F (121°  4° C). 4. Both Both the the baki baking ng oven oven and and the the stor storag age e oven oven shou should ld be equipped equipped with air-air--- circulati circulating ng systems systems and temperature indicators with controls. 5. Elect Electro rodes des should should not be place placed d in the storag storage e oven oven unless unless suffic sufficie ientl ntly y dry as receiv received ed or proper properly ly baked. 6. The weldi welding ng electr electrod odes es shoul should d be used used within within one one hour after removal from the storage oven. 7. Elec Electr trod odes es remo remove ved d from from the the stor storag age e oven oven and and exposed posed in a clean, clean, dry locat locatio ion n for for times times long longer er than than those those specified specified should should be re-re--- baked baked as describe described d under under item (2). Elect Electro rodes des expose exposed d to water, water, grease, or dirt should be destroyed.

SM08---001---001.00 8. Whenweld Whenweldin ing g isdone isdone inareas inareas ofhigh ofhigh humi humidi dity ty,, itis advisabl advisable e to store a suitable suitable quantity quantity of electrod electrodes es in a small small porta portabl ble e oven oven from from which which electr electrod odes es may be drawn one at a time by the welder. For For any addition additional al informati information on concerni concerning ng repair repair of  chords, picture frame sections, or welding of various addit additio ions ns to the chords chords,, consu consult lt LBCE LBCE givi giving ng the ident identiification tag information, amount and location of damage, location and object to be added on, etc. The use of covered stick electrode (SMAW) or solid wire electrod electrode e (GMAW (GMAW --- S) or flux flux cored cored wire wire electrod electrode e (FCAW) is permitted. For covered stick electrode, use 3/32 inch ( 2.4mm) or 1/8 1/8 inch inch (3.2mm) diameter diameter electrode electrodes s of A.W.S. A.W.S. E7018 class class.. Use the proce procedu dures res given given below below,, which which will will proproduce duce a 1/8-1/8---3/16 inch inch (3.2---4.8mm ) one one pass pass fill fillet et weld: Elec Electr trod ode e Size Size  Amperage, A Voltage, V Trav ravel Speed, eed,

3/32 3/32 inch inch (2.4mm) 6060 --- 100 21 ----- 23 23 7 inch nches (177.8mm)/min

Elec Electr trod ode e Size Size  Amperage, A Voltage, V Trav ravel Speed, eed,

1/8 1/8 inch inch (3.2mm) 9090 --- 135 22 ----- 23 23 8 inch nches (203.2mm)/min

For For wire weldi welding ng please please note note desired desired weld weld size. size. If weld fill fillet et size size is 3/16 3/16 inch inch ( 4.8mm) or smalle smallerr use use the the GMAW---S process. All welding to be done in the flat position only. Use the GMAW---S process with A.W.S. ER70SER70S----3 or ER70SER70S----6 wire wire and 100% 100% CO2 gas shieldshielding. For 0.045 inch (1.1mm) diameter wire use CO 2 at 25 to 35 scfh*, voltage set at 20 volts and wire speed  4.6 ---5.0mm -5. 0mm) per minute. set to 182---198 inches ( 4.6 If weld weld fill fillet et size size is 1/4 1/4 inch inch or larg larger er use use the the FCAW FCAW proprocess. Welding can be done in the flat, horizontal, vertical up and overh overhead ead posit positio ions. ns. Use the FCAW FCAW proces process s 2 with with A.W.S. A.W.S. E71TE71T----1 wire wire and 100% 100% CO or 75% 75% Argo Argon n 2 and 25% CO gas shielding as recommended by the weld weld wire wire manufa manufactu cturer rer.. For For 0.045 0.045 inch inch (1.1mm) diamdiameter eter wire wire use use the the shie shield ldin ing g gas gas flow flow set set at 30 to 40 scfh scfh,, voltage set at 24 volts and wire speed set to 220---240 inches (5.6 --- 6.1mm ) per minute. * SCFH (Standard (Standard Cubic Feet Feet Per Hour).

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SM09---001---002.00 Acceptable Cosmetic Conditions Which Do Not Require Repair

1

1. See See Appen Appendi dix x A.

Repairable Conditions Conditions Which Which Must Be Corrected Corrected 1. Broken, bent, kinked, or or missing missing lattice, lattice, diagonal, or picture frame lattice. 2. Cracks in welds welds or braces braces other than than chord chord members, or boom, fly, or jib lugs.

Non-Repairable Conditions Which Require The Section To Be Destroyed To Avoid All Possibility Of Future Use

6 2

1. 2.

3

5 3.

4.

5. 6.

4 1.

Pin Connect Connecting ing Lug (Female) 2. Latti Lattice ce

3. Chor Chords ds 4. Diagona Diagonall 5. Picture Picture Frame Frame Lattice Lattice

6.

Pin Connect Connecting ing Lug (Male)

7.

Any cracks cracks in in main main chord members members or boom, fly, or jib lugs. Unacceptabl Unacceptable e dents or pitting pitting in in or corrosion corrosion on the chord members. members. (See  Appendix A.)* Overall straightness straightness of each each of the chords chords is is not within 3/16 inch ( 4.8mm ( 4.8mm)) per free span (distance between lattice), or 1/4 inch (6.4mm) 6.4mm) over length of section. Any prior prior repairs repairs on the the chord members members or boom, fly, or jib lugs (other than authorized lattice replacement). Cracks which continue continue into the chord chord in welds joining parts to chord members. Chord members members which have had had brackets, brackets, rigging parts, walkways, etc. welded on which are not original equipment. Obvious deformation deformation of the section. section.

* Consultatio Consultation n with LBCE LBCE is required required in this this area.

Figure 1 Nomenclature/List Of Terms

Repairing Damaged Tubular Booms, Flys, And Jibs Introduction This procedure provides information for identification, inspection, and repair of tubular booms, flys, and jib sectio sections ns manufa manufactu ctured red by Link Link-B -Belt elt Const Construc ructio tion n Equipment (LBCE), which have certain specific types of damage. These instructions instructions are not intended intended to repair live masts. The scope scope of repairab repairable le damage damage to attachme tachments nts is limi limited ted to only only those those compo componen nents ts liste listed d in the “Lattice Repair Parts Parts Book”. It is important to note note that LBCE will not assume responsibility for repairs made to attachments, unless those repairs are made by a certif certified ied Link Link-B -Bel eltt repres represent entati ative, ve, using using these these proprocedures. The suggestions made or procedures given are for informa formatio tion n only only and are based based on LBCE’s LBCE’s knowle knowledg dge e of  the produc product. t. The repairperso repairpersonne nnell must must assume assume theresponsi sponsibi bilility ty as to the workm workmans anshi hip p andthe ownermust ownermust bear the final responsibility responsibility as to its use. Prior to starting any repair work, all information contained in these procedur procedures, es, must be read and thorough thoroughly ly understoo understood. d.

The alloy alloy steel steel used used in the manufa manufactu cture re of tubul tubular ar boom boom,, fly, fly, and jib sectio sections ns necess necessita itates tes the use of special procedures for the removal and replacement of  damaged lattice, diagonals, or picture frame lattice. Strict adherence to the following procedures is absolutely necessary. It is very very impo import rtan antt that that the the latti lattice ce elem elemen ents ts on a boom boom,, fly fly, or jib sectio section n be mainta maintain ined ed and kep keptt in good good condicondition. tion. Damage Damaged d lattic lattice e allow allow deflect deflectio ion n of the main main chord chord tubes tubes when when under under load load so that that they they are no longe longerr in line; which destroys the true column effect of the boom, fly, fly, or jib. The result is reduced boom, fly, fly, or jib strength and capacity.  All inspection and repair work should be done by qualified personnel. personnel. The welding of lattice, diagonals, diagonals, and pictu picture re frame frame latti lattice ce requi requires res a unique unique skill skill and consciconscientious workmanship. workmanship. It is therefore of of the utmost imimportance that the workman studies these instructions, learns them, follows them, and takes time to develop the skill through practice. The area of the boom, fly, or jib section being repaired must must be free free of moist moisture ure prior prior to any repai repairr work work which which requires welding, gouging, or cutting. 1 of 18

SM09---001---002.00 Serial Number

Part Number

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L 0595 059573 73 18M3610 00 0000 000 0000 0000 000

C

Material Designation

Style 1

Part Number

18M1234 L 0726012 Serial Number

Style 2 Figure 2 Typical Identification Plates

Preparation For Repair The nomenclature, or list of terms, used throughout these instructions are given in Figure 1.

DANGER Use only LinkLink-Belt Belt approved materia materials. ls. Any deviation deviation from these materials could result in seriou serious s person personal al inju injury ry,, deat death, h, or major major equipmen equipmentt damage. damage. In the event event the boom, fly fly, or jib jib sect sectio ion n I.D I.D. plat plate e is miss missin ing g or unre unread adab able le,, repa repair ir of that that sect sectio ion n is not not reco recomm mmen ende ded d unti untill it can can be posi positi tive vely ly iden identi tifi fied ed.. Seek Seek assi assist stan ance ce from from LBCE LBCE Servic Service e Departme Department nt for proper proper method methods s of identification.

