Grove Crane AT400E SERIES SUPERSTRUCTURE OPERATOR’S AND SAFETY HANDBOOK MANUAL

OPERATOR’S AND SAFETY HANDBOOK

AT400E SERIES SUPERSTRUCTURE S/N_________________________

PUBLISHED: JANUARY 1994

LIST OF EFFECTIVE PAGES Original . . . January 1994

ii

Page Numbers

Change In Effect

Title Page thru xiv 1−1 thru 1−9 2−1 thru 2−61 3−1 thru 3−17 4−1 thru 4−24 5−1 thru 5−20 6−1 thru 6−2 7−1 thru 7−21

Original Original Original Original Original Original Original Original

Page Numbers

Change In Effect

ELECTROCUTION HAZARD TO PREVENT DEATH OR SERIOUS BODILY INJURY OPERATE THIS CRANE WITHIN ANY DISTANCE OF A POWER SOURCE

OR

NEVER POWER LINE WITHOUT FIRST NOTIFYING THE POWER OR UTILITY COMPANY OP ERATE MACHINE, ANY PART THEREOF OR LOAD WITHIN 20FEET OF ANY

NEVER ELECTRICAL POWER LINE OR POWER SOURCE OR SUCH DISTANCE AS IS

SPECIFIED OR REQUIRED BY LOCAL OR OTHER APPLICABLE SAFETY CODES OR REGULATIONS OPERATE MACHINE WITHOUT CONSULTING LOCAL OR OTHER APPLICABLE

NEVER SAFETY CODES OR REGULATIONS. OPERATE,

SERVICE OR MAINTAIN THIS MACHINE WITHOUT PROPER

NEVER INSTRUCTIONS. REMEMBER IT IS THE EMPLOYER‘S RESPONSIBILITY TO IMPLEMENT THE ABOVE AND TO PROVIDE ALL SAFETY DEVICES OR MEANS THAT MAY BE NECESSARY OR REQUIRED FOR ANY USE, OPERATION, SET − UP, OR SERVICE. HANDLE

PERSONNEL WITH THIS MACHINE WITHOUT WRITTEN APPROVAL

NEVER FROM GROVE MANUFACTURING COMPANY

READ YOUR OPERATOR’S MAKE SAFETY FIRST −NOT LAST!! HANDBOOK

NOTE

DO NOT REMOVE OPERATOR’S MANUAL FROM THIS MACHINE

GROVE SUNDERLAND ENGLAND

THIS MACHINE IS NOT EQUIPPED WITH ANY WARNING OR INSULATING DEVICES. EXTREME CAUTION MUST BE EXERCISED

BY ALL PERSONNEL WORKING WITH AND AROUND THIS MACHINE WHEN IN THE PROXIMITY OF ENERGISED POWER SOURCE OR POWER LINES ELECTRICITY CAN CAUSE SEVERE BODILY INJURY OR DEATH IF CONTACT OCCURS. ALL PERSONNEL MUST BE ADEQUATELY WARNED OF SAFETY PROCEDURES. iii

CHANGE RECORD Change No.

Effective Date

Date Entered

Entered By

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

____________

iv

NOTICE TO OWNER/USER Should this crane become involved in an accident, please contact your local Grove distributor immediately and relate details of the incident so he can notify the Grove Manufacturing Company. If the distributor is unknown and/or cannot be reached, please contact the Grove Manufacturing Company, (091) 5656281. (Address: Grove Worldwide Sunderland, England, SR3 3XR).

DO NOT OVERLOAD Weight of load should always be known before any attempt is made to lift it.

WARNING DO NOT OPERATE THIS CRANE WITH A JIB (SWINGAWAY OR EXTENSION) TAKEN FROM ANOTHER CRANE OR WITH ONE ORDERED AND FIELD INSTALLED UNLESS THE PROPER JIB LOAD CHART HAS BEEN INSTALLED IN THE CRANE CAB. WARNING HIGH TENSILE STEEL IS USED IN THE CONSTRUCTION OF THIS CRANE.SPECIAL FABRICATION PROCEDURES ARE REQUIRED WHEN USING THIS STEEL.IT IS THEREFORE ESSENTIAL TO REFER TO GROVE CRANES SERVICE DEPARTMENT BEFORE CARRYING OUT ANY ALTERATIONS OR REPAIRS

v

FOREWORD

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

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

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

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

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

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

Changes from the first printing of this manual that have been made in the text are marked by a vertical bar ( I ) on the margin of the page opposite the change.

In the event some text is removed, and is not replaced with new or changed material, a deletion arrow is used where the text was deleted.

In the event there is a change in an illustration, a hand with a pointing finger will be used to point out where the change occurred A CHANGE RECORD page is included as page iv herein. It is intended that the recipient of the changes keep this CHANGE RECORD updated as each change is received by him.

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

WARNING A WARNING IS USED TO EMPHASIZE THAT IF AN OPERATION, PROCEDURE,OR PRACTICE IS NOT FOLLOWED EXACTLY,DEATH OR INJURY TO PERSONNEL MAY RESULT. vi

CAUTION A CAUTION IS USED TO EMPHASIZE THAT IF AN OPERATION, PROCEDURE, OR PRACTICE IS NOT FOLLOWED EXACTLY, EQUIPMENT DAMAGE MAY RESULT. NOTE A note is used to emphasize an important procedure or condition.

The purpose of this manual is to describe the procedure for operating the crane and routine maintenance. Other work involving the repair or replacement must be carried out by suitably trained and qualified persons.

PARTS. Only genuine Grove parts should be used for replacement, these can be obtained through our distributors parts departments.

SERVICE. We suggest that owners will benefit from taking full advantage of our service arrangements, which our distributors provide.

TRAINING. Wherever possible, we encourage operators to visit our works for instruction and training. For details write to Product Support Office, Grove Cranes Sunderland, SR4 6TT. Please quote the crane serial number on all communications. This will make it easier for us to give you prompt and efficient service, by enabling us to identify correctly your particular machine.

vii

CODE OF PRACTICE FOR SAFE USE OF CRANES − CP 3010 AND B.S 7121 ISSUED BY BRITISH STANDARDS INSTITUTE We consider that the information given in this Operating Instruction Book together with that displayed on the crane and in the crane cab(s), is adequate for correct and safe operation of the the crane within the specified capabilities. For further detailed information regarding definitions, legislation, siting of cranes, procedures, precautions, requirements for drivers, slingers and signalers etc, all persons involved with the use of the crane should ensure that they are conversant with the relevant section of the above named British Standard Publication.

INSONORISED CRANES −FIRE HAZARD Plastic foam is used to absorb noise inside the engine compartment. it is a self extinguishing grade and is unlikely to cause a fire. However, if it is soaked with fuel or oil it becomes a serious fire hazard.

THE FOAM SHOULD BE INSPECTED WEEKLY Contaminated foam should be replaced immediately.

WARNING IF FIRE OCCURS, THE PLASTIC FOAM GIVES OFF NOXIOUS FUMES.

viii

TABLE OF CONTENTS Page

SECTION I GENERAL INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1 LIST OF SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1

SECTION II SAFETY PRECAUTIONS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1 CRANING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−10 JIBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−35 WIRE ROPE AND SHEAVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−36 CONTROLLED FREE−FALL HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−41 ELECTRICAL HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−42 PERSONNEL PLATFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−58 COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−59 DON,T FORGET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−60

SECTION III DESCRIPTION GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 MAJOR COMPONENTS AND SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 Hydraulic Systems and Components . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Pump and Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3 Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3 Turntable Assembly And Swing Mechanism . . . . . . . . . . . . . . . . . . . 3−3 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Main Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Outrigger System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 ix

Page Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Swingaway Boom Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 CAB CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Engine Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Engine Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Foot Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Hand Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Engine Distress Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Job Site Travel Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . 3−8 Differential Lock Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Differential Locked Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Transmission Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Rear Steer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Rear Steer Indication Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Rear Steer Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Crane Function Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Transmission Range Selector Switch . . . . . . . . . . . . . . . . . . . . . . . 3−9 Transmission Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . 3−9 Low Air Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Dual Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Brake Foot Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Park Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Park Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Emergency Pump Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Rear Axle Steering Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Craning Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Outrigger Selector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Outrigger Extension/Retraction Switch . . . . . . . . . . . . . . . . . . . . 3−11 Swing and Telescope Control Lever . . . . . . . . . . . . . . . . . . . . . . . 3−11 Boom Lift and Main Hoist Control Lever . . . . . . . . . . . . . . . . . . . 3−12 Hoist Rotation Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12 Third Wrap Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12 Swing Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12 Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12 x

