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are of exclusive property of AUTOGRU RlGO S.p.A.

No Part thereof can be used, duplicated, reproduced or sent in any form

or in any way without written consent of AUTOGRU RlGO S.p.A.

@ Copyright RIGO 1999

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Via Casetta, 38 - 37015 DOMEGLIARA I VERONA - ITALIA -P 0456861500 R.A -FAX 0456861114
http://www.rigo.corn - E-mail: [email protected]
 * * GUARANTEE ***

AUTOGRU RIGO S.P.A. GUARANTEES ITS PRODUCT FOR A PERIOD OF 12

MONTHS FROM THE DELIVERY DATE.
THIS GUARANTEE COVERS ONLY THE REPLACEMENT OR REPAIR, AT AUTOGRU
RIGO S.P.A.'S EXCLUSIVE OPTION AND ON AUTOGRU RIGO S.P.A.'S
PREMISES OR AT ONE OF ITS AUTHORIZED SERVICE WORKSHOPS, OF THOSE
PARTS WHICH AUTOGRU RIGO S.P.A. UPON ITS INSPECTION SHALL FIND
DEFECTIVE IN MATERIAL OR WORXMANSHIP.
ANY FREIGHT COST, LABOR AND TRAVEL EXPENSE FOR THE REPAIR OR PART
REPLACEMENT ARE EXCLUDED FROM THE GUARANTEE.
NO INDEMNITY OR REIMBURSEMENT SHALL BE PAID FOR ANY DANAGE,
INCLUDING THOSE CAUSED BY PRODUCT FAILURE, FOR LOSS OF REVENUE OR
ANY OTHER CAUSE, ALSO IN THE EVENT OF A POSSIBLE DELAY.
THIS GUARANSEE BECOMES NULL AND VOID IF THE PRODUCT IS NOT USEY IN
COMPLIANCE WITH AUTOGRU RIGO S.P.A.'S INSTRUCTIONS AND
SPECIFICATIONS, OR IF ANY PART IS REMOVED OR REPAIRED BY
UNAUTHORIZED PERSONNEL OTHER THAN AUTOGRU RIGO'S.
NO GUARANTEE IS GIVEN FOR BREAKAGE CAUSED BY IMPROPER OR NEGLIGENT
USE OF THE PRODUCT. THIS GUARANTEE DOES NOT COVER AMY COMPONENT
MANUFACTURED BY AUTOGRU RIGO S.P.A. AND THE BUYER SHALL NOT HOLD
AUTOGRU RIGO S.P.A. LIABLE FOR ANY REASON.
NO GUARANTEE IS GIVEN FOR SECOND-HAND PRODUCTS.
AUTOGRU RIGO S.P.A. IS ALWAYS AVAILABLE T0 GIVE YOU CLARIFICATIONS
AND OR SUGGESTIONS AND T0 ASSURE YOU THE BETTER PERFORMANCE OF THE
PRODUCT .
 FUCHS BOOM: ASSEMBLY PROCEDURES

In order to assemble the boom completely, follow these directions:

(taking a look at the spare parts manual for drawings references)
1. - Position the section drawing no. 2 3 0 7 1 0 0 0 4 on apposite
supports;
- place the 6 boom telescoping ropes drawing no. 5 1 0 0 2 9 1 6 0 and
the return rope drawing no. 5 1 0 0 2 9 1 6 1 in a stretched manner
(see picture I ) ;
- put the telescoping cylinder drawing no. 230710005 on
brackets .
2. - Pass the cables drawing no. 5 1 0 0 2 9 1 6 0 inside the pulleys
frame support located at the ends of the telescoping cylinder
drawing no. 2 3 0 7 1 0 0 0 5 , paying attention that the ropes threaded
terminals are on the Same side of the lock valve installed on the
cylinder head. Now assemble the pulleys drawing no. 5 1 0 0 2 9 1 7 1 with
its relative bearings drawing no. 006510670 and its relative
spacers drawings no. 510023227 and 5 1 0 0 2 9 0 7 6 on the pin drawing no.
510029075 (see picture 2 ) ; on the outside of the support install 2
bearings drawing no. 006510670 with its relative seegers drawing
no. 0 1 1 5 1 0 1 2 5 .
3. P u t the telescoping cylinder into the section drawing no.
230710004 rear entrance and make it slide on the trackway inside
the section, for approximately 1 , 5 meter. This is a delicate
procedure, therefore pay attention to guide carefullythe insertion
in order to avoid cables damages (see picture 3 ) .
Block the telescoping ropes terminals on the section drawing no.
230710004 with the pin drawing no. 5 1 0 0 2 9 1 7 3 and its relative lock
elastic washers (see picture 4 ) .
Finish to put the telescoping cylinder into the section, keeping
the ropes terminals in tension in order to avoid cables tangling
and damages. When the cylinder is completely in, position the
threaded terminals onto the cylinder itself, (see picture 5 ) and
fix them with some iron wire. Lock the return rope drawing no.
5 1 0 0 2 9 1 6 1 with its pins drawing no. 5 1 0 0 2 9 1 7 9 and elastic lockpins.
Install the rear sliding pads supports drawing no. 5 1 0 0 0 2 5 4 4 and
its relative ertalon sliding pads drawing no. 5 1 0 0 2 9 1 7 7 .
In order to position the telescoping cylinder inside the section,
you need a resistant band suitable for the cylinder weight lifting,
and a overhead traveling crane.
4. Position the first section drawing no. 2 3 0 7 1 0 0 0 3 on apposite
Supports; install the complete front sliding pads drawing no.
5 1 0 0 2 9 1 7 5 and drawing no. 5 1 0 0 2 9 1 7 6 inclusive of ertalon (see
picture 7 ) .
Insert backwards the whole group described above, from the front
part of the first section drawing no. 2 3 0 7 1 0 0 0 3 until the fixing
ears on the telescoping cylinder meet the holes of the fixing pins
located on the rear side of the first section.
Put the pins drawing no. 5 1 0 0 2 9 1 7 4 into the holes adding their
relative lock elastic washers (see picture 6 ) .
Untie the 6 threaded terminals and position them according to
picture 6. During this operation, the 2 parts of'the return cable
must be completely outside of the first section.
At this moment install on the first section the pulleys of the
second section return drawing no. 5 1 0 0 0 5 4 4 5 inclusive of their
relative bearings and tension kit drawing no. 2 3 0 7 1 0 0 0 1 ; roll up
the return rope drawing no. 5 1 0 0 2 9 1 6 1 onto the pulleys, and lay the
2 parts on the first section upper side, so that the arch made is
toward the front part of the pulleys themselves; tight the terminal
with iron wire on the first section. In order to perform this
operation use the overhead traveling crane, to lift and push the
group inside the section.
5. Position the boom drawing no. 230710002 on appropriate
supports; install the front sliding pads supports drawings no.
5 1 0 0 2 9 1 7 5 and 5 1 0 0 2 9 1 7 6 with their relative ertalon sliding pads
drawing no. 5 1 0 0 2 9 1 7 7 (see picture 8 ) .
Insert backwards the whole group described above, from the front
part of the first section (see picture 9) until the fixing ears on
the telescoping cylinder meet the holes of the fixing pins located
on the rear side of the first section.
Put the pins drawing no. 5 1 0 0 2 9 1 7 3 into the holes adding their
relative lock elastic washers (see picture 1 0 ) .
At this point insert the threaded terminals with the elastic
washers into their relative holes.
Before putting into tension the cables, put the return cable on the
half-moon located on the boom base. Then, acting on the rope
return joined with the cables tension system, you can retract the
boom; in this way you can adjust both the rope return and the
telescoping cables tension (see picture 1 1 ) .
6 . Insert now the lateral sliding pads (see picture 1 2 ) ; telescope
the boom out and align all sections acting both on the lateral and
lower sliding pads. Assemble the pulleys and relative pins on the
boom head .
7. Finally, install the winch on the boom (see picture 1 3 ) .
OIL CHECXlNG M D OIL CHANGE IN THE WINCH AND AUXlLlARY WlNCH
REDUCTlON GEARS F1G.AJ