The Style Style 1 I.D. I.D. plate has a large large alphab alphabeti etical cal desig designanation tion stampe stamped d on it. Using Using these these letter letters, s, refer refer to Table able B thru Table D for specific specific welding welding technique techniques s requiredto requiredto repair the boom, fly, or jib section. If a Style 2 identification plate is used, and the repair technique requires that the material type be known, seek assistance from LBCE Service Department for material identification before proceeding with repairs. Locat Locate e the ident identifi ificat catio ion n plate plate and recor record d the part part numberand seria seriall numberto numberto have have avail availabl able e befor before e conta contactcting the factory. If the factor factory y I.D. I.D. tag and other other infor informat matio ional nal or cautio cautionnary ary tags tags are are on the the latti lattice ce bein being g repl replac aced ed,, it will will be necnecessary essary to replac replace e them. them. The The I.D. I.D. plate plate can be remov removed ed by carefu carefulllly y cuttin cutting g throu through gh the tack tack welds welds and reloc relocatating it on the replacement replacement lattice. Any Warning Warning or Caution labels must be ordered from a LBCE distributor.

Identification

Inspection

Differ Different ent types types of materi material als s are used used in the chord chord members members of tubular tubular boom, fly and jib sections. sections. It is impo importa rtant nt to determ determine ine the correc correctt materi material al type, type, of the attachment being repaired, since welding procedures vary based on on the material used. used. There are two styles styles of I.D. or identification plates.

 All inspection and repair work suggested in these procedures should be done on a non-working boom, fly, fly, or jib which has been separated separated into individ individual ual sections. These sections are then to be positioned positioned in such a manner that the work can be performed in a safe, proper fashion.

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Figure 3 Inspect For Cracks At Weld Note: Note: In an emergency emergency situat situation ion,, repairs repairs can be done with the the attachment attachment installed. installed. However, However, extreme care must be taken to fully support it, relieve any stress and remove all load from the damaged attach attachment ment.. In this this situat situation,only ion,only one lattice lattice,, diagodiagonal, etc., can be replaced at a time.

Prior to repair, the entire section should be thoroughly insp inspec ecte ted d so all all area areas s in need need of repa repair ir can can be loca locate ted. d. The inspection should proceed as follows:

Inspection Equipment 1. The inspecti inspection on equipme equipment nt should should be such stanstandard equipment as a portable light, wire brush, probe, 10X magnifying glass, marker (chalk, crayon, etc.), magnetic magnetic particle, particle, dye penetrant, penetrant, and other non-destructive testing equipment.

Inspection Procedure 1. Thoro Thorough ughly ly clean clean the entireboom entireboom,, fly fly, or jibsection jibsection of all mud, dirt, grease, oil, etc. so adequate inspection may be performed. 2. Establ Establisha isha patter pattern n of worki working ng from from one one conne connecti ction on to the next next to ensure ensure each each conne connecti ction on is exami examined ned.. 3. Clos Closely ely obser observe ve any areas where where the paint paint has been chipped, wrinkled, or is missing, or contains faint rust lines or marks (See Figure 3). 4. Inspect Inspect section section and note note points points listed listed in Figu Figure re 1.

General Instructions And Procedure Selection 1. The section section serial serial number number,, the nature of of the work work performed, date of the repair, and the names and clock clock number numbers s of those those peopl people e invo involv lved ed shoul should d be recorded and made part of the machine records. 2. Enviro Environme nmenta ntall condi conditio tions ns should should be such such that that they they do not not hinder hinder the perfo performa rmance nce of the mainte maintenan nance ce or create create an un-wel un-welda dablesurfa blesurface ce condi conditio tion n such such as moisture, extreme cold, etc.

3. Proper Proper toolin tooling g and safety safety equipm equipment ent,, in good worki working ng order order, shoul should d be used. used. See See ANSI ANSI Z49 Z49 “Safety in Welding and Cutting”. 4. Use of low-hyd low-hydro rogen gen electro electrode des s is requi required red in many portions of these procedures. procedures. See “Appen“Appendix B” for the care of low-hydrogen electrodes. 5. Unle Unless ss othe otherw rwis ise e note noted, d, all all weld weldin ing g shou should ld be perperformed with DC reverse polarity. 6. All repairs repairs,, other other than on on chord members, members, may be repaired by good good conventional conventional methods. Vee out out the entire weld on lattice, diagonals, and picture frame frame latti lattice. ce. Repair Repair welds welds must must be done done with with lowlowhydrogen type welding electrode such as E7018. 7. Vee Vee out the entir entire e cracked cracked weld of of structural structural plate plate components, a minimum of 3 inches (7.6cm) beyond the end of the crack. 8. For For any additi addition onal al infor informat matio ion n conce concerni rning ng repai repairr of  chords chords or weldi welding ng of vario various us additi addition ons s to the chords, please consult LBCE giving identification plate plate informati information, on, amount amount and location location of damage, damage, location and object to be welded, etc. 9. Select Select proper proper repair repair procedu procedure re using using Table A. Referto “App Append endix ix C” to locat locate e andorder andorder repairparts repairparts.. 10. Picture frame lattice repair requires extra steps to mainta maintain in alignm alignment ent in additi addition on to the standa standard rd proprocedures given here. Refer to “Appendix F,” F,” Repair Of Picture Frame Lattice.

Guidelines For Straightening Of Lattice, Diagonals, And Picture Frame Maximum allowable uniform curvature, where no repair pair is necessary necessary on lattice, lattice, diagonal diagonals, s, and picture 0.8mm per 30.5cm 30.5cm), fram frame e latti lattice ce,, is 1/32 1/32 inch inch per per foot foot (0.8mm or less.

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SM09---001---002.00 Type Of Section

Refer to figure given below for illustration.

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Type Of Damage -- Refer To Procedure Noted

Bent, kinked, broken, or otherwise damaged

Bent less than 1 inch across 36 inches (2.54cm across 91.44cm) and without damage to lattice, diagonal, or picture frame lattice to chord weld.

With Withou outt dama damage ge to the the weld that joins the lattice, diagonal, or pictur ture frame lattice to the chord.

With damage to the weld that joi joins the the latti ttice, ce, diagonal, or picture frame lattice to the chord.

Procedure A

Procedure C

Non-repairable

Booms & Luffing Booms Coped, Figure 5 Pinched, Figure 6 Flattened, Figure 7

Procedure A Procedure A Procedure A

Procedure C Procedure C Procedure B,C

Procedure C Procedure C Procedure C

Jibs Pinched, Figure 6 Flattened, Figure 7

Procedure A Procedure A

Procedure C Procedure B,C

Procedure C Procedure C

Flys Coped, Figure 5

Procedure A

Procedure C

Procedure C

Square Chord Towers Figure 4

“Procedure “A” --- “Straightening” “Procedure “B” --- “Replacement Of Lattice By Lap Replacement” (Flattened Lattice Only) “Procedure “C” --- “Replacement Of Lattice, Diagonals, Or Picture Frame By Complete Replacement” Table A General Procedure Selection Index

 A lattice, diagonal, diagonal, or picture frame lattice with a uniform curvature, greater than the maximum allowable mentioned, but but less than the ratio of 1 inch inch across 36 91.44cm), may be straig inche inches s (2.54cm across 91.44cm straighthtened. ened. Curvature Curvature in excess of this ratio requires requires complete replacement of the lattice, diagonal, or picture frame lattice. Curvature in excess of 1 inch across 36 inches (2.54cm across 91.44cm ) requires replacement of  the lattice, diagonals, or picture frame lattice (See Figure 8).

3. Do not not use use a hammer hammer or otherwis otherwise e strike strike the the tube. This may result in localized structural damage to the tube. 4. Do not not use heat. heat. Heat Heat may destr destroy oy the the physic physical al strength of the steel in area where heat is applied. 5. After After straig straighte htenin ning, g, re-in re-inspe spect ct the lattic lattice, e, diago diagonal nal,, or picture frame lattice to chord welds per section on “Inspection” earlier in this procedure.

Procedure “A” --- Straightening

(Flattened Lattice Only)

1. Bends Bends should should be be drawn drawn out by clamp clampin ing ga4 x4 inch inch (101.6mm x 101.6mm) timberagai timberagainst nst the bent bent lattice, diagonal, or picture frame lattice with large clamps clamps.. Care Care shoul should d be taken taken to preven preventt local localize ized d crushing or or denting of the tube tube with the clamps. It may be necessary to block away from the tube to allow for over-bend and spring back. 2. Sectio Section n must must be warme warmerr than than 50° 50° F (10° C) when straighti straighting ng bent lattice, lattice, diagona diagonals, ls, or picture picture frame lattice.

Flatt Flattene ened d lattic lattice e that that are damage damaged d may be replac replaced ed by the lap “Replace “Replacement ment Procedu Procedure” re” which follo follows. ws. If  cracking occurs in any welds of the lattice/chord tube  joint, the procedure for complete replacement given in “Replacement Of Lattice, Diagonals, Or Picture Frame Lattice Lattice By Complet Complete e Replaceme Replacement nt --- Booms, Booms, Flys, Flys, And Jibs” must be used.

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Procedure “B” --- Replacement Of Lattice By Lap Replacement

Note: Note: This This sectio section n does does not apply apply to diagon diagonal al replacement.

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Figure 4 Tower/Luffing Boom Lattice

Figure 6 Pinched Lattice

Figure 5 Coped Lattice

Figure 7 Flattened Lattice

Replacement Procedure: 1. Remov Remove e the damage damaged d lattice lattice by cuttin cutting g at each end. See Figu Figure re 9. 2. Angle Angle the cut to miss the diago diagonal. nal. Note: Note: This This is a diffi difficu cult lt cut cut to make. make. Usecaution Usecaution not to cut out beyond the weld and into the chord.