Page Swing Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13 Swing Lock Control (Positive Lock Type) . . . . . . . . . . . . . . . . . . 3−13 Accessory Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13 Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13 Panel Light Dimmer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13 Work Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13 Boom Flood Lights Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . 3−13 Cab Circulating Fan (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14 Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14 Four−Way Flasher Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14 Steering Column Tilt Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14 Steering Column Telescope Control . . . . . . . . . . . . . . . . . . . . . . . 3−14 Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14 Spotlight (Optional) (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14 Skylight Wiper (Optional) (Not Shown) . . . . . . . . . . . . . . . . . . . . . 3−14 Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−15 Armrest Adjustment Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−15 Bubble Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−15 Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−15 Heat Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−15

SECTION IV OPERATING PROCEDURES PRE−STARTING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Signal and Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Foot and Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Hookblock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Steering Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−4 Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5 xi

Page Idling the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5 Racing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6 CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6 CRANE TRAVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−7 Traveling − General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−7 Moving the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−9 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−10 Steering Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−10 Front Wheel Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−11 Rear Wheel Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−11 Four − Wheel Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−11 Crabbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−11 Traveling − Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−12 Traveling − Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−13 Inter Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−13 Control Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−13 Preload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−14 USING YOUR LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−14 CRANE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−16 Setting the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−16 Stowing the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−18 Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−19 Elevating and Lowering the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−20 Elevating the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−20 Lowering the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−20 Emergency Boom Operating Procedures . . . . . . . . . . . . . . . . . . . . . 4−21 Telescoping the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−22 Extending the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−22 Retracting the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−22 Lowering and Raising the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−23 Lowering the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−23 Raising the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−23 Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−23

xii

Page

SECTION V LUBRICATION GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1 Hydraulic Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−5 Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−5 Arctic Conditions (Below 0 degrees F [−18 degrees C]) . . . . . . . . . 5−6 Anti wear Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−7 LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−7 VAPOUR CORROSION INHIBITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−16 WIRE ROPE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−17

SECTION Vi OPERATIONAL AIDS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1 LOAD MOMENT INDICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1 ANTI−TWO BLOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1 CONTROL LEVER LOCKOUT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1

SECTION VII SET UP AND INSTALLATION PROCEDURES GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−1 INSTALLING CABLE ON THE HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−1 CABLE REEVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−2 WEDGE AND SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−3 Correct Method of Fixing the Rope to the Socket . . . . . . . . . . . . . . . 7−3 Single Hook and Pearweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−6 ERECTING AND STOWING THE SWINGAWAY BOOM EXT . . . . . . . . . 7−7 Erecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−7 Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−9 Setting the Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−11 Setting the Telescoping Extension Length . . . . . . . . . . . . . . . . . . . . 7−12 Extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−12 Retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−13 MAGNET EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−16 xiii

Page

LIST OF FIGURES Transportation and Lifting Data Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−7 Dimension Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−9 Cab Controls and Indicators (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . 3−16 Cab Controls and Indicators (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . 3−17 Steering Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−12 Terms to Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−15 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−17 Lubrication Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18 Lubrication Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−19 Installing Cable Anchor Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−2 Erecting and Stowing the Swingaway Boom Ext (Sheet 1 of 2) . . . . 7−14 Erecting and Stowing the Swingaway Boom Ext (Sheet 2 of 2) . . . . 7−15

xiv

SECTION 1 GENERAL INTRODUCTION This Handbook provides information for the operators of the Model AT400E Series Grove Crane.

The lift capacities are listed on the Load Chart in the cab.

The all terrain crane incorporates a parallel box type, all welded steel frame, using planetary drive axles to provide four−wheel drive. Axle steering is accomplished utilizing hydraulic steer cylinders. The engine is mounted at the front of the crane and provides motive power through a six speed transmission. Hydraulic, double box, sliding beam outriggers are integral with the carrier frame.

The carrier frame incorporates oscillation lockout cylinders to which the axles are mounted. Axle oscillation is provided through the front and rear axle suspension cylinders.

The superstructure is capable of 360 degree rotation in either direction. All crane functions are controlled from the fully−enclosed cab mounted on the superstructure. The crane is equipped with a three−section, trapezoidal, cable synchronised boom. Additional reach is obtained by utilizing an optional triangular boom extension (swingaway). Lifting is provided by a main hoist and an optional auxiliary hoist.

NOTE Throughout this manual, reference is made to left, right, front, and rear when describing locations. When operating the crane from the carrier, these reference locations are to be considered as those viewed from the operator’s seat with the superstructure facing forward over the front of the carrier frame. When operating the crane from the superstructure these reference locations are to be considered as those viewed from the operator’s seat with the superstructure facing rearward with the boom directly over the rear of the carrier frame.

1−1

LIST OF SPECIFICATIONS GENERAL Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT400E Series Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Load Chart in Cab Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4 Gross Weight . . . . . . . . . . . . . See lifting and transportation decal on cab door CAPACITIES Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 gallons (189 litres) Engine Lubrication System . . . . . . . . . . . . . . . . . . . . See Engine Specification Hyd Tank (Reservoir Capacity) . . . . . . . . . . . . . . . . . . . 64.4 gallons (244 litres) Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 quarts (11.5 litres) Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50ounces (1.5 litres) Axle Planetary Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 quarts (2.4 litres) Axle Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 quarts (20 litres) Transmission and Torque Converter . . . . . . . . . . . . . . . . 28 quarts (26.5 litres) FIRE EXTINGUISHER Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.75 lb (1.25 kg) TRANSMISSION Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Gear Ratios . . . . . . . . . . . . . . . . . . . . 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5th . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6th . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.83 Rev . . . . . . . . . . . . . . . . . . . . . . . . . . . 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 WHEELS AND TYRES. Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435lb/ft (59.0 nm) Tyre Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G20 XL 15.5 / 80 R20

1−2

TYRE PRESSURES Tyre Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 PSI (10.1 BAR) NOTE This pressure is correct for “on rubber” duties and road speeds up to 80 kph.

However, this will affect ride characteristics, therefore if the machine is to be driven long distances the tyre pressure could be reduced to 105 psi (7.25 bar) to improve the ride, but MUST be returned to 146 psi prior to commencing “on rubber” lifting.

BRAKES. Type Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Wedge − Air Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Wedge − Air PUMP (EMERGENCY STEER) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.727 gal. (2.75 litres) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . @ 100 rpm at 0 psi STEERING PUMP Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Output . . . . . . . . . . . . . . . . . . . . . 5.9 gpm at 1000 rpm (22.5 lpm @ 1000 rpm) STEERING GEAR (CARRIER) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recirculating Ball with Worm Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w/Two Circuit Steering System Steering Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.6:1 HYDRAULIC PUMPS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GPM . . . . . . . . . . . 1−39 gpm (147 lpm), 1−35 gpm (132 lpm), and 1−16 gpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (61 lpm @ 2500 rpm) SWING MOTOR. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbit Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 cu.in (15.7 cu. cm) per rev 1−3

AIR COMPRESSOR Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Piston Displacement @ 1250 rpm . . . . . . . . . . . . . . . . . 12ft3 / min (cm3 / sec) Maximum Recommended rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 Minimum Pressure Required to Unload . . . . . . . . . . . . . . 60 psi (4.22 kg/cm2) SWING GEARBOX. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Reduction Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.98 : 1 BOOM Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . −3° to +78° Optional Extensions . . . . . . . . . . . . . . . . 25ft (7.6 m) Swingaway or 25 to 43 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (7.6 − 13.1m) telescoping swingaway HOIST Grove Model HO−15E−20G Drum Dimensions Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 inch (30.5cm) Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 inch (51cm) Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/16 inch (16mm) Cable Capacity Max Rope Stowage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508 feet (155m) Permissible Line Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to the Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulls and Reeving Info Chart in Cab COUNTERWEIGHT Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolt on Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . (See Axle Weight Distribution Chart) OUTRIGGERS. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Box Beam and Inverted Jack Extended Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 feet (5.6m) Retracted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 feet (2.3m) AIR HYDRAULIC SWIVEL Air Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Oil Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRICAL SYSTEM. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single wire ground return (chassis) System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.

1−4

CAB HEATER(S) Carrier Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot Water Superstructure Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Combustion Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volts Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel

1−5

ENGINE SPECIFICATIONS MAKE & MODEL

CUMMINS 6BTA5.9

TYPE BORE STROKE DISPLACEMENT HORSEPOWER (NET) GOVERNED RPM TORQUE (NET) COMBUSTION SYSTEM COOLING SYSTEM CAPACITY LUBRICATION SYSTEM

6 Cylinder O.H.V 4.02 in (102mm) 4.72 in (120mm) 359 cu.in. (5.9L) 135.3 2800 250 lbs.ft (34.6 kgm) @ 1800 RPM 4 cycle, Turbocharged Liquid−10.5 gal. (39.7 L) 17.3 quarts (16.4 L)

1−6

1−7

AXLE WEIGHT DISTRIBUTION CHART POUNDS

KILOGRAMS

DESCRIPTION GROSS FRONT LBS. LBS.

