G0010 Flat Rack Unloading and Commissioning Procedure

1. Unload the flat rack
2. Remove all the chains and the module bash plates
3. Remove all loose parts, ie tyres, mudguards, etc
4. Remove modules - there are 3 different options.
   1. With forklift through angles guides
   2. With crane using strops on lifting point 1- see photo
   3. With crane and chains or strops, on lifting point number 2 - see photo
5. Unload chassis off the flat - as indicated on photo
6. Put 30 litres of fuel in tank, open fuel filter bowl to allow fuel to flow, close bowl when full and leave fuel tap "on". Check sight tube clamps for leaks.
7. Remove load transfer blocks and ensure that they are not mixed up, as load transfer clearance has been set ex New Zealand. 8mm Allan key.
8. Get modules ready for loading onto chassis.
9. Take module bash plates off and remove small chain box. 13mm Spanner and 16mm spanner.
10. Undo hydraulic motors from mounting brackets. 19mm socket spanner
11. Ensure correct shims for Hydraulic motors are not mixed up when removed.
12. Fit night light to module - Spanner: 17mm & 13mm.
13. When mounting crane, connect air to module locks to unlock.

Crane Mount

1. Connect crane supply hoses to modules, ensuring that the hoses do not get twisted when tightened. Spanners: 46 41 36 32 27 22 mm
2. Place hoses in operating position before tightening to allow them to rotate to their natural lay.
3. Thread 19 core cables through base of module up to module junction box, putting spira/flex around cable where it goes through module base. Screw driver & side cutters
4. Load modules and push clear of LTB bases.
5. Refit LTB's using M10x40 cap screws, 262 loctite and torque to 75Nm. 8mm Allan key
6. Pull modules back against stop blocks to 40' lifting position. NB remount hydraulic motors, ensure correct shim are put in place.
7. Check side guide for clearance and fit required fit shim to correct, allowing 0-2mm clearance max.
8. Connect crane supply hoses to modules and tighten LS & LX hoses.

   LS: 22mm spanner (LH Crane)

   LX: 19mm spanner (RH Crane)

9. When securing LS/LX and traverse hoses using cable ties, tie clear of valve handles and do not position between pipes and chain boxes, if so insure there is no contact.
10. Pull 19 core up to module junction box and terminate so as to connect into numbered connector blocks.

Fill hydraulic tank to top of sight glass. Hydraulic oil Castrol - Hyspin 46 or 68

Make sure hydraulic tank suction line taps are open to allow oil to pump.

Engine start-up procedure

1. Check coolant is above radiator core, fill oil tank to top of sigh glass, check engine oil is at max level.
2. Check air supply is connected to engine.

   Do not disconnect stop spring to run engine as emergency stop will not operate.

3. Connect air supply to chassis via front coupling plate. Need air to start.
4. Connect remote for unit to control box, check stop button is in "run" position, must be connected for unit to operate.
5. Connect battery, make sure battery terminals are connected.
6. Turn key on and check hour meter is running, alternator warming lamp is on, and oil pressure warming lamp is on.
7. Turn key to glow position and hold. Glow lamp should come on, then go out after 15 seconds.
8. Turn key off and check that engine stop has released.
9. Turn key on. Press remote stop button and check engine stop has released.
10. Advise all men working on the machine that you will be starting the engine.
11. Select high speed, start engine and make a brisk inspection of valves, pump and manifolds for obvious leaks. If found, stop engine and rectify.
12. Ensure hydraulic oil is in sight glass.
13. Check hydraulic oil level is in transit position.
14. Extend then retract, full stroke, non-stop all cylinders on left hand crane only.
15. Stop engine and fill oil to top of sight glass.
16. Extend then retract all cylinders on right hand crane only, checking oil level at all times.
17. Re top up the hydraulic oil.
18. Check all fittings for leaks.
19. Start engine and run all functions one after the other, full stroke each function,
20. Select low speed, check and set main relief on the PVG 32- refer to service info H0005 - check gauge shows 4100PSI , check for leaks.
21. Select High speed and check pressure setting of 2200psi.
22. Top up oil if below full mark.
23. Traverse cranes to each lifting position and confirm operation of module.
24. Traverse cranes to between lifting positions and confirm the following if the machine is a SB360 Trombone.
25. Check that green crane position light are on when crane are in their correct position.
26. Check that warning beeper is sounding when cranes are off station.
27. Check cylinder rods for damage and paint and check for leaks.
28. Check the load transfer clearance is 1-2mm.
29. Check hose travel.
30. Check operations of center twistlock beam ends and all twistlocks.
31. Check that all functions are in accordance with the decals.

    Any faults found with the electrical control system or interlock system should be rectified immediately.

32. Set proximity switches, full extend and mark and retract 110mm and set proximity. Should be set - check only.
33. Torque wheel nuts refer to Sidelifter Manual for details.
34. Place in tool box the following for export machines:

    1 x hard hat

    1 pair link lock connectors

35. Fit padlocks to tool box and secure keys to key ring.
36. Chassis certificate plate - check only.
37. Fit all decals according to decal kit.
38. Grease brake shafts, 6 nipples per axle + landing legs and centre twistlock beam.
39. Check that mudflaps and guard are fitted ok.
40. If specified, fit link-lock spacer pole stowage brackets, mount and tie down poles and place connectors in tool box.
41. Check all items are fitted as per specification sheet.
42. Check wheel alignment.
43. Procedures to follow are Test AS 103 and Per Delivery AS 104.