3. Grind Grind cut surfac surface e square square,, i.e. i.e. grind grind the angul angular ar hacksaw cut square with the lattice for a good welding fit-up. fit-up. Take care not to damage adjacent parts.

CAUTION Any cut or gouge in the main chord will make the section section non-repairable. non-repairable. When grinding grinding or polishing the chord, do not use any form of hard hard grinding grinding disc. disc. Use only resin resin backed backed sandi sanding ng disc disc of 80 to 100grit. 100grit. Excess Excessiv ive e metal metal may be remov removed ed and and the the secti section on may be rend render ered ed nonnon-re repa paiirabl rable e and and must must be destroyed.

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Scale Measure here

Figure 8 Measuring For Straightness

Figure 10 Area Cleaned For Welding

Figure 9 Removing The Lattice

Figure 11 Lattice Clamped In Place

4. Chec Check k tosee ifrepla ifreplace ceme ment nt tube tube willfit willfit snug snuglyont lyonto o stub and in the proper proper position position and alignme alignment. nt. If  necessary, necessary, carefully shape or contour contour the replacement lattice for proper fit-up. 5. Clea Clean n area area to be weld welded ed tobrigh tobrightt clea clean n meta metall (See (See Figure 10). 6. Align Align and clamp lattice lattice into into positio position n for welding welding (See Figure 11). 7. Weld Weld all all arou around nd each each end. end. All All weldsiz weldsizes es shou shouldbe ldbe 3/16 3/16 inch nch ( 4.8mm). Use Use an A.W A.W.S. .S. 1/8 1/8 inch (3.2mm) E7018 E7018 elect electro rode. de. (The (The ampere amperes s and voltvoltageshould ageshould be set withi within n the rangesrecom rangesrecommen mended ded by the electrod electrode e manufactu manufacturer rer.. See “AppendixD”). AppendixD”). 8. Inspect Inspect welds; welds; corre correct ct if required required.. 9. Touch ouch up the paint paint on all all affect affected ed areas areas of the section. 6 of 18

Procedure “C” --- Replacement Of Lattice, Diagonals, Or Picture Frame By Complete Replacement Lattice, diagonals, or picture frame lattice which are damaged may be repaired by complete replacement. This This proced procedurecove urecovers rs both both lattic lattice e anddiagon anddiagonals als of the flattened, pinched or coped type end connection.

Replacement Procedure: 1. Remove Remove the lattice, lattice, diago diagonal, nal, or or picture picture frame latlattice tice abov above e the the chor chord d alon along g sect sectio ion n C-C---C in Figure 12. Note: Note: Be care careful ful not to damage damage main chord chord member.

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C Full Section Lattice (coped)

Chord

C

C

Flattened End Lattice

Chord

C

C

C

C Chord

Pinched End Lattice

Figure 14 Removed Double Flattened Lattice Using An Abrasive Cut-Off Tool

End View

Figure 12 Removal Of Lattice

Figure 15 Removed Coped Lattice Using A Hacksaw

Figure 13 Removed Single Flattened Lattice

2. Removal Removal of the the lattice, lattice, diagonal diagonal,, or picture picture frame lattice lattice is most most easily easily accompli accomplished shed on flatten flattened ed diagonals agonals,, single single flattened flattened lattice, lattice, pinched pinched lattice lattice and pinched diagonals by cutting well above the weld and manually flexing the tube until it separates rates just above above the weld. weld. See Fig Figure ure 13. For For double double lattice lattice connectio connections ns of the flattened flattened type and for coped lattice and diagonals, a hacksaw or similar similar cutting cutting tool must be used. See Figure Figure 14 and Figure 15.

Figure 16 Ground Down Diagonal Weld

3. Carefu Carefulllly y grind weld weld down down to within within 0.010 0.010 --- 0.020 0.020 inch nch (0.3mm --- 0.6mm) of the the cho chord surf surfac ace e as shown shown in Figur Figure e 16, Figure Figure 17, 17, and Figure Figure 18. No metal should be removed from the chord member.

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Figure 17 Ground Down Lattice Weld

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Figure 19 Chord Polished Clean

Figure 18 Ground Down Coped Weld

CAUTION The The mark marks s made made duri during ng the foll follow owiing polishing polishing procedures procedures must run parallel to the chord length. length. Care must be taken taken so that no gouging or deep grinding grinding is done. Excessive Excessive damage to the chord can result in a non-repa non-repaira irable ble condit condition, ion, and the the section section must be destroyed.

4. Using Using a fine fine (80-(80---100 grit) grit) resin resin backe backed d disc, disc, poli polish sh the the weld weld area area to a brig bright ht clea clean n meta metal. l. See See Figure 19.

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Figure 20 Lattice Alignment

5. Check Check to ensure ensure that the the replacemen replacementt tube will will fit fit snugly onto the chord and in proper position and alignme alignment. nt. If necessary necessary,, carefull carefully y contour contour or shape shape the replacement for for a proper fit-up. fit-up. A good fit-up will aid in proper heat and weld size control resulting in a better repair job. 6. Positi Position on the replacem replacement ent tube to be welded welded into into the proper proper locati location on and clamp into place. place. See See Figur Figure e 20. Do not not tack tack weld. weld. Check Check to ensure ensure that that all all grea grease se,, oil, oil, and and pain paintt are are remo remove ved d from from the the area area to be welded.

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Welding Welding Instructions Refer to the headings in Table B thru Table D to obtain the proper welding instructions for sections with and without “Material “Material Stamping” codes. codes. Welding Welding instructions tions for for type type “A” and “B” materi material al are the same. same. ProceProcedures dures for type “C” material material are different. different. In addition, addition, the type “C” material flys and jibs require particularly close close control. control. Therefor Therefore, e, three differen differentt sets of welding welding procedures have been listed to be used.

Before proceeding, check the material type recorded in “Preparation For Repair” found on Page 2 to ensure that the proper instructions are used. Some Some lattic lattice e repair repairs s to hammer hammerhea head d top sectio sections, ns, and to the tapered extensions they attach to, require an  A.W.S.  A.W.S. E9018 covered stick electrode, flux core, or solid wire electrod electrode e equivale equivalent. nt. Please Please contact contact LBCE Service Department for additional information.

All Booms and Luffing Booms or Stamped ”C” Material Boom Sections 1.Preheating 1. Preheating is is not always required, but control of of heat input must be exercised. Preheat is required if the base metal is below 50° F ( 10° 10° C) or if the base metal is wet or oily. 2.4 mm) or 2.The use of stick or wire electrod electrode e is permitted. permitted. For For stick electro electrode, de, use 3/32 inch (2.4 or 1/8 1/8 inc inch h (3.2mm) diame diameter ter elect electro rodes des of A.W.S. A.W.S. E7018 E7018 class. class. Use the proced procedure ures s given given below below,, which which will will produc produce e a 1/8 inch inch ( 3.2  mm) to 3/16 inch ( 4.8mm) one pass fillet weld:

Elec Electr trod ode e Size Size  Amperage, A Voltage, V Trave ravell Spee Speed, d,

3/32 3/32 inch inch (2.4mm) 6060 --- 100 21 --- 23 7 inch inches es (177.8mm)

1/8 inch (3.2mm) 9090 --- 135 22 --- 23 8 inches (203.2mm)

For solid wire electrode (GMAW---S) or flux core wire electrode (FCAW) welding, please note desired weld size: If weld fillet fillet size is 3/16 inch inch or smaller smaller,, use the GMAW-GMAW--- S process. process. All welding welding to be done done in the flat positio position n only only. Use the GMAWGMAW---- S process process with A.W.S. A.W.S. ER70SER70S---- 3 or ER70SER70S---- 6 wire and 100% CO2 gas shieldi shielding. ng. For For 0.045 inch (1.1mm) diameter wire, use CO2 at 25 to 35 scfh, voltage set at 20 volts, and wire speed set to 182--- 198 inches ( 4.6 --- 5.0m) per minute. If weld weld fille fillett size size is 1/4 inch inch or large largerr, usethe FCAWproce FCAWprocess. ss. Weld Weldin ing g canbe done done in the flat, flat, horiz horizon ontal tal,, vertic vertical al up, and overhead overhead positions. positions. Use the FCAW FCAW process process with A.W.S. E71TE71T --- 1 wire and 100% CO2 or 75% 75% Argon Argon and 25% CO2 gas shielding, as recommended by the weld wire manufacturer. manufacturer. For 0.045 inch (1.1mm) diameter wire, use the shielding gas flow set at 30 to 40 scfh, voltage set at 24 volts, and wire speed set to 220 --- 240 inches (5.6 --- 6.1m ) per minute. 3.Weld in the replacement tube as shown in Figures: Coped end connections --- Figure 22, Figure 23, Figure 24 “A”, Figure 26 Pinched end connections --- Figure 24 “B”, Figure 27, Figure 28, and Figure 29 Note the starting and finishing positions and rod angle. 66° C) or less before welding the opposite side. 4.Allow the weld area to cool to 150° F ( 66°

5.After welding, clean and inspect the repair area and touch up the paint as necessary. Table B

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All Fly and Jib Sections or Stamped ”C” Material Fly and Jib Sections Only 1.Because of the smaller size of the fly and jib, repair must be performed with close control and special care. The welding procedures given given below must be followed. If the welding machine used does not have reliable current and voltage indicating devices, “Appendix E” gives guidance for properly setting the machine. 2.Also due to the smaller size of the fly or jib, welding requires a person who has acquired a high degree of skill and is a conscientious conscientious workman. It is a must that practice welds be made duplicating duplicating as nearly as possible the welds to be made before before starting the work. work. Preheat is required required if the base metal is below below 50° F (10°C) or if the base metal is wet or oily. 3.The use of covered stick electrodes (SMAW) or solid wire wire electrode (GMAW-(GMAW--- S) is permitted. All welding machines don’t perform equally when running E7018 3/32 inch ( 2.4mm) diameter electrodes or 0.035 inch (0.89mm) wire wire elect electro rodes des.. If practi practice ce welds welds show show inabi inabilility ty to hold hold an arc, arc, this this mayindicat mayindicate e instab instabililityof ityof the weldwelding equipment and a different machine should be used. 4.For covered stick electrodes (SMAW), use 3/32 inch ( 2.4mm) diameter electrodes electrodes of A.W.S. A.W.S. E7018 class. All values reported here have been obtained using a Hobart T --- 225 machine. Use the procedures given below, below, depending on fly or jib chord size: Amp.