REAR LBS.

GROSS FRONT REAR KG KG KG

Max. Axle Loads Allowed

(22000)

(22000)

(998)

Max. Tyre Loads Allowed

(22046)

(22046)

(10000) (10000)

Complete Basic Machine (Including 4x4 Chassis W/Cummins 6BT5.9 Engine, G20 Michelin Tyres, Full Fuel and Hydraulic Oil 37506

17076

20430

17009

7744

9265

−391 +276 +1348 +803

+901 −104 −342 −304

+231 +78 456 226

−177 +125 +611 +364

+409 −47 −155 −138

(998)

ADD: Spare Tyre & Hanger: Headache Ball in Trough 25’ Boom Ext. & Brkts.

20 Ton Hookblock (Stowed in Trough)

1−8

+510 +172 1006 499

DIMENSION CHART 1−9

SECTION II SAFETY PRECAUTIONS GENERAL. It is impossible to compile a list of safety precautions covering all situations.However, there are basic safety precautions that MUST be followed during your daily routine. Safety is YOUR PRIME RESPONSIBILITY, since any piece of equipment is only as safe AS THE PERSON AT THE CONTROLS. With this thought in mind, this information has been provided to assist you,the operator, in promoting a safe working atmosphere for yourself and those around you. It is not meant to cover every conceivable circumstance which could arise.

It is intended to present basic safety precautions that should be followed in daily operation.

Because you, the operator, are the only part of the crane that can think and reason, your responsibility is not lessened by the addition of operational aids or warning devices. Indeed, you must guard against acquiring a false sense of security when using them. They are there to assist, NOT direct the operation.Operational aids or warning devices can be mechanical, electrical, electronic, or a combination thereof. They are subject to failure or misuse.

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

REMEMBER, failure to follow just one safety precaution can cause that accident to people or equipment.

You are responsible for the safety of yourself and those around you.

Ensure you and those working with you are aware of any special dangers where you are operating the crane. Be especially careful of dangerous ground and objects, including buildings, near the crane.

Be aware at all times that you are responsible for the safety of yourself, your coworkers, the crane and everything around it. Make certain the crane is properly maintained, and then pay attention to winds, boom deflections, rope sway, and any unusual things, which you, as a crane operator, may notice which would not be important to others.

2-1

Know and abide by the basic safety rules.

Read and understand the Operator’s and Safety handbook before entering the cab.

2-2

Follow directions on all placards. Know what they mean and follow their instructions.

Be prepared for the work day.

2-3

Operators must be thoroughly familiar with safe crane operating practices and have a complete understanding of all operation and maintenance instructions provided. Operators should be physically fit and thoroughly trained, with related experience, not be easily excitable, not be subject to epileptic seizures, and not be using any drug that could impair physical,visual, or mental reactions or capabilities.

Wear the proper clothing for the job. Wear personnel protective equipment as required by local or job regulations.

Inspect the crane every day (before the start of each shift). Ensure that routine maintenance and lubrication are being dutifully performed. Don’t operate a damaged or poorly maintained crane. You risk lives when operating faulty machinery, including your own.

Know the area in which you are working. Familiarize yourself with work site obstructions and other potential hazards in the area.

Use caution when in the vicinity of overhanging banks or edges.

Keep your shoes clean. Before entering the cab, clean any mud or grease from your shoes. This will reduce the possibility of your foot slipping off a control pedal, possibly resulting in an accident.

2-4

Since certain shoe sole materials are more slip resistant than others, all operating and service personnel should wear footwear with high slip resistant sole material.

Avoid a dirty or greasy crane. Keep the cab, deck, and foot and hand holds free of mud and grease for operator safety. Dirty equipment fails rapidly and makes good maintenance difficult.

Observe and heed possible pinch points while performing maintenance or other work.

Check for WARNING tags placed on the crane. If found, refuse to operate the crane until repairs are made and WARNING tags are removed by authorized personnel.

Before performing maintenance, disconnect the battery, remove the ignition key, and place WARNING SIGNS in the cab.

2-5

Proper lubrication is a requirement in any heavy equipment operation. Follow the factory recommendations regarding the lubrication time intervals and types of lubricants used. Adjust time intervals accordingly, when working under severe conditions.

When adding oil to the hydraulic system, follow the manufacturer’s recommendations. Mixing the wrong fluids could destroy seals, causing machine failure.

When performing maintenance, refer to the appropriate manual for instructions.

Consult the factory if there is any question regarding procedures or specifications.

Do not attempt repairs you do not understand!

BEFORE performing maintenance on the crane, remove all weight from outrigger jack cylinders, and lower attachments to the ground or place them on suitable blocking.

Pressurized air and hydraulic oil can cause serious injury. Be certain all lines,components, and fittings are tight and serviceable. Use a piece of cardboard or wood to search for suspected leaks in hydraulic systems and soapy water to search for leaks in pneumatic systems.

Never exceed the manufacturer’s recommended relief valve pressure settings.

Always replace the guards or other safety devices which may have been removed during crane repair or adjustment.

Have an approved fire extinguisher available and know how to use it. Inspect as required to ensure it is fully charged and operable.

Maintain battery electrolyte at the proper level. Check the state of charge indicator with a flashlight.

A spark or flame could cause a battery explosion. Don’t short across the posts to check the charge.

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

Wear your safety glasses when servicing batteries.

2-6

Don’t smoke while performing battery maintenance.

Disconnect the grounded battery clamp first when removing a battery and connect it last when installing battery.

Before charging a battery, consult the battery manufacturer’s instructions.

Avoid battery acid contact with the skin and eyes. If accidentally contacted,flush the area with water and consult a doctor immediately.

Follow standard safety precautions when refueling. FUEL IT SAFELY.

2-7

Be careful when checking the coolant level. Shut down the engine and allow the radiator time to cool before removing the radiator cap.

Unless authorized and approved by Grove Manufacturing Company, do not make any modifications, alterations, or changes to a crane which could in anyway affect it’s original design. Such action invalidates all warranties and capacity charts, and makes the owner/user liable for any resultant accidents.

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

Keep your fingers away from potentially hazardous areas.Keep brakes properly adjusted. Keep brake linings free of oil and grease. Do not over lubricate the bearings or brake anchor pins. Refer to the Service Manual.

2-8

Use cleaning solutions that are non-flammable and approved for the work being performed.

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

Do not store flammable materials on the crane at any time.

Never get off or on a moving crane.

When getting on or off a stationary crane, use both hands and use the handrails and steps provided.

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

2-9

When getting on or off a stationary crane, use both hands and use the handrails and steps provided.

When shutting down the crane adhere to the following: - engage the parking brakes - lower the boom and the load - place the controls in neutral - chock the wheels - ensure the swing lock is engaged - remove the ignition key - lock the machine and install vandal guards, if used.

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

CRANING OPERATION. Check crane stability before lifting loads. Ensure the outriggers (or tires if lifting on rubber) are firmly positioned on solid surfaces. Ensure the crane is level, brakes are set, and the load is properly rigged and attached to the hook.Lift the load slightly off the ground and recheck the stability before proceeding with the lift. Determine the weight of the load before you attempt the lift.Check the load chart against the weight of the load.

Most accidents involving mobile hydraulic cranes are caused by the following: - crane out of level - bad surface conditions - outriggers used improperly or not used at all - inadequate blocking under outrigger floats - improper crane operation.

2-10

After the crane has been properly set-up, make a dry run before making the first lift. Become familiar with all factors peculiar to the job site. Know what moves to make BEFORE attaching the first load. Plan ahead.

Unless lifting within On Rubber capacities, outrigger beams must be fully extended, jack cylinders extended and safety locks set, to provide maximum leveling of the crane. Remove all weight from tires before lifting on outriggers.

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

2-11

Use the sight level bubble indicator to ensure crane leveling.

Use the load line to determine the levelness of the crane. It should always lie in the center of the boom. Check at two points 90 degrees apart.

Be sure the hoist line is vertical before starting the lift. Don’t subject the crane to side loadings.

Measure the load radius before making lifts and stay within approved lifting areas. Check your load chart!

The importance of properly leveling a crane cannot be overstressed. A crane only slightly out-of-level can quickly encounter a tipping condition.

Barricade the area around which the crane is working.

Don’t interfere with the proper functioning of operational aids or warning devices. Monitor them regularly and see they get the proper care.

2-12

Always refer to the capacity on the load chart in the cab BEFORE making any lift.

Position the hoist line to the radius required - then lift the load. Stay within the approved work area for the load being lifted.

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

Operate the engine at or near governed RPM during performance of all crane operations.

