Published 4-20-2015, Control # 502-01 5-9
RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT
IDLER DRUM AND CABLE FOLLOWER
Description
The main and auxiliary hoists are equipped with an idler
drum on the forward side of the hoist. The main hoist idler
drum is used to keep the hoist cable from coming in contact
with the boom. When the crane is also equipped with an
auxiliary hoist, the idler drum on the auxiliary hoist is used to
keep the hoist cable from coming in contact with the main
hoist. The cable follower is mounted on the rear side of it’s
respective hoist. The cable follower applies a downward
spring pressure against the cable onto the hoist drum, to
ensure that the cable will be uniformly wound onto the hoist
drum, and also prevent cable from jumping under abnormal
line conditions.
Maintenance
Idler Drum
Removal and Disassembly
1. Remove the bolt, washer, and lockwasher from the right
side of the idler roller (Figure 5-3).
2. Support the idler roller and withdraw the shaft from the
left side. Take care not to lose the dowel pin on the end.
3. Remove the roller from between the side plates.
Cleaning and Inspection
1. Clean all rust and dirt from the shaft.
2. Inspect the shaft and roller for cracks, scoring, or
grooving. Replace if necessary.
Assembly and Installation
1. Position the roller between the side plates
2. Install the shaft through the left side plate and the roller.
Ensure the flat on the shaft end aligns with the stop
welded on the side plate, align the dowel pin.
3. Secure the shaft to the right side plate with a bolt,
washer and lockwasher. Apply Loctite 243 to the bolt
threads.
Cable Follower
Removal and Disassembly
1. Loosen the adjusting nuts and remove the tension
spring and adjusting rod from both sides of the hoist (see
Figure 5-3).
2. Remove the tack welds from the bolt heads securing the
arm to the cable follower roller.
3. Support the cable follower roller and remove the bolts
and washers securing the arms to the angles on each
end of the roller. Remove the cable follower roller.
4. Disassemble the cable follower roller as follows.
a. Remove the two bolts and washers securing the
angle to the right side of the shaft.
b. Remove the shims and roller from the shaft.
c. If necessary, remove the bearing and bearing
housing from both ends of the roller.
5. Remove the bolt and locknut securing the arm to the
spring attaching lever on each side of the hoist. Remove
arms and levers from the side plates.
NOTE: Be sure to mark each arm and lever as to what side
(left or right) they were removed from. This will be
helpful during installation.
Cleaning and Inspection
1. Clean all grease from the shaft, bearing, and roller.
2. Check the shaft, roller, and bearings for cracks, scoring,
or grooving. Replace if necessary.
3. Check the spring tension. If the springs will not provide
sufficient tension when adjusted, replace them.
Assembly and Installation
1. Install the left arm through the bushing on the left side
plate. Install left spring attaching lever on the arm and
secure with a bolt and locknut. Apply Loctite 243 to the
bolt threads.
2. Repeat step 2 on the right side.
3. Assemble the cable follower roller as follows.
a. Apply high strength retaining compound Loctite 680
to the bearing housings and the bearings. Install
them in both ends of the roller.
b. Install the shaft into the roller with a least one shim
on each end.
c. Position the angle on the right side of the shaft and
secure with two bolts and washers. Apply Loctite
243 to the bolt threads.
4. Position the cable follower roller on the arms and secure
with four bolts and washers. Center the roller between
the hoist drum flanges and tighten the bolts. Tack weld
the bolt heads.
5. Attach one end of the tension springs to the levers on
each side. Install the adjusting rod through the lug on
each side plate and connect to the other end of the
spring. Install the adjusting nuts on each rod and tighten
enough to take the slack out of the springs.
6. Using a grease gun, apply grease to the fittings on each
side plate bushing.
7. Adjust the roller as follows.
Reference Only
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