Volt.

Speed Of Travel -- Inches (mm) Per Minute

Outside Dia. Of Chord 1 --- 1/4 inches

85 A

23V

9.5 (241.3)

 All Larger Fly Or Jib Chords

85A

23V

8.5 (215.9)

5.Weld in the replacement tube as shown in Figures: Flattened end connections conne ctions --- Figure Figure 25, Figure Figure 30, Figure Figure 31, and Figure Figure 32. Pinched end connections --- Figure 24 “B”, Figure 27, Figure 28, and Figure 29. Coped end connections --- Figure 22, Figure 23, Figure 24 “A”, and Figure 26. 6.For solid wire electrode welding (GMAW---S), all welding to be done in the flat position only. Use the GMAW---S process with A.W.S. ER70S---3 or ER70S---6 wire and 100% CO2 gas shielding. shielding. For 0.035 inch (0.89mm) diameter wire, use CO2 at 25 to 35 scfh, voltage set at 19 volts, and wire speed set to 240 ---260 inches (6.1---6.6m ) per minute. 7.Allow the weld area to cool to 150° F ( 66°C) or less before welding the opposite side. 8.After welding, clean and inspect the repair area and touch up the paint as necessary. Table C

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All 2.25” x 2.25” 2.25” Square Chords and 3.5” x 3.5” Square Chords Chords or Stamped Stamped “A “A” and “B” Material Boom and Jib Sections 1.Preheat the chord and replaceme replacement nt tube in the area to be welded welded to 350° F (177 ° C) (minimum) (minimum) to 550° 550° F 1 288 C   Do D o not no t over ov er or unde un der r heat heat.. ( ° ) (maximum). Tempilsticks Tempilsticks shoul should d be used used to determ determine ine the temper temperatu ature. re. 2.The use of covered covered stickelectrode (SMAW) (SMAW) or solidwire electrode electrode (GMAW-(GMAW--- S) is permitted. permitted. For For covered covered stickelectrode(SMAW),use3/32inch(2.4mm )or1/8inch( 3.2mm )diameterelectrodesofA.W.S.E7018 class. Use the amperage, voltage, and travel speed recommended by the electrode manufacturer to 8mm m ) onepass fillet obtaina1/8inch( 3.2mm )to3/16inch( 4. 8m fillet weld. weld. Some Some exampl examples es aregivenin “App Appenendix D” for the flat, vertical, and overhead positions. For solid wire electrode (GMAW---S) welding, all welding is to be done in the flat position only. Use the GMAW---S process with A.W.S. ER70S---3 or ER70S---6 wire. Soli Solid d Wire Wire Elec Electr trod ode e Size Size G a s Ty p e G a s Fl ow R a t e ( s c f h ) Vo l t a g e , V W i r e Sp e e d  Ampe  Am pera rage ge,, A

0.03 0.035 5 inch inch (0.89mm ) 1 0 0 % C O2 2 5 --- 3 5 19 2 4 0 --- 2 6 0 i p m (6.1 --- 6.6mpm) 130 13 0 --- 150 15 0

0 . 0 4 5 in c h (1.1mm ) 100% CO2 3 0 --- 4 0 20  4.6 ---5.0mpm -5. 0mpm ) 182 ----- 198 ipm ( 4.6 165 16 5 --- 185 18 5

3.Wel 3. Weld d in replacemen replacementt tube as shown in Figures: Figures: Coped end connections --- Figure 22, Figure 23, Figure 24 “A”, and Figure 26 Pinched end connections --- Figure 24 “B”, Figure 27, Figure 28, and Figure 29 Flattened end connections --- Figure 25, Figure 30, Figure 31, and Figure 32 Note the starting and finishing positions and rod angle. 4.The 4. The weld should should be completed completed without delay delay.. If the weld area cools cools below 350° F ( 177 ° C), preheat preheat the area area again. 5.After welding, clean and inspect the repair area and touch up the paint as necessary. 1 Tempilsticks are temperature indicating crayons and are available from local welding suppliers or Tempil Corp., 132 West 22nd St., New York, NY 10011

Table D

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Figure 23 Rod Position And Angle For Lattice Weld Outside Outside Boom Figure 21 Splice Kit

Finish

Start

Note: As of January 1, 1996 splice kits kits and proceprocedures dures that that were were previ previous ously ly avai availab lable le have have been been disdiscontinued.

Start

Finish COPED LATTICE “A”

Start

Finish

Finish

Start

FLATTENE FLATTENED D LATTICE LATTICE “B”

PINCHED PINCHED LATTICE LATTICE OR SINGLE

Figure 24 Welding Sequences

Figure 22 Rod Position And Angle For Start Of Lattice Weld Inside Boom (Use Opposite Position And Angle If Weld Is Started Outside First)

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Finish Start

Start Finish

Start

Finish

Figure 27 Rod Position And Angle For Start Of Lattice Weld Inside Boom (Use Opposite Position And Angle If Weld Is Started Outside First)

Figure 25 Welding Sequence For Flattened Lattice

Figure 26 Rod Position And Angle For End Of Lattice Weld Outside Boom -- Start Position For Inside Weld

Figure 28 Rod Position And Angle For Lattice Weld Outside Outside Boom

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Figure 29 Rod Position And Angle For End Of Lattice Weld Outside Boom

Figure 31 Rod Position And Angle For End Of Lattice Weld

Figure 30 Rod Position And Angle For Start Of Lattice Weld Inside Boom

Figure 32 Rod Position And Angle For Start Of Weld For Lattice

Appendix A Tubular Boom, Fly, And Jib Chord And Lattice Corrosion, Pitting, Or Dents The information contained in this appendix is to be used used when when consid consideri ering ng tubul tubular ar chord chord and lattic lattice e corrocorrosion, pitting, pitting, or dents. These guidelines guidelines state what is acceptable based on structural strength.

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Corrosion Or Pitting: LBCE will allow corrosion corrosion or pitting up to a depth of  7.5% of of the nominal nominal wall thickness without replacing replacing the latticeor latticeor condemn condemningthe ingthe chordand chordand therefo therefore re the boom, boom, fly, fly, or jib section. section. This This will will be allowe allowed d provid provided ed that the amount, size, and location location of the damage is not deemed deemed excessiv excessive e by a qualif qualified ied LBCErepresenLBCErepresentative. For For example: A tube boom, fly, fly, or jib section with a wall thickness of 0.095 inch ( 2.4mm), would have an allowable pit depth of 0.007 inch ( 0.2mm).

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 As an alternative to measuring the t he depth of the damage, the actual tube wall thickness may be measured with an ultrasonic wall thickness measuring device or other other suitab suitable le means. means. The The tube tube wall wall thickn thickness ess must must be at least 92.5% of the nominal thickness.

Dents: LBCE will allow up to 20% 20% of the nominal nominal wall thickthicknessor1/8inch( 3.2mm )ofdentdepthwhicheveris smaller for tube boom, fly, and jib section chords. LBCEwillallowupto100%ofthenominalwallthicknessor1/8inch( 3.2mm )ofdentdepthwhicheveris smaller for tube boom, fly, and jib section lattice.  A dent de nt by defin de fin ition it ion doe s not redu re duce ce wall wa ll thic th ickn knes ess. s. Thedentdepthgivenwillonlybeallowedifthetube wall wall thickne thickness ss has notbeen reducedby reducedby gougi gouging ng or other means. Follow Follow the thickness thickness requirements requirements listed for corrosion corrosion or pitting pitting if the wall thickness has been been affected. affected. The dent dent depth listed will be allowed provided provided that the number number, size, and location location of the dent(s) is/are not deemed excessive by a qualified LBCE representative.

Cause For Rejection:  Any main chord or lattice damage which exceeds the cosmetic guidelines stated above requires the section be taken out of service immediately.

Repair:  All damaged areas that fall into the acceptable category as outli outlinedabov nedabove e are to be treate treated d as cosme cosmeticdamticdamage only only.. It is not not recom recommen mended ded that that they they be repair repaired. ed.  All lattice damage which exceeds the limitations limitations stated above requires the lattice be replaced.