2-13

Extend boom sections equally. Keep the lifting lines and the boom as short as the load and conditions will permit. Remember, the load chart capacities are based on equally extended boom sections. This does not apply on cranes where the telescopic sequence is automatic.

Do not exceed crane rating. Do not rely on the crane tipping stability to determine the maximum lifting capacity. Do not exceed the capacities shown on the load chart in the cab. REMEMBER: ALL LIFTING DEVICES (HEAD-ACHE BALL, BLOCK, JIB, ETC.) - ARE PART OF THE LOAD. 2-14

Always check the capacity of the crane as shown on the load chart before making any lifts.

Know the weight of all loads before you attempt a lift. Ensure the load to be lifted is within the rated lifting capacity of the crane.

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

2-15

NEVER exceed the rated lift capacity shown on the load chart. Always check the load chart to ensure the load to be lifted at the desired radius is within the rated capacity of the crane.

NEVER use the crane stability to determine capacity. It may be too late when you find out.

Multiple crane lifts are not recommended. The use of more than one crane to make a lift requires the ultimate in equipment, engineering, operating skill,and lift coordination.

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

1.

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

2.

Use one signal person and be sure he is qualified.

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

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

Be certain cranes are of adequate lifting capacity.

5.

Use outriggers on cranes so equipped.

2-16

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

7.

Lift only from a stationary position - DO NOT TRAVEL.

8. If possible, provide approved radio equipment for voice communication between all parties engaged in the lift.

9. Ensure the load lines are directly over the attach points to avoid side loading the cranes.

Always use enough parts-of-line to accomodate heavy lifts. Provide a safety allowance and reeve more parts of line, rather than fewer parts, than you need.

Refer to the values on the load capacity chart for the line weight ratios.

Watch the tail-swing of the revolving superstructure, especially if there are people or obstacles in the area.

Always make daily inspections of the wire-rope and replace worn, rusty, or frayed ropes.

Always place the load on the ground when lubricating or adjusting.

A qualified signal man should be available at all times and especially when; - working in vicinity of power lines - the crane operator cannot clearly see the load at all times - moving the crane in an area or direction in which the operator cannot clearly see the path of travel.

At all times use standardized hand signals previously agreed on and completely understood by the operator.

2-17

If communication with the signalman is lost, crane movement must be stopped until contact is regained.

Watch the load at all times. Watch the signalman and/or load while it is moving.

In case you must look in another direction, stop the operation immediately.

2-18

2-19

Use only one qualified signalman whenever vision is obscured and follow only his directions. But . . . . .

. . . . . Obey a signal to stop from anyone.

KEEP THE BOOM SHORT. Swinging loads with a long line can create an unstable condition and possible structural failure of the boom.

2-20

Sound a warning before moving the crane or when approaching personnel.

Always move toward the load and move slowly. Use a tagline to control the load.

Stay clear of the sheave wheels, holes, and lattice work in telescoping booms and other potentially dangerous areas whenever the crane is in operation.

2-21

Pinch points are impossible to eliminate. Keep all portions of your body away from cable drums, sheaves, pulleys, lift cylinders, and other moving parts of the crane. Be extremely careful when performing maintenance on the crane.

Cranes equipped with an extendable counterweight must have the counterweight in extended position prior to lifting.

Use extreme caution when lifting with more than one hoist.

Do not strike any obstruction with the boom. If the boom should accidentally contact an object; stop immediately. Inspect the boom. Remove the crane from service if the boom is damaged.

Never push or pull with a crane boom.

Do not add to the counterweight to increase capacity.

2-22

When lifting loads, lift slowly and proceed with caution.

Maintaining a steady tension may free the load without shock loading the crane.

Cranes are designed and rated to handle freely suspended loads. Do not pull post, piling, or submerged articles that may have a heavy accumulation of mud, silt, or sand.

When lifting loads, the crane will lean toward the boom and the load will swing out, increasing load radius. Ensure the load capacity chart is not exceeded when this happens.

Check the swing brake. Make certain the swing brake operates correctly.Unexpected free swinging of a boom can be dangerous.

Wind and other factors such as boom length, boom angle, size and weight of load being lifted, etc. can affect crane stability and crane structures. Practical working loads for each particular job and lift shall be established by the user depending upon conditions that exist at the time a lift is being made. Appropriate capacity reductions shall be made whenever conditions indicate the possibility that a loss of crane stability or structural damage could occur. Be extremely cautious if wind velocity approaches 20 miles per hour.

2-23

Exercise caution when swinging loads.

Never swing or lower the boom into the carrier cab.

Stop the hook block from swinging when unhooking a load.

Swinging rapidly can cause the load to swing out and increase the load radius.

Swing the load slowly. Swing with caution and keep the load lines vertical.

Operate the crane only from the crane operator’s seat. Operating from any other position, such as reaching in a window, constitutes a safety hazard.

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

2-24

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

When using a controlled free-fall hoist, slowly return the hoist to normal lowering speed before stopping the descent of a load. Quick stops could cause the machine to fail. Also refer to CONTROLLED FREE-FALL HOIST information in this section.

Do not attempt to change/shift speeds, on multiple speed hoists, with hoist in motion.

Never pull sideways with the boom. Booms and swing systems are not designed to side pull and may be damaged if subjected to excessive side loading. Booms are designed for lifting only freely suspended loads.

2-25

NEVER permit anyone to ride loads, slings, hooks, etc., for any reason.

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

Never stand or work on or near the superstructure while the crane is moving or swinging.

2-26

Keep everyone away from suspended loads. Allow no one to walk under a load.

Ensure that all slings, ties, and hooks are correctly placed and secured before raising or lowering the load.

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

2-27

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

2-28

Check all braking and holding devices before operation. Perform an operational check of all braking (wheel and swing) and safety holding devices before starting any crane or traveling operations.

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

Allow no one to ride on the crane, carrier deck, engine compartment, etc.

Tag line personnel must guide the load from the ground.

2-29

Use only slings or other rigging devices rated for the job and use them properly.

Never wrap the hoist cable around a load.

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

2-30

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

Exercise extreme caution when picking and carrying a load. Never pick and carry a load with a crane that is not authorized for such operation.

When performing pick and carry operations or operating on sloping ground,carry loads much less than capacity. Keep the load low, carry the load uphill from the crane, swing only to keep the load uphill, and always place the loads on the high side.

When traveling with a load, the boom should be carried in line with the direction of motion.

Report any crane damage immediately.

2-31

Check all pin connections, bolts, latches, locks, braking and restraining devices, and operational aids before operation. Perform a visual inspection and replace / tighten any damaged or loose devices prior to initiating any crane or traveling operations.

2-32

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

CAUTION IT CAN BE DANGEROUS TO LEAVE A CRANE UNATTENDED FOR EXTENDED PERIODS WITH THE BOOM IN AN ELEVATED POSITION SINCE IT IS POSSIBLE, DUE TO THERMAL CONTRACTION OF THE OIL, LOCK VALVE OR PISTON SEAL LEAKAGE, FOR THE BOOM TO CREEP Clearly dependent upon the position of the boom such creep could result in damage to the crane cab or some adjacent structure. Accordingly it is recommended that the crane is not left unattended for extended periods unless it is secured as follows:1.

Lower the load to the ground and disconnect from the lifting gear

2.

Fully retract the boom combination and lower to the horizontal. Secure the hookblock.

2-33

3.

Ensure the handbrake is applied and the slew lock engaged.

4.

Stop Engine(s) and remove the ignition key(s), lock cab doors(s).

5.

Chock the wheels on inclines

Be alert-stay alert.

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

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

When shutting down the crane adhere to the following: - engage the parking brakes - lower the boom and the load - place the controls in neutral - chock the wheels - ensure the swing lock is engaged - remove the ignition key - lock the machine and install vandal guards, if used.

2-34

JIBS.

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

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

2-35

Stay outside of the jib sections.

Avoid falling or flying pins as they are freed or removed.

WIRE ROPE AND SHEAVES. The following information is taken from a National Consensus Standard as referenced by Federal Government Agencies.

All wire rope will eventually deteriorate to a point where it is no longer useable.

Wire rope shall be taken out of service when any of the following conditions exist: 1. In running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand in one lay.

2. Wear of one-third the original diameter of outside individual wires. Kinking, crushing, bird caging, or any other damage resulting in distortion of the rope structure.

3.

Evidence of any heat damage from any cause.

4.

Reductions from nominal diameter of more than: 1/64 inch for diameters up to and including 5/16 inch 1/32 inch for diameters 3/8 and 1/2 inch inclusive 3/64 inch for diameters 9/16 to 3/4 inch inclusive 1/16 inch for diameters 7/8 to 1 1/8 inches inclusive 3/32 inch for diameters 1 1/4 to 1 1/2 inches inclusive.