OIL L N E L CHECKlNG AMD CHANGING IN THE WINCH BRAKE FIG.18

WINCH F1G.19

BLOCK FIG.20

BLOCK PWLLMS WEAR CHECKING FIG. 21

SELF-LOCKING SOCKETS FIG. 22

P W I N G THE G M P S FIG. 22
011 CHECKlNG AND 011CHANGE IN THE WNCH AND AUXlLlARY
WlNCH REDUCTION GEARS Fig.17
0 Check oil level at least monthly (150 hrs of operation).
Check oii after the first 501100 hrs of operation.
0 Check oil every 2500 hrs of operation.
Oil level checking
Unwind the rope from the drum until the inspection hole on the drum is visible
0 Position plug at 90" to the vertical centre line of the winch
0 Remove plug the oil level should reach the lower edge of the hole
If required top up with the Same type of oil.
Oil change
To changed the oil proceed as follows :
Position plug vertically downwards
Remove plug and drain thoroughly
Rotate winch drum to have the plug at 90" to the vertical centre line, as for level checking
Pour is petroleum and refit plug
Turn winch by a few turns and stop it, positioning the plug vettically downwards
Remove plug and drain petroleum thoroughly
Turn dnim to bring the plug at 90" as for level checking
Pour in new oil to level and refit the plug

OIL LEVEL CHECKlNG AND CHANGING IN THE WlNCH B W K E

Fig.18
To check the oil level, remove plug (2).
The oil level should touch the bottom edge of the hole. If it does not, top up with the Same type of
oil.
To change brake oil, rernove drain drainage plugs (3) and (2) :
* Let the oil drip well
0 Replace plug (3)
Pour in new oil through hole (1) until it reaches the level
Replace plugs (1) and (2)

NOTE: Carefully clean the plugs before refitting. lnspect the assembly for leaks. Avoid mixing
different types of oil, always follows lubricants chart.

WlNCH Fig.19
Lubricate bearing flange

BLOCK Fig.20
Lubricate the bearings and the end points of the pin Support hook

Pag. 3
BLOCK PULLEYS WEAR CHECKlNG Fig. 21
When replacing the hope, the pulleys should be inspected for wear or darnage and replaced if
required
Wom, damaged or undersized pulleys might damage the rope
Remernber that the diameter of a new rope is always larger of the old rope
The pulley grooves could be wom out because of the smaller diameter of the old mpe

Rope tlse and Maintenance

Uncoiling the wire rope
lnsufficient importance is usually given to the uncoiling operation which is often camed out
without due consideration
Sometimes, when installing a coiled rope, one begins by cutting the wrapping; an end is then
pulled out of the resulting mess while trying to unravel it; at the end of operation, the rope will be
bent and chinked and the effect on its perfomance can be imagined.
Uncoiling the rope in a workmanlike manner will reduce labour, as any accident and waste of time
is avoided; the simple tooling required is of minimal cost and will be fully paid back by better rope
utilisation.
The rope can be delivered by the manufactured wound on a core or more sirnply coiled, as per
custorner's request.

If the rope is wound on a core, a suitably long and thick bar should be inserted in the core hole,
laying the bar ends on two stands having sufficient height to enable the core to rotate freely; then
pul1 the rope end, while braking the core flange with a wooden or iron plank to prevent the rope
frorn getting loose on the core and keep unwinding.

If the rope is simply coiled, place the coil on a reel and, keeping it hoiizontal, uncoil the rope by
pulling on its end so as to have the coil and reel rotate. In this case also the reel should be braked
to prevent loosening of the rope. A small coil can be unwound by holding the end of the rope and
rolling the coil on the ground vertically.
lmproper winding of the rope, even when no kinks occur, may generate Stresses which tend to
"open" the rope and make it lose its compactness. In this case, also the wire Strands become
unbalanced and the rope might become deformed in operation and therefore less efficient.
When winding from above rope over the drum, arrange the coil so as to have rope go over it.
When winding from below (rope under the drum), arrange the coil to have the mpe go below it.
For tight, uniform winding, brake the coil with a wooden plank to keep the unwinding rope taut.
Proper winding of the first rope layer is of paramount irnportance; if it is properly laid, the following
layers will line up automatically. This is important when using smooth drums. When starting to
wind on a new drum, control the rope by hitting it with a wooden mallet to keep the tums ciose.
When unwinding the rope, roll the coil on the ground so as to have the rope straight as before
shipment.

IMPORTANT: A new rope should be run in buy operating initiaily at low speed and under light
loads.
SELF-LOCKING SOCKETS Fig. 22
Proper Fitting ' A"
lmpmper Fitting 'B"
The wire rope end should be on the sloped side of the socket. The loaded rope should be in line
with the socket eye. If the rope is fastened the other way, a kink will occur where the rope enters
the socket
NOTE: The use of ciamps on socket-wedge fastenings is not recommended. Clamps will simply
reduca the coupling strength.
WARNING: Use a wedge suitable for the drum socket. A wmng sized wedge is hazardous and
might not hold. Size and type are marked on the wedges and sockets. The socket may take two
or more rope sized, while the edge should suit the specific rope sized used.