DANGER Boom, fly, or jib chord members are not to be repa repair ired ed unle unless ss appr approv oved ed by LBCE LBCE.. Any Any authorized repairs must be performed by a LBCE LBCE weld weld spec specia iali list st.. Impr Improp oper er repa repair ir procedures could result in serious personal injury, injury, death, death, or major equipment damage.

Appendix B Care Of Electrodes The low-hydr low-hydrogen ogen characteri characteristics stics of electrod electrodes es should should not be taken for granted. granted. Hydrog Hydrogen en is an unwanted

SM09---001---002.00 chemical element in welding most types of steels including all the alloy steels. Normally Normally, the higher strength alloy steel low-hydrogen electrodes are packaged in hermetically sealed containers and have less than 0.2% moisture in the coating. ing. Such electrod electrodes es are suitable suitable for immediate immediate use provi provided ded the conta contain iner er has not not been been damage damaged d and the electrod electrodes es have not been exposed exposed to the air. air. Some Some electrodes, however, are packaged in cardboard containers with “moisture proof wrapping” which may or may not provide adequate protection. To preven preventt under under bead bead cracki cracking ng in welds, welds, the foll followi owing ng steps are recommended recommended for for the conditioning conditioning and handling of low-hydrogen electrodes: 1. As soon soon as elect electro rode de contai containeris neris opene opened, d, theelectrodes should be removed and placed into a baking oven. 2. Electro Electrodes des should should be baked accordi according ng to the manufa manufactu cturer rer’s ’s instr instruc uctio tions ns (usua (usuall lly y 800° 800° F ( 427 ° C ) for for one one hour) hour).. The elect electro rode des s shoul should d be putintotheovenat500° F( 260 ° C ) maxim maximumand umand heated up to 80° F ( 427 ° C) with the electrodes placed no more more than three layers layers deep on a tray. tray. Note: Note: This This baking may be omitted omitted only only if the user is satisfied that the electrode coating, as ready for use, contains less than 0.2 percent moisture.

3. Whether Whether baked or or not, the electro electrodes des should should be immediat immediately ely transferred transferred to a storage storage or holding holding oven at 250° 25° F (121°  4° C). 4. Both Both the the baki baking ng oven oven and and the the stor storag age e oven oven shou should ld be equipped with air circulating systems and temperature indicators with controls. 5. Electr Electrod odes es should should not be placed placed in the storag storage e oven oven unless unless suffi sufficie cientl ntly y dry as receiv received ed or proper properly ly baked. 6. The weldi welding ng elect electrod rodes es should should be used used withi within n one one hour after removal from the storage oven. 7. Elec Electr trod odes es remo remove ved d from from the the stor storag age e oven oven and and exposed posed in a clean, clean, dry locat locatio ion n for for times times longe longerr than than those specified should be re-baked as described under under item (2). Electr Electrod odes es exposed exposed to water water,, grease, or dirt should be destroyed. 8. Whenweld Whenweldin ing g isdone isdone inareas inareas ofhigh ofhigh humi humidi dity ty,, itis advisabl advisable e to store a suitable suitable quantity quantity of electrod electrodes es in a small small porta portabl ble e oven oven from from which which electr electrod odes es may be drawn one at a time by the welder.

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L 0595 059573 73 18M3610 00 0000 000 0000 0000 000

Part Number

C

Material Designation

Style 1

Part Number

18M1234 L 0726012 Serial Number

Style 2 Figure 33 Typical Boom, Fly, or Jib Section

Appendix C Ordering Replacement Parts Proper identification of replacement parts is crucial to ensurethe ensurethe struct structura urall integ integri rity ty of the attach attachmen ment, t, as well well as ease ease the assemb assembly ly and weldi welding ng proces process. s. Order Order rereplacement parts as follows: 1. Locate Locate the ident identif ifica icatio tion n plate plate and recor record d the serial serial number number,, part number number,, and chord chord material material type. type. See Figure 33.

DANGER Use only LinkLink-Belt Belt approved materia materials. ls. Any deviation deviation from these materials could result in seriou serious s person personal al inju injury ry,, deat death, h, or major major equipmen equipmentt damage. damage. In the event event the boom, fly fly, or jib jib sect sectio ion n I.D I.D. plat plate e is miss missin ing g or unre unread adab able le,, repa repair ir of that that sect sectio ion n is not not reco recomm mmen ende ded d unti untill it can can be posi positi tive vely ly iden identi tifi fied ed.. Seek Seek assi assist stan ance ce from from LBCE LBCE Servic Service e Departme Department nt for proper proper method methods s of identification.

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2. Ther There e are are two two styl styles es of I.D I.D. plat plates es.. The The Styl Style e 1 plat plate e includes a material material designation. designation. Style 2 plates do do not. not. If a Styl Style e 2 iden identi tifi fica cati tion on plat plate e is used used,, and and the the repai repairr techni techniqu que e requi requires res that that the materi material al be known, seek assistance from LBCE Service Department partment for material material identificati identification. on. Locate Locate the ident identifi ificat catio ion n plate plate andrecord andrecord the part part numbe numberr and serial number to have available before contacting the factory. 3. Refe Referr to the the “Lat “Latti tice ce Repa Repair ir Parts arts Page age Code Code Cros Cross s Reference Index” located the “Lattice Repair Parts Book Book”. ”. Use the cross cross refere reference nce to determi determine ne which Parts Page Code lists the replaceable parts for the damaged attachment. 4. Review Review the Parts Parts Page Page Code Code and identif identify y the part numbers for any damaged lattice to be replaced. Note: Some components, components, for any given attachattachment ment,, may may not not be list listed ed on the the Parts arts Page. age. On Only ly those components which are serviceable will be listed.

5. Forwa Forward rd thereplacem thereplacement ent part part number numbers s requi requiredto redto LBCE when ordering replacement lattice.

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Appendix D Welding Current Table* (Use DC Reverse) Amps Flat

Amps

Amps

Size

Volts

Range

Optimum

Vertical

Overhead

3/32 in (2.4mm)

21 --- 24

70 --- 110

100

70 --- 100

70 --- 100

1/8 in (3.2mm)

21 --- 24

90 --- 160

140

90 --- 135

90 --- 160

*Handbook for Welding Low Alloy, High Tensile Steels, Alloy Rods Company, Division of Chemetron Corporation, Copyright 1964 by Alloy Rods Company, AR---30 (Formerly HB---3) 5---769 Edition 3.

Appendix E Training Instructions Required Before Welding Tubular Jib Structures. Materials: 3/4 3/4 inch inch (19.1mm) wide wide x 3-3---3/8 inche inches s (85.7mm) long long x 12 gauge (2.8mm) thick steel, with bright finish on one side. The purpose of this test sample is to set the welding machine current (amps), voltage voltage (volts), and arc travel speed speed to obtai obtain n the requi required red heat heat input input witho without ut the use of any any mete meters rs.. In effe effect ct,, this this samp sample le serv serves es as a know known n heat test. Heat input is controlled controlled by voltage, voltage, current, and arc travel speed. In order to maintain the toughness of “C” type materials, it is mandatory that heat input be controlled. Previou Previous s instructi instructions ons have shown shown the actual actual conditio conditions ns used to weld each type lattice to chord connection. The same voltage and current was used in all cases and only the arc travel speed was adjusted to obtain the correct heat input for the different types. The test sample has been sized for the 23V, 85A, and 6.75 inches (171.5mm) per minute arc travel speed.

Use Of “Heat Input Test Samples” (“HITS”) 1. Run Run seve severa rall pass passes es on scra scrap p mate materi rial al to adju adjust st the the welding machine for good electrode running performance. This may be considered considered “Initial Coarse Coarse  Adjustment”. 2. Tack both both ends ends of the “HITS “HITS”” to a scrap scrap plate. plate. Securely fasten the ground cable cable to the plate. Allow the tack welds welds to cool to room temperatu temperature. re. This assembly should should be located in a draft-free draft-free area. If  wind wind or draf draftt is blow blowin ing g over over the the “HIT “HITS” S”,, shie shield ld it so that the draft condition is eliminated.

3. Strike Strike an arc arc at the extreme extreme end end of the the “HITS” “HITS” and weld weld a bead bead to the the othe otherr end. end. Meas Measur ure e the the time time required to make this 3---3/8 inches ( 85.7mm) long weld. weld. The correc correctt time time is 30 seco seconds nds.. The corre correct ct result is as follows: a. A continu continuous, ous, even weld weld must must be made. b. The The weld weld must must not not meltthro meltthroug ugh h the the strip strip at any any point. c. The time time must must be be 30 seco seconds nds  2 seconds. If all all these these condi conditio tions ns are met, met, the heat heat input input is correct. correct. If the arc is is lost durin during g the travel travel time, time, the test test is not not good good.. If the the weld weld melt melts s throu through, gh, current, voltage, voltage, or or speed is wrong. wrong. Since the time is easily checked on a heavier plate, the welder may want to practice speed control on heavier heavier material material before before making test welds. welds. If  speed is correct and melt through still occurs then the current setting must be reduced. 4. Once a successfu successfull “HITS” “HITS” is produ produced, ced, the the welder welder is ready to weld jib “Type C” materials. 5. This establi establishes shes the correct correct curren currentt and voltage voltage settings and 6.75 inches (171.5mm) per minute travel speed. However, However, some lighter members require quire a faster faster travel travel speed and furthe furtherr practi practice ce must be done to obtain the new correct speed. This This spee speed d can can be esta establ blis ishe hed d on any any scra scrap p matematerial rial beca becaus use e the the volt voltag age e and and curr curren entt have have been been set set by producing a good “HITS”.