5. In standing ropes, more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection.

Refuse to work with worn or damaged wire rope.

Demand to see the rope inspection record required by law and inspect the wire rope yourself. Don’t take another person’s word.

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

2-36

Never handle wire rope with bare hands.

Inspect the boom nose and hook block sheaves for wear. Damaged sheaves cause rapid deterioration of wire rope.

Use the wire rope that is specified by the manufacturer.

2-37

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

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

2-38

Ensure hoist cable (wire rope) is properly routed.

2-39

Two-blocking MUST BE AVOIDED, to prevent damage to your crane and to avoid creating a safety hazard. Two-blocking exists whenever the load block,headache ball, rigging, etc. come into physical contact with the boom, boom nose, sheave, jib, etc. Two-blocking can cause hoist lines (wire rope) rigging, reeving, and other components to become highly stressed and overloaded in which case the wire rope may fail allowing the load, block, etc. to free fall.

Your crane is equipped with an anti-two block warning system. If the system has been damaged, removed from the crane, or a malfunction is suspected, refuse to operate the crane if the warning system is not installed and operating satisfactorily.

2-40

Caution must be used when lowering or extending the boom - let out cable simultaneously to prevent two-blocking the boom nose and hook block. The closer the load is carried to the boom nose the more important it becomes to simultaneously let out cable as the boom is lowered. Keep the hookblock, etc.at least 12 inches (30.48 cm) away from the boom nose at all times.

CONTROLLED FREE-FALL HOIST. When using your crane during controlled free-fall hoisting operations, the following recommendations are offered: Exercise caution when using (optional) controlled free-fall hoists -smooth and gradual snubbing of load is necessary to avoid high shock loads.

Use single-part (line) reeving only.

Fully extend and set the outriggers.

Ensure the crane is level and on a firm supporting surface.

Use main boom whenever feasible.

Reduce load values to 30% of the cranes rated load values or 50% of the permissible line pull values as indicated on the crane load capacity chart or the hoist manufacturers maximum allowable rating, whichever is less.

2-41

ELECTRICAL HAZARDS. Read and abide by this WARNING placard posted on the crane.

ELECTROCUTION HAZARD TO PREVENT DEATH OR SERIOUS BODILY INJURY THIS CRANE WITHIN ANY DISTANCE OF A POWER SOURCE OR NEVER OPERATE POWER LINE WITHOUT FIRST NOTIFYING THE POWER OR UTILITY COMPANY OP ERATE MACHINE, ANY PART THEREOF OR LOAD WITHIN 20FEET OF ANY

NEVER ELECTRICAL POWER LINE OR POWER SOURCE OR SUCH DISTANCE AS IS

SPECIFIED OR REQUIRED BY LOCAL OR OTHER APPLICABLE SAFETY CODES OR REGULATIONS OPERATE MACHINE WITHOUT CONSULTING LOCAL OR OTHER APPLICABLE

NEVER SAFETY CODES OR REGULATIONS. OPERATE,

SERVICE OR MAINTAIN THIS MACHINE WITHOUT PROPER

NEVER INSTRUCTIONS. REMEMBER IT IS THE EMPLOYER‘S RESPONSIBILITY TO IMPLEMENT THE ABOVE AND TO PROVIDE ALL SAFETY DEVICES OR MEANS THAT MAY BE NECESSARY OR REQUIRED FOR ANY USE, OPERATION, SET − UP, OR SERVICE. HANDLE

PERSONNEL WITH THIS MACHINE WITHOUT WRITTEN APPROVAL

NEVER FROM GROVE MANUFACTURING COMPANY

READ YOUR

MAKE SAFETY FIRST −NOT LAST!! OPERATOR’S HANDBOOK NOTE

DO NOT REMOVE OPERATOR’S MANUAL FROM THIS MACHINE

GROVE SUNDERLAND ENGLAND

Crane operation is extremely dangerous when close to an electrical power source. A mobile hydraulic crane is more vulnerable due to the natural maneuverability and versatility of the crane.

Extreme caution must be exercised by all personnel working with and around your crane when in the proximity of an energized power source or power lines.

All personnel must be adequately warned of safety procedures.

2-42

Assume all power sources are electrically energized (“hot” or “live”) until you have absolutely reliable information to the contrary.

When operating in the vicinity of power lines, have the power company cut off the power and ground the lines. Obey the following rules, at all times, whether the power is cut off or not.

2-43

-Position the crane far enough away from power sources to ensure that no part of the crane or load can reach to within an unsafe zone. This includes the crane boom (fully extended to maximum height, radius,and length) and all attachments (jibs, boom extensions, rigging, tag lines, etc.).

-Erect a suitable barricade to physically restrain the crane and all attachments (including the load) from entering into an unsafe distance from the power source.

-Obtain positive and absolute assurance that power has been turned OFF.

2-44

IMPORTANT - Always consider the wire rope, hoist cable, pendant cables, taglines, etc. as conductors.

EXERCISE EXTREME CAUTION AND PRUDENT JUDGEMENT WHENEVER ELECTROCUTION HAZARDS EXIST - OPERATE SLOWLY AND CAUTIOUSLY. Federal law prohibits use of cranes closer than 10 feet (3.048 m) to power sources - to be safe, double that (i.e. 20 ft. [6.096 m]).

Comply with all federal, state, and local laws and regulations.

It is not necessary to touch a power line or power source to become electrocuted. Electricity, depending on magnitude, can jump or become induced into a crane. “Low” voltages can also be dangerous.

Be alert.

Keep all parts of the crane (ropes, lines, load block, and load) at least 20 feet(6.096 m) from the line.

Slow down crane operations.

2-45

Whenever a load, wire rope, crane boom or any portion of a crane contacts or approaches too closely to an electrical power source, everyone in, on, and around the crane can be seriously injured or killed!

THE ONLY SAFE WAY TO OPERATE A CRANE IS TO STAY AWAY FROM ELECTRICAL SOURCES!

2-46

Assume that every line is “hot.”

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

Warn all personnel of danger. Allow no unnecessary personnel in the area. Permit no one to lean against or touch the crane. Permit no one including sling men or load handlers to hold load, lines, or rigging gear.

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

2-47

The use of boom guards, proximity devices, insulated hooks, links, or mechanical limit stops does not assure safety. Even if codes or regulations require the use of such devices, failure to follow rules listed here may result in serious injury or death. You should be aware of some of the limitations of the devices.

Boom Cage / Guards afford limited protection from electrocution hazards.They are designed to cover only the boom-nose / point, and a portion of the boom.

Performance of boom cages/guards is limited by their physical lengths, insulating characteristics, and the operating environment (e.g. dust,dirt, moisture, etc.).

2-48

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

2-49

The only protection afforded by a link is that which is obtained below the link -electrically downstream, provided the link has been kept clean and free of contamination and is periodically (right before use) tested for its dielectric integrity.

2-50

Proximity sensing devices are available in different types. Some use boom nose (localized) sensors and others use full boom length sensors. No warning may be given for components, cables, loads, etc. located outside of the sensing area.

Much reliance is placed upon you, the operator, in selecting and properly setting the sensitivity of these devices.

2-51

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

2-52

Some variables with which you must be aware are: 1. Proximity devices are supposed to detect the existence of electricity-not it’s quantity or magnitude.

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

3.

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

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

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

Plan ahead and plainly mark a safe route before traveling under power lines.Erect rider poles on each side of the crossing to assure sufficient clearance is maintained.

2-53

Overhead lines tend to blow with the wind. Allow for this when determining safe operating distances.

2-54

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

DO NOT depend on grounding!

Grounding of a crane affords little or no protection from electrical hazards.The effectiveness of grounding is limited by the size of the (wire) conductor used, the condition of the ground, the amount of the voltage and current present, etc.

Power source contacts have been known to cause serious arcing due to grounding.

2-55

Tag lines should always be made of non-conductive materials.

2-56

Any tag line that is wet or dirty enough can conduct electricity.

Working in the vicinity of radio frequency transmission towers / sources may cause a crane to become electrically “charged.” Survey the work site and develop specific safety precautions and operating procedures, prior to commencing operations.

If contact is made with a power source - THINK - DON’T PANIC. 1.

Warn everyone to stay away from the crane.

2.

Attempt to free the crane by operating the crane functions.

3.

Stay in the crane until the power source has been deenergized.

2-57

Only as a Last Resort should an operator attempt to leave the crane upon contacting a power source.

If it is absolutely necessary to leave the operator station, JUMP COMPLETELY CLEAR OF THE CRANE - DO NOT STEP OFF. Hop away with both feet together. DO NOT walk or run.