Fig. 22
Clamps should be placed as shown in the figure " C .
The "Uwbracket should always be on the rope end and the base should be on the longer part of
the rope.
The cfamps should not be staggered, i.e. , there should not be a clamp with its "U" bracket on the
short end and the next with its "U" bracket on the long end of the rope. This layout would distort
the rope and does not ailow this type of fastening to be tensioned. If all the damps are laid with
their "Un on the long end of the rope the strands will be damaged and dangerous situations will
ensue.
The ctamps should not be spaced by less than 6 times the rope diameter. When replacing the
wire rope, use the type specified in the spare parts catalogue. The machines are designed for a
specific type and size rope. The use of other ropes than specified will reduce rope life and
possibly cause breakage. In our case, this is expressly forbidden by the National Wo* Safety
Organisation. Any accidents rnay entail criminal liability. All the ropes used shall be inspected
daily.
Rope Cuttng
If a rope has to be cut, both cut ends should be tied to keep the strands in place. On preformed
ropes, one tie at each end will be sufficient. On not preformed ropes, two ties should be applied
for diameters up to 22mm and for larger diameters, tie is recommended.
Three basic methods are recommended to cut a wire rope :
1) By grinding wheel
2) By shearing tools ( wire cutter for thin ropes, rope cutter for the thicker ones )
3) By oxyacetylene blow torch
Rope Lubrication
A wire rope is a mechanical component.
Whenever the rope goes over a pulley and stretches its strands mb against each other.
Lubrication is needed to limit the wear caused by this.
Lubrication also prevents rope decay due to tust and corrosion.
NOTE: A rusty rope is dangerous, as its residual strength could not be determined. Most wire
ropes are lubricated during manufacture, however, this lubrication does not last as long as the
rope. It is squeezed out when the rope is stretched over a pulley, when drenched by rain, etc..

For the above reasons the ropes Shall be Periodically Lubricated.

Do not use raw or spent oil or grease as a lubricant, as these may contain sand or acid matter,
both harmful to the rope.
Pag. 5
No cut and dried rule for lubrication intervals could be Set forth as this depends on the operating
...
conditions of the rope.
A rope operating in a humid environment should be lubricated more frequently than in a dry
ciimate, to prevent rust and comsion.
It is not recommended to lubricate the ropes used for draggling.
Wire rope lubricants should rneet the following specifications :
Contain no alcohol or acids
Be sufficiently adhesive to stick to the rope
Be capable of seeping among the wires and strands
Form a high strength .film
W ithstand oxidation
Remain flexible and ductiie
Rope wear inspection
A corroded rope should be replaced.
Strands wh'ere rnore than one wire has broken, should carefully be watched. Breakages on the
outer, wom part of the wire indicate abnormal deterioration. Breakages in the pulley gruoves
indicate abnormal conditions, possibly wear or failure of other, invisible wires. One or more
breakages in the grooves require rope replacement.
Wire ropes generally fail in those parts which run over pulleys, wind on drums or are subjected
to altemate stresses. Failure occuning near the anchor points are due to fatigue stresses
concentrated at such points. This type of failure calls for rope replacement or anchor points
modification to remove the fatigue points.
Severe wear or breakage may occur under any pulley where rope stroked is limited, or in
contact with stands. Special care should be given to rope inspection at these points.
Rope stretching is generally more evident at running in, when the windings adjust and Set.
Concurrently, the rope diameter will diminish, but rope conditions should not be judged on this
basic.
The time for rope replacament is indicated by abrasion, outer wire rubbing and hammering,
snapped wires, pitting and severe corrosion, accidentals kinks or other tampering which might
strain the rope structure.
Pulleys, guards, guides, drums, flanges and any other surface coming in contact with the rope
during operation should also be checked during the inspection. Any harmful abnormality to the
rope should be corrected. The equipment and specifically the pulleys and d n ~ mgrooves, shall
be inspected and set right before installing a new rope.
The rope should be replaced if any of the following conditions occur.
For ropes in operation, when six broken wires or three broken wires in a strand are found when
winding the rope.
For extension or idle ropes, when more than one broken wire is found in a strand.
Abrasion, hammering or rubbing causing strand diameter reduction by more than 113.
Rope deterioration due to corrosion.
Accidental kinks due to severe stressing or other damages causing over-stretching of the rope
SmCtuE.
Evidence of any damage due to heat from a blowtorch or by a voltaic arc consequent to
contact with a live line.
A reduction of the nominal diameter exceeding I,2mm for diameters up to 29mm; 1,6mm for
diameters ranging from 22 to 28,5rnm; 2,4mm for diameters ranging from 31mm to 38mm.
Any other evident defomation due to uneven load distribution over the strands.
Severe rusting, or rope breakage near the anchor points.
Baring of the rope core, even in one point only.