Heat Input Test Sample To weld weld at 9.5 inche inches s (241.3mm ) per minute minute requires requires 3---3/8 inches (85.7mm ) of weld be made in 21 seconds. To weld weld at 8.5 inche inches s (215.9mm ) per minute minute requires requires 3---3/8 inches (85.7mm ) of weld be made in 24 seconds.

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Appendix F Repair Of Picture Frame Lattice When lattice members at the end of a boom, fly, or jib section picture frame lattice (See Figure 1) are damaged, several problems develop that hinder the use of  “regular” lattice repair methods in these instructions. Therefore, it is necessary to understand what is different about replacing picture frame members and list those extra steps to be used for repair. First: The most important important part of this procedure procedure is maintaining the alignment of the pin connections during repair so that the section will properly properly pin-up when the repair repair work work is compl complete eted. d. W When hen a pictu picture re frame frame latlattice tice is damage damaged d it is likel likely y that that alignm alignment ent,, (squar (squarene eness) ss) and proper proper locat locatio ion n of the pin pin conne connecti ction on is throw thrown n off. off. Therefore, when replacing the lattice members at the ends ends of the boom boom sectio sections ns it is necess necessaryto aryto re-al re-alig ign n the pin connections by pinning that section to a section in excellent condition; (which of course, would normally pin pin with with it). it). If anothe anotherr sectio section n is not not avail availab able, le, extra extra care care should be taken to maintain the original dimension (Vertical, (Vertical, Horizontal Horizontal and Diagonal). Diagonal).

DANGER Unde Un derr no circ circum umst stan ance ces s shou should ld pict pictur ure e frames frames be driv driven en in place place.. Locat Locate e pict pictur ure e frame frame latti lattice ce by hand hand only only. If necess necessary ary,, grind grind pict picture ure frame frame lengt length h to fit. fit. Prest Prestres ressed sed or damaged picture frame lattice could result in seriou serious s person personal al inju injury ry,, deat death, h, or major major equipment damage.

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Second:  It will be necessary to select a working site which which is flat, flat, level level,, and of a suitab suitable le surfac surface e for for worki working. ng.  A size at least equal to t he width of the section and the length of the two sections, the one being repaired and the other being used to hold alignment. Third: Set the sections sections (unpinned) (unpinned) on blocks (saw horses, or other suitable surface) at a good working height. height. The supports supports should should be approxi approximatel mately y 24 ---- 36 50.8---76.2 mm) from inches( inches( 50.8-from each each endof both both sectio sections ns (4 places). Fourth:   IfIf the factor factory y I.D. I.D. tag andother infor informat matio ionalor nalor cautionar cautionary y tags are on the lattice lattice being being replaced replaced,, it will be necess necessary ary to repla replace ce them. them. The Stainl Stainless ess Steel Steel I.D. I.D. plate can be removed by carefully cutting through the tack tack welds welds and reloca relocatin ting g it on the repla replacem cement ent lattic lattice. e.  Any warning or caution labels will have to t o be ordered from a LBCE distributor.

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0301

3

4

8 1. 2.

Boom Boom Foot Foot Pin Upper Upper Frame Frame

3. 4.

Hydraul Hydraulic ic Boom Boom Side Side Window Window Shoe Shoe

5. 6.

4

7

Front Front Shoe Shoe Suppo Support rt Head Head Machine Machinery ry

6

5 7. 8.

Cylind Cylinder er Suppor Supportt Boom Hoist Hoist Cylinder Cylinder

Figure 1 Boom Nomenclature Nomenclature

Hydraulic Boom Inspection Introduction The following information information is provided for the identification and inspection of diamond embossed hydraulic boom sections manufactured by Link---Belt Construction Equipmen Equipmentt (LBCE). (LBCE). LBCE cannot cannot assume assume responresponsibility for repairs of any kind made to hydraulic boom sections because it will neither control nor inspect the repai repairs. rs. This This docum document ent is for for refere reference nce purpo purposes ses only only.. For information concerning tubular fly and jib attachments for hydraulic cranes, refer to SM Keysheet Area 9---1. It is very very impor importan tantt to mainta maintain in the hydra hydraul ulic ic boom boom section in good good working working condition condition.. Damaged Damaged hydraulic hydraulic boom boom sectio sections ns can allow allow major major deflec deflectio tion n of the boom boom’s ’s corner corner member members, s, known known as chord chord angle angles, s, which which may resul resultt in boom boom failur failure. e. The The alloy alloy steels steels used used in the manufacture of hydraulic boom sections necessitates the use of special procedures. Inspection procedures should be performed by qualified individ individuals uals with knowled knowledge ge and experien experience ce in steel fabric fabricati ation on.. It is of the utmos utmostt impo importa rtance nce to study study these instructions instructions and follow follow them closely. closely. Identification of terms used throughout this SM are given in Figure 1.

Identification The part part number number and serialnumb serialnumber er,, of each each boom boom section, tion, is located located on an identi identifica fication tion tag. tag. On the tip section, it is located on the side plate of the head machinery. ery. On all other other sections it is is located on on the bottom bottom of  the front front shoe shoe suppo support. rt. Figur Figure e 2 shows shows an exampl example e of  an identification tag.

A

Identification Tag

A

Packet Number Part Number

D7M0016 P002929 0695058 OB 01

445

TW

Boom Section Serial Number Figure 2 Typical Identification Tags

Documentation & Analysis 1. The specific specific inspecti inspection on criteria criteria on the “Hydraul “Hydraulic ic Boom Field Inspection Form” must be followed in order order to evaluate evaluate the boom boom section section properly properly.. A sample of the form is shown on pages 6---11. 2. The infor informat matio ion n gather gathered ed should should be given given to a LBCE Representative or Product Specialist at the factory for evaluation.

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Service Manual Spacer Blocks

Chord Angle

Figure 3 Set Boom Section On Blocking

General Inspection  All inspection procedures procedures suggested in this document must be performed on a non---working boom which has been disassembled and separated into individual sections. For boom boom disassembly disassembly procedure, procedure, see SM Keysheet Keysheet Area 17-17--- 1. These sections sections are then to be posit positio ionedand nedand secure secured d in such such a mannerthat mannerthat thework can be performed in a safe, proper fashion. The inspection equipment needed is such standard items as: portable light light wire brush probe 10X magnifying glass marker (chalk, crayon, etc.) string line two magnetic blocks of equal size magnetic particle compound dye penetrant other nondestructive testing equipment 1. Thoroug Thoroughly hly clean clean entire entire boom section section of of all mud, mud, dirt, grease, oil, etc., so adequate inspection may be performed. 2. Througho Throughout ut the inspectio inspection, n, you will be be asked to collect data from different locations on the boom section. Positions Positions of “TOP”, “TOP”, “BOTTOM”, “LEFT”, “LEFT”, and “RIGHT” are to be interpreted as if the boom were were insta installlled ed on the crane, crane, viewi viewing ng the boom boom from from the operator’s seat.

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Figure 4 Chord Angle Squareness

3. Set boom boom section section up on on blocking blocking or or sawhorses sawhorses of  of  equal height approximately 4 ft ( 1.2 m) from each end of the subject subject boom section section.. Make sure the width of the blocking or sawhorses is greater than the width of the boom boom section. section. See Figure Figure 3. 4. Observe Observe closely closely those those areas areas where the the paint has has been chipped, wrinkled, or missing, or contains faint rust lines or marks. 5. Other Other types types of damag damage, e, such as as dents in in the top, top, botto bottom, m, or side side plate plates, s, bracke brackets ts with with dents dents or cracked welds, interference between boom sections, etc. requires review by a LBCE representative to determine if boom section can be repaired. 6. The nature nature and dimensi dimensiona onall location location of any defordeformity should be recorded on the “Hydraulic Boom Field Inspection Form”. Form”.

Chord Angle Squareness  After the initial general inspection, the chord angle squarenes squareness s should should be taken into consider consideratio ation. n. It can be checked by using a small square or large square with with spacer spacer blocks blocks,, of equal equal size, size, as shown shown in Figu Figure re 4. The nature and dimensional location of any deformity should be recorded on the “Hydraulic Boom Field Inspection Form”. Form”. Subsequent damage discovered and documented to this point, will assist in the analysis of further deformities which may be found during the remaining inspections. tions. The true magnitude magnitude of damage damage and the repairability of boom sections may be determined by the inspection data data taken here. Statements taken from from the operator and/or oiler, as to the situation which caused the damage, are also essential.

Service Manual 10 ft (3.1m)

10 ft (3.1m)

10 ft (3.1m)

B

C

 A  A

B

C

Bubble Level

 

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Straight Edge D

Measure Here

Measure Here

D

Spacer Block

Spacer Block

Spacer Block Chord  Angle

Shim Figure 6 Angle Roll

B --- B Figure 5 Boom Section Twist

Boom Section Twist Inspection Boom section twist is the axial relationship from the rear of the section section to the front of the section. section. This inspecti spection on also also helps helps to determ determine ine if the the boom boom sect sectio ion n is straight. To inspect for twist, the boom section should be right side up on on blocking or or sawhorses. Inspect in four four places places per “Hyd “Hydrau raulilic c Boom Boom Fiel Field d Inspec Inspectio tion n Form” Form” and record record values. Refer to Figure Figure 5 for example. 1. Positio Position n level on on two equal size size spacer blocks blocks at Location A---A. 2. Adjust the position position of the boom boom section to achieve level reading at Location A---A. 3. Mainta Maintain in boom boom sectio section n posit positio ion n durin during g the remai remainnder of inspection. 4. Move Move level and and spacer spacer blocks blocks to next next location location.. 5. Add shim(s), shim(s), as as required, required, between between spacer spacer block block and level (one side only), to achieve level reading. 6. Record Record the positi position on and thick thickness ness of the the shim(s) shim(s) used to the appropriate diagram above. 7. Repeat Repeat Steps Steps 4 throu through gh 6 every every 10 ft (3.1m) down the length of the boom section.