When operating cranes equipped with electromagnets you must take additional precautions: - Permit no one to touch the magnet or load.

- Alert personnel by sounding a warning signal when moving a load.

- Do not allow the cover of the electromagnet power supply to be open during operation or at any time the electrical system is activated.

- Shut down the crane completely and open magnet control switch prior to connecting or disconnecting magnet leads.

- Use only a non conductive device when positioning a load.

- Lower magnet to stowing area and shut off power BEFORE leaving the operator’s cab.

Following any contact with an energized electrical source, thoroughly inspect the wire rope and all points of contact with the crane.

Advise your distributor of the incident and consult the factory for advice and crane inspection instructions prior to resuming operations.

PERSONNEL PLATFORMS. NOTE Platform as used herein is defined as any attachment made to a crane boom which is intended to elevate or position people and includes work baskets, cages, or other devices for handling personnel.

2-58

Handling of personnel from the boom is not authorized except with equipment furnished and installed by Grove Manufacturing Company.

Written approval shall be obtained from Grove Manufacturing Company prior to handling personnel.

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

Check operating procedures for cold weather starting.

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

Clean the crane, especially the boom, of all ice and snow.

Allow ample time for hydraulic oil to warm up.

During freezing weather, frequently check all air tanks for water.

Always handle propane tanks according to the suppliers instructions.

Never store flammable materials on the crane.

Before lifting, ensure the load is not frozen to the ground or other surface.

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

2-59

DON’T FORGET.

LOAD CHARTS REPRESENT THE ABSOLUTE MAXIMUM ALLOWABLE LOADS, WHICH ARE BASED ON EITHER TIPPING OR STRUCTURAL LIMITATIONS UNDER SPECIFIC CONDITIONS. KNOWING THE PRECISE RADIUS OF OPERATION, BOOM LENGTH, AND ANGLE SHOULD BE A PART OF YOUR ROUTINE PLANNING AND OPERATION. ACTUAL LOADS, INCLUDING NECESSARY ALLOWANCES, SHOULD BE KEPT BELOW THESE CAPACITY FIGURES. WORKING AREAS MUST BE ADHERED TO WHEN DETERMINING ALLOWABLE LOAD FROM LOAD CHART(S).

ENSURE THE COUNTERWEIGHT IS FULLY EXTENDED BEFORE OPERATION. IF THE CRANE IS NOT LEVEL, LOAD CAPACITIES ARE REDUCED WHEN LIFTING ON THE LOW SIDE. DON’T BE MISLED BY OPTICAL ILLUSIONS.USE YOUR BUBBLE LEVEL.

2-60

IF YOU SHOULD ENCOUNTER A TIPPING CONDITION, START LOWERING THE LOAD WITH THE HOIST LINE AND RETRACT OR ELEVATE THE BOOM TO BRING THE LOAD IN. NEVER LOWER OR EXTEND THE BOOM, THIS WILL AGGRAVATE THE CONDITION. WHEN USING THE HOIST AVOID SUDDEN STOPS. INCREASED LOADING WILL RESULT AND COULD CAUSE TIPPING OR A STRUCTURAL FAILURE TO OCCUR. EVEN IF A HYDRAULIC LINE MAY BE SHEARED OR BROKEN ON THE LIFT OR EXTENSION CYLINDERS, THE CRANE WILL STILL FUNCTION SUFFICIENTLY TO GET THE LOAD DOWN. MAXIMUM LIFTING CAPABILITY IS AVAILABLE AT THE SHORTEST RADIUS, MINIMUM BOOM LENGTH AND HIGHEST BOOM ANGLE.

2-61

SECTION III DESCRIPTION The crane is fully self contained. All crane functions are either electrically or hydraulically controlled and operated. The main functions of the superstructure are: raising and lowering loads with the hoists, swinging the boom, raising and lowering the boom, and extending and retracting the boom. Hydraulic cylinders activate the elevation and telescope systems. The hoist and swing systems are driven by hydraulic motors. The outrigger beams and stabilizers may be extended and retracted from the superstructure. In addition to the normal craning functions, control for driving the crane are also located in the superstructure cab.

MAJOR COMPONENTS AND SYSTEMS. CAB ASSEMBLY. The cab is all−steel, acoustically−treated, fully enclosed with tinted safety glass windows throughout. The cab contains all controls and indicators for roading and crane operations. Access to the cab is provided by a sliding door which contains a safety glass window. The latch handle on the door must be actuated to both close or open the door. A lock is provided in the latch handle to provide locking of the cab door. Grab handrails are provided beside the door opening to aid the operator in getting in and out of the cab.

The windshield in the cab is a stationary tinted safety glass windshield.

The side window of the cab is a two section window assembly. The front section is stationary and the rear section slides. A self locking latch on the sliding window maintains the window in a closed and locked position.

The rear window in the cab is also a two section sliding window. A self locking latch maintains the window in a closed and locked position.

The cab has a skylight with a tinted safety glass window. Either a manually operated or an electric motor driven skylight wiper is available to remove moisture from the skylight.

The cab seat is mounted on a track assembly, allowing it to be adjusted to a comfortable distance from the steering wheel and front console. The seat back is adjustable as is the headrest. An armrest on each side of the seat houses the hydraulic remote controls used for the control of crane functions.

3−1

The armrests swing up behind the seat and latch in place making it easier for travel or for the operator to enter or exit the cab and are adjustable fore and aft to maximize operator comfort. Also incorporated in the armrests is a safety device to disable the controllers while the armrests are up in the latched position.

In addition to the safety device in the armrests is a tape switch incorporated in the cab seat. This switch deactivates the controllers when the operator leaves the seat.

A 2.26 kg (5lb) dry chemical type fire extinguisher is mounted in the cab under the operator’s seat.

A single blade windshield wiper is installed to remove moisture from the windshield. The wiper arm is driven by an electric motor which is controlled by a two speed switch located on the front console panel. A windshield washer system is also installed to spray a cleaning solution onto the windshield. It consists of two nozzles (one on each side of the wiper arm), a canister which is located in the cab, and a pump assembly.

Because there is only one engine on this crane, it can be controlled from both the superstructure and carrier cabs. Each ignition switch, when positioned to acc or on, supplies voltage through the electrical swivel to certain gauges and indicators in the other cab. The engine oil pressure gauges, water temperature gauges, tachometer and fuel level gauges are connected in parallel with one sender unit.

HYDRAULIC SYSTEM AND COMPONENTS. The hydraulic system is designed to provide adequate pressure and gpm output for simultaneous operation of various crane functions.

Reservoir.

The reservoir is a 64.4 gallon (244 litres) steel tank located on the right side of the carrier. A full flow return type 10 micron filter is installed in the reservoir.

Hydraulic Oil Cooler.

An air cooled hydraulic oil cooler is mounted on the right side of the superstructure. The oil cooler consists of a hydraulic radiator, a by−pass valve, a fan and an electrical fan motor. The fan draws cool air through the cooling fins of the oil cooler.

3−2

Pump and Disconnect.

The hydraulic pump and disconnect are mounted on a drive pad of the torque converter. With the disconnect engaged and the engine and torque converter operating, the pump provides oil to the hydraulic components.

The hydraulic pump is a gear−type pump and consists of three sections. The first section of the pump, the one on the mounting flange end, provides and output of 39 gpm (147 lpm). the second section provides 35 gpm (132 lpm) and the third section supplies 16 gpm (61 lpm).

The disconnect assembly is provided for cold weather starting and consists of a housing lever, movable collar and a sliding splined sleeve. The disconnect housing is connected to the torque converter drive pad and the pump is bolted to the disconnect housing.

Directional Control Valves.

The directional control valves are four−way, three position valves with either an open or closed spool. The valves are grouped into valve banks permitting simultaneous independent control of crane functions. The closed spool type valves are equipped with integral check valves to ensure components will remain stationary when the valves are closed. Each valve bank contains a main relief valve. In addition, certain crane functions are further protected by a circuit relief valve.

TURNTABLE ASSEMBLY AND SWING MECHANISM. An anti−friction ball bearing supports the superstructure and attaches it to the carrier allowing 360 degrees of continuous rotation (swing) in either direction.

The swing function is accomplished through use of a hydraulically−driven motor driving a gearbox which in turn drives the roller bearing via an external gear. A spring and hydraulically actuated, hydraulically released brake is provided to stop swing and hold the superstructure in the desired position. To further secure the superstructure in a desired position, a positive mechanical swing lock is also provided.

3−3

Swing Motor.

The hydraulic swing motor is a low speed, high torque motor. The motor provides indirect drive power for turntable swing through the swing gearbox.