NOTE: If the last condition is localised on a sliding rope and the affected section may be removed
by a new anchoring, this can be done to avoid replacing the whole rope.

Pag. 6
BOOM
FRONT M D REAR StfDlNG PADS ON TH€ BOOM CHECKING M D REPLAClNG
FIG. 8-14 3

GREASE LUBRICATION POINTS F1G. 13-15-16 3

BOOM COMPENSATlQN RQPES ADJUSTMENT FlG. 11 3

Pag. 2
FRONT AND REAR SLJDING PADS ON THE BOOM CHECKING AND
REPiACING Fig. 8-14
lnspect the pads every 6 rnonths.
Replace the pads when the boom axis is negative

Sliding pads checking

For this check, the boorn extensions should be fully pulled out and their position checked
visually.
If during this check the boom tends to seffle at a positive angle (+), the sliding pads are still
perfectiy efficient
If on the other hand the boorn tends to seffle at a negative angle (-), the pads are excessively
wom and should be replaced with new ones.

Front pads replacing

With the boom all the way down, pul1 out the first extension by about 2m.
Lift the extension with a hoisting tackie or fork-lift truck
Remove the pins fastening the supporis to the boom body and rernove supports with the pad.
Replace the worn pads with new ones and reinstall.
Refit the pad Support and put the pin.
Pull out the other extensions and proceed as above.

Rear pads replacing

To repiace the rear pads, you need to dismantle the boorn; contact a RlGO authorized workshop.

Boom pulley wear checkiiig

When replacing the rope, the pulleys should be inspected for wear or damage and replaced ii
reqUired.
Worn, damaged or undersized pulleys might damage the rope.
Rernernber that the diameter of a new rope is always larger than the old one.
The puiley grooves could be wom out because of the smaller diarneter of the old rope.

GREASE LUBRlCATlON POINTS Fig. 13-15-16

To lubricate, spread with a brush all the boorn sections on all the element, in the parts indicated in
the picture.
Connection between raising jack and boom.
Connection between raising jack and turret.
Boom and Turret connection.

BOOM COMPENSATlON ROPES ADJUSTMENT Fig. 11

If crane or conpensation-ropes are new, check every day ropes tension for a month. Ropes have
an adaptation period and they can loosen and cause some phasedisplacements during
proportional boom telescoping or retracting.

Pag. 3
 GREASING AND LUBRlCATION ...

Before injecting the lubricant into the pressure nipples, clean the latter thoroughly to keep
mud, dust, foreign matter, etc., from mixing with the lubricant, thereby decreasing or
voiding altogether the lubricating action and acceleratjng the wear of the parts to be
lubricated.
- The time or mileage lubricating intervals given below are indicative arid apply to normal
crane duty. They might therefore change according to operating conditions, road
conditions and because of seasonal factors.
Lubricate every 100 workingl hours, unless othewise specified.

LUBRICANT SELECTION ACCORDING T 0 AMBIENT TEMPERATURE

-20"C1+5QC +5°C1+300C +3O0C/+5O0C -30°C1+65"C
LUBRICANT
1V 95 min IV 95 min N 95 min 1V 95 min
1SO 3448 VG 100 VG 150 VG 320 - VG 150-200
AGlP BIasia 100 Blasia S 220
ARAL Degoi BG 200 Degol BG 150 - Degof BG 320. Degol GS 220
BP MACH G 2 XP 100- GR XP 150 GRXP 320- - Enersyn HTX220
CASTROL Alpha SP 100 Alpha SP 150 Alpha SP 320 1 Alpha SN 150
CHEVRON non ieaded gear . non leaded gear nun leaded gear
compaund 100 compound 150 compound 320

TYPE OF GREASE

Pag. 2
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