Chord Angle Roll Inspection  Angle roll defines the parallel relationship relationship between section tion angl angle e chor chords ds.. This This shou should ld be done done on the the top top and and botto bottom m of the boom boom sectio section, n, as shown shown in Figu Figure re 6. 6. Repeat this procedure every 1 ft (0.3m) over the entire lengt length h of the boom boom sectio section, n, recor recordi ding ng the resul results ts on the “Hydraulic Boom Field Inspection Form”. 1. Star Starti ting ng at the the base base of the the sect sectio ion, n, divi divide de and and labe labell the boom section in 12 inch (30cm) segments. 2. Be sure to to mark all all four four corners corners of the the boom boom section along the entire length of each chord angle. 3. Each locatio location n consists consists of the four corresp correspond onding ing marks at each linear position down the section. 4. Numb Number er each each loca locati tion on down down the the leng length th of the boom section. 5. Meas Measur urem emen ents ts willbe willbe take taken n acro across ss the the top top and and the the bottom of the section at each location marked. 6. Starti Starting ng at the base of section section,, posit positio ion n spacer spacer blocks and straight edge on the first marks (top). 7. Record Record the two measur measureme ement nt as illus illustra trated ted above. above. 8. Move Move strai straight ght edge edge and spacer spacer blocks blocks to correcorresponding location on the bottom of the section. 9. Measure Measure and and record record the dimen dimensio sions. ns. 10. Move Move straig straight ht edge edge andspacer andspacer blocks blocks to next next localocation down the length of boom section (top). 11. 11. Repe Repeat at Step Steps s 7 thro throug ugh h 10 ever every y 12 inch inches es (30cm) down the length of the boom section.

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String Line Spacer Blocks Chord  Angle

A

Top View Boom

Right Bow

Left Bow

Figure 7 Minor Axis Bow

Minor Axis Bow Minor axis bow is when the boom section is bowed to the left or right. To inspect inspect the boom boom section for this condition, the boom section must be in the upright position. position. Take measurements every 3 ft (1m) and record measurements on the “Hydraulic Boom Field Inspection Form”. Form”. Note the example in Figure Figure 7. 1. Posi Positi tion on boom boom sect sectio ion n on its its bott bottom om surf surfac ace e so the the head machiner machinery y or collar clears clears the ground. ground. Secure the boom section to sturdy saw horses or blocking 2. Star Starti ting ng at the the base base of the the secti section on,, divi divide de and and mark mark the boom section in 3 ft (1m) segments. 3. Be sure to to mark all all four four corners corners of the the boom secsection along the entire length of each chord angle.

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4. Meas Measur urem emen ents ts will will betaken betaken at the the top top and and the the botbottom of the section down the entire length of the boom section. 5. Positi Position on spacer spacer blocks, blocks, of of equal equal size, at each each end of chord angle. 6. Pull Pull a stri stringov ngover er each each spac spacer er bloc block k and and tie tie it tothe very end of the boom section. 7. The strin string g must be taught taught and span span clearly clearly bebetween the spacer block at each end of the chord angle. 8. Measur Measure e and record record the distance distance between between the chord angle and the string at each of the marked locations. 9. Relocate Relocate the spacer spacer blocks blocks and string string to the next next chord angle. 10. Repeat Steps 5 through 9 for each of the four chord angles.

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String Line Spacer Blocks Chord  Angle

A

Side View Of Boom Negative Camber

Positive Camber

Figure 8 Major Axis Camber

Major Axis Camber Camber Major Major axis axis camber camber is when when the boom boom sectio section n is bowed bowed up or down. down. To inspec inspectt the boom boom sectio section n for for this this condi condi-tion the boom section must be positioned on its side. Take measurements every 3 ft (1m) and record measurements on the “Hydraulic Boom Field Inspection Form”. Form”. Note the example example in Figure Figure 8. 1. Posit ositio ion n boom boom secti sectionon onon its its LEFT LEFT sideso sideso the the head head machinery or collar collar clears the ground. ground. Secure the boom section to sturdy saw horses or blocking. 2. Star Starti ting ng at the the base base of the the sect sectio ion, n, divi divide de and and mark mark the boom section in 3 ft (1m) segments. 3. Be sure sure to mark mark all all four four corners corners of the the boom boom section along the entire length of each chord angle.

4. Measuremen Measurements ts will be be taken on on both sides sides of the sectio section n down down theentire theentire lengt length h of the boomsecti boomsection on.. 5. Positi Position on spacer spacer blocks, blocks, of equal equal size, size, at each end end of chord angle. 6. Pulla Pulla stri stringove ngoverr each each spac spacer er bloc block k and and tie tie it tothe very end of the boom section. 7. The strin string g must be taught taught and span span clearly clearly between the spacer block at each end of the chord angle. 8. Measur Measure e and record record the distanc distance e betwee between n the chord angle and the string at each of the marked locations. 9. Relocate Relocate the spacer spacer blocks blocks and and string to the next next chord angle. 10. 10. Repe Repeat at Step Steps s 6 thro throug ugh h 9 for for each each ofthe four four chor chord d angles.

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3 4 5 6 7

1. 2. 3. 4. 5. 6. 7.

Head Machi Machinery nery Tip Sectio Section n Tip Secti Section on Extend Extend Cable Cable & Pulley Pulley Outer Outer Sectio Section n Center Center Sectio Section n Inner Inner Sectio Section n Base Base Sectio Section n

Figure 9 Typical Five Section Boom Nomenclature

Hydraulic Boom Inspection Introduction The following information information is provided for the identification tion and inspe inspecti ction on of two piece piece forme formed d hydrau hydraulilic c boom sections manufactured by Link---Belt Construction Equipmen Equipmentt (LBCE). (LBCE). LBCE cannot cannot assume assume responresponsibility for repairs of any kind made to hydraulic boom sections because it will neither control nor inspect the repai repairs. rs. This This docum document ent is for for refere reference nce purpo purposes ses only only.. For information concerning tubular fly and jib attachments for hydraulic cranes, refer to SM Keysheet Area 9---1. It is very very impor importan tantt to mainta maintain in the hydra hydraul ulic ic boom boom section in good good working working condition condition.. Damaged Damaged hydraulic hydraulic boom sections sections may result in boom boom failure. The steels used in the manufacture of hydraulic boom sections necessitate the use of special procedures. Inspection procedures should be performed by qualified individ individuals uals with knowled knowledge ge and experien experience ce in steel fabric fabricati ation on.. It is of the utmos utmostt impo importa rtance nce to study study these instructions instructions and follow follow them closely. closely. Identification of terms used throughout this SM are given in Figure 9.

A

Identification Tag

A

Packet Number Part Number

J7M1534 BTJ7012 0702038 OB 01

445

TW

Boom Section Serial Number Figure 10 Typical Identification Tags

Identification

Documentation & Analysis

The part part number number and serialnumb serialnumber er,, of each each boom boom section, tion, is located located on an identi identifica fication tion tag. tag. On the tip section, it is located on the side plate of the head machinery ery. On all all othe otherr sect sectio ions ns it is loca locate ted d on the the fron frontt of the the bottom shoe shoe support. Figure 10 shows shows an example example of  an identification tag.

1. The specific specific inspecti inspection on criteria criteria on the “Hydraul “Hydraulic ic Boom Field Inspection Form” must be followed in order order to evaluate evaluate the boom boom section section properly properly.. A sample of the form is shown on pages 7---12. 2. The infor informat matio ion n gather gathered ed should should be given given to a LBCE Representative or Product Specialist at the factory for proper evaluation.

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1

2

Figure 12 Digital Inclinometer

1. 2.

Use Typica Typicall Saw Horses Horses When Placing Placing Section Section On Flat Use Form Form Fit Fit Saw Horse When Placing Placing Section Section On Round Round

Figure 11 Set Boom Section On Stable Blocking

General Inspection  All inspection procedures procedures suggested in this document must be performed on a non---working boom which has been disassembled and separated into individual sections. For boom boom disassembly disassembly procedure, procedure, see SM Keysheet Keysheet Area 17-17--- 1. These sections sections are then to be posit positio ionedand nedand secure secured d in such such a mannerthat mannerthat thework can be performed in a safe, proper fashion. The inspection equipment needed are such standard items as: portable light light wire brush probe digital inclinometer inclinometer 24 inch (60cm) straight edge 10X magnifying glass marker (chalk, crayon, etc.) string line two magnetic blocks of equal size magnetic particle compound dye penetrant other nondestructive testing equipment

DANGER Secure Secure boom section sections s to adequat adequate, e, stable stable supports during during inspection. inspection. Boom sections sections are extremely extremely heavy heavy.. Unexpected Unexpected movement movement of boom sectio sections ns could could cause cause damage, damage, injury injury,, or death. death. Properly Properly stabiliz stabilize e boom sections sections before beginning work.