Swing Gearbox.

The swing gearbox is a sun and planetary gear type, driven mechanically by the swing motor. The swing gearbox rotates the turntable at a reduced operational speed.

Swing Brake.

The swing brake assembly consists of a brake assembly mounted on the swing gearbox. The swing brake is hydraulically controlled by the operator from the superstructure cab through use of the swing brake foot pedal and the swing brake control valve.

BOOM ASSEMBLY. One boom is available on the crane, a three section 27 to 70 foot (8.2 to 21.3m) cable extended boom.

The boom is trapezoidal in design and utilizes one 5.5 inch (13.9 cm) telescopic cylinder. The telescoping sections are supported on graphite impregnated nylatron wear pads. Adjustable side wear pads prevent metal to metal contact between the sections. The boom nose consists of either three, four or five sheaves mounted on heavy duty tapered roller bearings and utilizes pin−type guards to allow easy reeving.

MAIN HOIST. The main hoist provides power and speed for all load raising and lowering operations. A vane type hydraulic motor drives the hoist drum by means of a planetary gear reduction system. A metallic disc brake is also an integral part of the hoist assembly. Optional indication of hoist drum rotation is provided by an electronic transmitter attached to the hoist with an electronically driven indicator on the main hoist control lever in the cab.

OUTRIGGER SYSTEM The outriggers are integral with the carrier frame but are controlled and operated from the superstructure. The outriggers are full hydraulic, double box type. They are positioned to provide a rigid four point platform (outriggers fully extended and set) capable of supporting the machine and its maximum load capacity. Integral holding valves and floats are standard equipment. A sight level bubble indicator is located in the superstructure cab to ensure crane levelling.

3−4

SWIVELS Electric and air/hydraulic swivels are used to route the air, electrical and hydraulic circuits to the superstructure from the carrier frame. These swivels are mounted as a single assembly and are installed at the centre of rotation.

ELECTRICAL SYSTEM. The electrical system is 12 VDC operation with 12 volt starting, consisting of an alternator and lead−acid batteries which are parallel connected. The system is the single wire−ground return type, utilizing the machine’s structure as ground.

OPTIONAL EQUIPMENT HEATER The heater is located beneath the cab. The fuel tank is located on the right side of the turntable. All heater controls are located within the cab. Defroster controls and tubing are provided with the heater BACKUP ALARM The backup alarm is an audio system to warn personnel outside the crane when the vehicle is backing up. The alarm system is electrical and consists of the backup alarm and associated wiring. The alarm is tied into the backup light electrical wiring and is activated when the backup light is activated. The backup alarm is installed on the rear of the turntable.

3−5

SWINGAWAY BOOM EXTENSIONS Two optional boom extensions are available to obtain additional boom reach.

One is a 25 foot (7.6m) swingaway and the other is a 25 to 43 feet (7.6 to 13.1m) telescoping swingaway, which can be pinned at 25, 34 or 43 feet (7.6, 10.3 or 13.1m) lengths.

Both boom extensions mount directly to the boom nose utilizing a four point attachment. The telescoping extension incorporates links which allow the swingaway to be offset zero (0), 15° or 30° from the boom nose. In addition, the swingaway can be stowed on the right side of the boom base section.

CAB CONTROLS AND INDICATORS NOTE The following paragraphs describe the controls and indicators located in the cab. The numbers in parentheses ( ) represent the index number from the figure titled Superstructure Cab Controls and Indicators.

NOTE Any reference made to left, right, front and rear when describing locations from the superstructure cab is to be considered as viewed from the superstructure operator’s seat with the boom directly over the rear of the carrier.

3−6

ENGINE CONTROLS AND INDICATORS Ignition Switch The ignition switch (1) is located on the right side of the front console bottom panel. It is a key operated switch with four positions; acc (3), off (0), run (1), and start (2). The switch is spring returned from start to run. With the switch in the off (0) position, all electrical power in the superstructure is off except the beacon lights, heater, and oil cooler fan. Positioning the switch to the acc (3) position energizes all electrical components except the engine fuel solenoid valve. Placing the switch in the run (1) position is the same as acc (3) except the engine fuel solenoid valve becomes energized. Placing the switch in the start (2) position energizes the starter relay which in turn energizes the cranking motor solenoid and cranks the engine for starting. Releasing the switch will allow it to spring return to the run (1) position. To shut down the engine, place the switch in the off (0) position.

Fuel Quantity Gauge The fuel quantity gauge (2) is located on the right side of the front console. The gauge indicates the quantity of fuel in the fuel tank and has a scale calibrated from zero (0), to 4/4. The fuel quantity gauge receives a signal from a sending unit in the fuel tank.

Engine Water Temperature Gauge The engine water temperature gauge (3) is located on the left side of the front console. Refer to the Engine Operators Manual for the correct water temperature reading.

Engine Oil Pressure Gauge The engine oil pressure (OIL PRESS) gauge (4) is located near the middle of the front console. The gauge indicates the engine oil pressure on the dual scale calibrated from zero (0) to 100 psi and zero (0) to 690 kPa. It receives a signal from an oil pressure sending unit on the engine.

Voltmeter The voltmeter (BATTERY) gauge (5) is located on the left side of the front console beside the steering column. The voltmeter indicates the voltage being supplied to or from the battery and has a scale of 20 to 32 volts.

Foot Throttle Pedal The foot throttle pedal (6) is the right most pedal on the cab floor. The pedal is connected to a valve which pneumatically actuates the throttle cylinder on the engine to control engine speed.

3−7

Hand Throttle The hand throttle (7) is located at the right side of the front console. The hand throttle is mechanically connected to the foot throttle and provides the operator with a means of maintaining specified engine rpm for crane operation. To use the hand throttle, depress the foot throttle to obtain the desired engine rpm, push the button on the hand throttle control knob and pull out on the knob. When pressure is felt, release the button and turn the locknut in a clockwise direction to lock the throttle at the desired rpm. To release the throttle, rotate the locknut counterclockwise, depress the button and push in on the cable. Fine adjustment of engine speed is accomplished by turning the control knob.

Tachometer The tachometer (8) is located on the left side of the front console. It is calibrated in rpm x 100 with a range of zero (0) to 40. The tach receives its signal from a sending unit on the engine.

Engine Distress Indicator The engine distress (ENGINE) indicator (9) is located at the top of the front console. The indicator is a red light that will illuminate if the engine oil pressure becomes abnormal and/or the water temperature is excessive. The indicator is energized by two switches electrically connected in parallel. To determine which system is abnormal, observe the appropriate gauge in addition to the indicator, the switches also energize a warning buzzer.

JOB SITE TRAVEL CONTROLS AND INDICATORS Differential Lock Control Switch The differential lock control switch (DIFF LOCK) (10) is located on the right side of the front console. Placing the switch the LOCKED position activates two solenoid valves to route air pressure to lock the front and rear differentials. With the differentials locked, the left and right wheels in each axle both rotate at the same rate. Placing the switch to the UNLOCKED position returns the axle to normal.

Differential Locked Indicator Light The differential locked indicator light (DIFF LOCKED) (11) is located at the top of the front console. The light illuminates when the differential lock control switch is in the LOCKED position and the front and rear differentials are locked.

Transmission Shift Lever The transmission shift lever (14) is located on the right side of the front console.

The lever has six different shift positions allowing the operator to select from three reverse speeds, neutral, and three forward speeds.

3−8

Rear Steer Control The Rear Steer (FRONT STEER) control (16) is a three position, spring centred to off, toggle switch located on the right side of the front console. By positioning the switch to the right, a control valve is actuated to turn the rear wheels to the left, which causes the crane to turn to the right. By positioning the switch to the left, a control valve is actuated to turn the rear wheels to the right, which causes the crane to turn to the left. Releasing the switch allows it to spring centre to the off position.

Rear Steer Indication Gauge The rear steer indication gauge (17) is located on the right side of the front console above the ignition switch. The indicator consists of a gauge with an indicator needle that shows the positioning of the rear wheels.

Rear Steer Indicator The rear steer indicator (18) is the middle indicator light at the top of the front console. The light illuminates when the rear wheels are not in a straight ahead position.

Crane Function Power Switch The CRANE FUNCTION POWER switch (22) is located on the left side of the front console. The switch has two placarded positions: ON and OFF. Positioning the switch to off takes all power away from the crane functions controlled by the hydraulic remote controllers on the armrests. This prevents inadvertent operation of functions due to bumping of the controllers while roading or any other operation.

Transmission Range Selector Switch The transmission range selector switch (23) is located on the right side of the front console panel at the bottom. The switch is a two position switch; 2WD (high range) and 4WD (low range). The switch controls a solenoid operated valve that operates the speed range and axle disconnect cylinders on the transmission.