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WARNING Solv Solven ents ts and and clea cleani ning ng solu soluti tion ons s can can be haza hazard rdous ous.. Seri Serious ous persona personall inju injury ry may result result from misuse misuse of these these products products.. Read and fo l l o w al l the manufacturer’s recommendations recommendations concerning solvents and cleaning solutions.

1. Thoroug Thoroughly hly clean clean the entire entire boom boom section section with with an approved cleaning solvent. Remove all mud, mud, dirt, grease, oil, etc., so adequate inspection may be performed. Allow the boom section to air dry. 2. Throu Through ghou outt the inspect inspectio ion, n, you will be asked to collect data from different locations on the boom section. Positions Positions of “TOP”, “TOP”, “BOTTOM”, “LEFT”, “LEFT”, and “RIGHT” are to be interpreted as if the boom were were insta installlled ed on thecrane, thecrane, viewin viewing g the boom boom from from the operator’s seat. 3. Set Set boom boom section section on blocki blocking ng or sawho sawhorse rses s of  equal height approximately 4 ft ( 1.2m) from each end of the subject subject boom section section.. Make sure the width of the blocking or sawhorses is greater than the width of the boom boom section. section. See Figure Figure 11. 4. Observe Observe closely closely those those areas areas where the the paint has has been chipped, wrinkled, or missing, or contains faint rust lines or marks. 5. Other Other types types of damag damage, e, such as as dents in in the top, top, botto bottom, m, or side side plate plates, s, bracke brackets ts with with dents dents or cracked welds, interference between boom sections, etc. requires review by a LBCE representative to determine if boom section can be repaired. 6. Inspect Inspect boom boom foot foot pin hole, hole, in the the base sectio section, n, to be sure the bushing is tight, uniform, and concentric within the machined machined hole. hole. Replace bushing if  if  necessary. 7. The nature nature and dimensi dimensiona onall location location of any defordeformity should be recorded on the “Hydraulic Boom Field Inspection Form”. Form”.

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8 in (20cm)

Measure Twist On Bottom Flat Inclinometer

10 ft (3m)  A

 A 10 ft (3m) B

B 10 ft (3m) C

C

Sectional View Boom Section Section Secured, Bottom Side Up

D

D

Figure 13 Boom Section Twist

Boom Section Twist Inspection Boom section twist is the axial relationship from the rear of the section section to the front of the section. section. This inspecti spection on also also helps helps to determ determine ine if the the boom boom sect sectio ion n is straight. To inspect for twist, the boom section should be placed bottom side up on blocking or sawhorses. Inspect in four places per “Hydraulic Boom Field Inspection spection Form” Form” and record record values. values. An digital digital inclino inclinommeter will be required required with an accuracy accuracy of ±5° . Refer to Figure 13. 1. Level Level the boom boom section section,, from end end to end, end, on two equal size saw horses. horses. The boom boom section should should be bottom side up.

2. Adjust Adjust the posit positio ion n of the boomsecti boomsection on,, at Locat Locatio ion n  A A --- A, to achieve level reading from side to side. (If  equipped, use Zero feature on inclinometer.) 3. Maintain Maintain the boom boom section section in this this position position durin during g the remainder of twist inspection. 4. Move inclino inclinometer meter to next locatio location n (Locatio (Location n B --- B). 5. Record Record the location location and inlin inlinomet ometer er reading reading per the diagram diagram above, above, using using the “Hydraul “Hydraulic ic Boom Boom Field Inspection Form”. Form”. 6. Repeat Repeat Steps Steps 4 throug through h 5 every every 10 ft (3.1m) down the length of the boom section (Location C---C, Location D---D). Note: Note: Locat Locatio ion n D--D on the the base base secti section on shoul should d be located directly above the boom foot pin.

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Measure Measure Gap

Sidewall

24 inch (60cm)

Straight Edge

Lateral Weld

Figure 14 Sidewall Flatness

Sidewall Flatness Sidewall flatness is a measurement of the waviness of  the the vert vertic ical al left left and and righ rightt hand hand wall walls s of the the boom boom.. To ininspect flatness, the boom section should be right side up on block blockingor ingor saw horse horses. s. Inspect Inspect the entir entire e lengt length h of each side of the boom, beginning at the weld seam at the rear. rear. Continu Continue e up and down the length of the boomin boomin 24 inch( inch( 60cm) incre incremen ments, ts, recor recordi ding ng thespecific location on the sidewall where it is least flat. Refer to Figure 14. 1. Posi Positi tion on boom boom sect sectio ion n on its its bott bottom om surf surfac ace e so the the head machiner machinery y or collar clears clears the ground. ground. Secure the boom section to sturdy saw horses or blocking.

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2. Star Starti ting ng at the the base base of the the sect sectio ion, n, divi divide de and and vert vertiicall cally y mark mark the the boom boom sect sectio ion n in 24 inch inch (60cm)segments, along both sidewalls of the boom section. 3. Measur Measureme ements nts will will be taken taken along along the entireleng entirelength th of the boom boom section, section, above above the lateral weld. weld. Be sure sure to mark mark the boom boom sectio section n along along its entire entire length and on both sides. 4. Using Using a straig straight ht edge, edge, locate locate and measure measure the largest gap in each marked segment along the boom section. 5. Recor Record d the size and and locatio location n of each gap gap on the “Hydraulic Boom Field Inspection Form”.

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Measure Distance From Sidewall To Each String Line Every 3 ft (1m)

A

String Line Spacer Block

Top View Boom

A

Right Bow

Left Bow

Figure 15 Minor Axis Bow

Minor Axis Bow Minor axis bow is when the boom section is bowed to the left or right. To inspect the boom section section for this condition, the boom section must be in the upright position. position. Take measurements every 3 ft (1m) and record measurements on the “Hydraulic Boom Field Inspection Form”. Refer to Figure 15. 1. Posit ositio ion n boom boom sect sectio ion n on its its bott bottom om surf surfac ace e so the the head machiner machinery y or collar clears clears the ground. ground. Secure the boom section to sturdy saw horses or blocking 2. Star Starti ting ng at the the base base of the the sect sectio ion, n, divi divide de and and vert vertiicall cally y mark mark the the boom boom sect sectio ion n in 3 ft (1m) segmen segments. ts.

3. Meas Measur urem emen ents ts willbe willbe take taken n at the the top top and and the the botbottom of the flat flat porti portion on of of the sidew sidewal all, l, down down the the entire length of both sides of the boom section. 4. Positi Position on spacer spacer blocks, blocks, of equal equal size, size, at each end end of the boom boom section. section. Be sure the spacer block block is resting on the flat portion of the sidewall. 5. Pulla Pulla stri stringove ngoverr each each spac spacer er bloc block k and and tie tie it tothe very end of the boom boom section. section. See Figure Figure 15. 6. The string string must must be taut taut and span clearl clearly y between between the spacer spacer block block at each each end of of the boom boom section. section. 7. Measur Measure e and record record the distanc distance e betwee between n the sidewa sidewallll and the strin string g at each each of the vertical vertically ly marked locations. locations. 8. Relo Reloca cate te the the spac spacer er bloc blocks ks and and stri string ng to the the oppo oppo-site side of the boom section. 9. Repe Repeat at Step Steps s 4 thro throug ugh h 8 for for the the othe otherr side side ofthe boom section.

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Measure Distance From Flat Plate To Each String Line Every 3 ft (1m)

A

String Line Spacer Block

A Side View Of Boom Negative Camber

Positive Camber

Figure 16 Major Axis Camber

Major Axis Camber Major Major axis axis camber camber is when when the boom boom sectio section n is bowed bowed up or down. down. To inspe inspect ct the boom boom sectio section n for for this this condi condi-tion the boom section must be positioned on its side. Take measurements every 3 ft (1m) and record measurements on the “Hydraulic Boom Field Inspection Form”. Refer to Figure 16. 1. Positi Position on boom boom section section on on its side side so the head head machinery chinery or collar collar clears clears the ground. ground. Secure Secure the boom section to sturdy saw horses or blocking. 2. Star Starti ting ng at the the base base of the the sect sectio ion, n, divi divide de and and vert vertiicall cally y mark mark the the boo boom sect sectio ion n in 3 ft (1m) segmen segments. ts. 3. Be sure sure to mark the the boom boom sectio section n along along the the entire entire length.

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4. Measuremen Measurements ts will be be taken on on both the the top and and the bottom of the boom section down its entire length. 5. Positi Position on spacer spacer blocks, blocks, of of equal equal size, at each each end of the boom section. 6. Pull Pull a stri stringov ngover er each each spac spacer er bloc block k and and tie tie it tothe very end of the boom section. 7. The string string must be be taut and and span clearl clearly y between between the spacer spacer block block at each each end of the boom boom section. section. 8. Measure Measure and recor record d the distanc distance e between between the flat surface surface of of the boom boom sectio section n and the string string at each of the marked locations. 9. Relo Reloca cate te the the spac spacer er bloc blocks ks and and stri string ng to the the oppo oppo-site surface. 10. 10. Repe Repeat at Step Steps s 6 thro throug ugh h 9 for for the the oppo opposi site te surf surfac ace. e.

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Link-Belt Construction Equipment Company Lexington, Kentucky   www.linkbelt.com Link-Belt

is a registered trademark. Copyright 2012. All rights reserved. We are constantly improving our products and therefore reserve the right to change designs and specifications.