Transmission Oil Temperature Gauge The transmission oil temperature gauge (55) has a dual scale of 140 to 320 degrees F and 60 to 160 degrees C. The gauge indicates the temperature of the oil in the transmission.

3−9

Low Air Pressure Indicator The low air pressure (LO AIR PRESS) indicator (25) is located at the top of the front console. The indicator is a red light that illuminates when the pressure in the air system(s) is below 75 psi (517 kPa). The indicator is controlled by two pressure switches electrically connected in parallel. In addition to illuminating the indicator, the pressure switches also energize a warning buzzer.

Dual Air Pressure Gauge The dual air pressure gauge (26) is located on the right side of the front console.

The gauge is a direct reading pressure gauge with two indicating pointers, green for the primary system and red for the secondary. The gauge has a dual scale calibrated from 0 to 150 psi and 100 to 1000 kPa. The gauge is connected to each air system through tubing.

Brake Foot Pedal The brake foot pedal (28) is to second pedal from the right on the cab floor. Depressing the pedal actuates an air valve to control application of the brakes.

Park Brake Control The park brake control (29) is located on the left side of the control panel at the bottom. The yellow control is a push−pull type air valve used to set and release the parking brake on the axle.

Park Brake Indicator The PARK BRAKE indicator (30) is located at the top of the front console. The indicator is a red light that will illuminate when the park brake control is in the on position.

Emergency Pump Switch The emergency pumps are situated on the carrier at the rear underside of the carrier. They are electrically driven from the crane battery and are to allow the following motions to be used should the engine seize up or become inoperative.

Hoist lower Swing left and right Outriggers extend, retract raise or lower.

The circuit is arranged so that pilot pressure to the crane controls and swing brake is still available even on the emergency pump only.

The sequence in an emergency is as follows: 3−10

WITH THE IGNITION ON, HOLD THE EMERGENCY PUMP SWITCH (33) IN THE ‘ON’ POSITION WHILST SELECTING THE DESIRED MOTION. The motions will be very slow and prolonged selection can run down the battery.

Be careful not to allow the pump motors to become hot by prolonged operation.

Rear Axle Steering Lock Control The REAR AXLE STEERING LOCK control (34) is located on the left side of the front console. Positioning the switch to the UNLOCKED position unlocks the rear axle and allows it to be steered as the front axle from the superstructure.

The rear wheels must be straight ahead and the control switch in the LOCKED position before the crane is driven from the carrier cab.

CRANING CONTROLS AND INDICATORS Outrigger Selector Panel The OUTRIGGER SELECTOR panel (12) is located on the left side of the front console. There are four two position, spring centred to off toggle switches on the panel. These switches in conjunction with the outrigger extension/retraction switch provide control of all four outrigger extension and stabilizer cylinders. Positioning any one of the toggle switches energizes a solenoid valve for the appropriate component to be operated. Positioning the outrigger extension/retraction switch energizes the control solenoid to allow hydraulic fluid to flow through the control solenoid valve and move the selected component in the desired direction.

Outrigger Extension/Retraction Switch The outrigger extension/retraction switch (13) has two placarded positions, EXTEND and RETRACT. It must be used in conjunction with the switches on the OUTRIGGER SELECTOR panel to control the operation of the stabilizer and extension cylinders. After positioning the switch on the OUTRIGGER SELECTOR panel, positioning the outrigger extension/retraction switch energizes the control solenoid to allow hydraulic fluid to flow through the control solenoid valve and the individual solenoid valve and move the selected component in the desired direction.

Swing and Telescope Control Lever The swing and telescope (SWING/TELE) control lever (15) is located on the end of the left armrest. The lever controls the swing and telescope functions. The lever, when positioned to the left or right actuates a control valve through hydraulic pilot pressure to provide 360 degrees continuous rotation in the desired direction.

3−11

Positioning the lever forward actuates the control valve to telescope the boom out and pulling the lever back actuates the boom to telescope in. Moving the lever in a diagonal direction actuates the two functions simultaneously.

Boom Lift and Main Hoist Control Lever The boom lift and main hoist (LIFT/MAIN) (19) is located on the right armrest.

The lever, when positioned to the left, actuates the control valve through hydraulic pilot pressure to raise to the boom. Positioning the lever to the right lowers the boom. Pushing the lever forward will let out the hoist cable and pulling the lever back reels the cable in. Moving the lever in a diagonal direction actuates the two functions simultaneously.

Hoist Rotation Indicators The hoist rotation indicator (21) is located on the top of the hoist control lever.

The indicator is electronically driven by a signal from an electric transmitter attached to each hoist frame. A pulsating signal is sensed by the operator’s thumb during operation.

Third Wrap Indicator The third wrap indicator (3 WRAP HOIST) (56) is located at the top of the front console. The indicator is a red light that will illuminate when three wraps or less of cable is on the hoist drum.

Swing Brake Control The SWING BRAKE control (24) is located on the left side of the front console at the bottom. The selector valve is controlled by a two position switch. It is used to direct a regulated flow of pressure to or from the swing brake.

Swing Brake Pedal The swing brake pedal (27) is located on the left side of the cab under the front console. The brake pedal is used to actuate the swing brake to slow or stop motion. Braking is proportional to pedal depression. With the pedal not depressed and the swing brake control valve disengaged, hydraulic pressure is applied to the brake, thereby, overcoming spring pressure and releasing the brake. Depressing the pedal actuates a swing power brake valve to apply pressure to the brake assembly. This pressure aids the spring pressure to overcome the hydraulic pressure being applied to the brake release circuit and applies the spring brake according to the pressure from the swing brake valve.

3−12

Swing Lock Control The swing lock control (31) is used to lock the superstructure in the over the front or over the rear position. The lock should always be engaged except for operating over the side duties or using the swinging motion.

To disengage pull out the knob to the unlock position and lift the handle.

Swing Lock Control (Positive Lock Type) − Optional The swing lock control handle (32) is located on the right side of the operator’s seat beneath the control armrest. The purpose of the swing lock is to secure the superstructure. When the control handle is pulled up, the swing lock is disengaged and swing can be accomplished. Pushing down on the control handle engages the lock.

ACCESSORY CONTROLS AND INDICATORS Lights Switch The lights (DRIVE/PANEL) switch (35) is located on the right side of the front console. The switch is a three position toggle switch. Positioning the switch to the on position illuminates the driving and panel lights.

Panel Light Dimmer Control The panel light dimmer (PANEL DIM) control (36) is located below the lights switch on the right side of the front console. When the lights switch is positioned to the on position, rotating the panel light dimmer control knob controls the brightness of the panel lights.

Work Light Switch (Optional) The WORK light switch (37) is a two position toggle switch on and off. It is located on the right side of the front console. The switch controls the crane’s work light.

Boom Flood Lights Switch (Optional) The BOOM flood lights switch (38) is a two position toggle switch (on and off) that is located on the right side of the front console panel. The switch controls the floodlights located on the boom base section.

Cab Circulating Fan (Optional) The cab circulating fan (39) is located on a mounting bracket above the window frame. A swivel allows the fan to be rotated. The fan is controlled by a switch (20) on the dashpanel.

3−13

Horn The horn button (40) is a push−button type switch located in the centre of the steering wheel. Depressing the horn button energizes a relay that in turn sounds the horn on the cab exterior.

Turn Signal Lever The turn signal lever (41) is located on the steering column forward of the steering wheel. Positioning the switch handle to the left causes the left front and left rear turn signals to flash. Positioning the switch handle to the right causes the right front and right rear turn signals to flash.

Four−Way Flasher Switch The four−way flasher switch (42) is located on the steering column just behind the turn signal lever. Pulling the handle out causes all the turn signal lights to flash. The lights will continue to flash until the turn signal lever is operated.

Steering Column Tilt Lever The steering column tilt lever (43) is located on the steering column behind the turn signal lever and the four−way flasher switch. Pulling back on the lever allows the operator to tilt the steering column to one of six different positions.

Steering Column Telescope Control The steering column telescope control (44) is located at the centre of the steering wheel. By turning the control counterclockwise, the operator can unlock the upper portion of the steering column and telescope the steering wheel in or out for ease of operation and comfort. Turning the control counterclockwise will lock the column in place.

Cab Dome Light The cab dome light (45) is located on the right rear corner of the cab roof and provides illumination of the cab. The light is controlled by a switch on the light.

Spotlight (Optional) (Not Shown) The spotlight is mounted on the outside of the cab roof in the right front corner.

The light can be tilted 180 degrees and rotated 360 degrees. The switch that activates the spotlight is located on the end of the spotlight arm.

Skylight Wiper (Optional) (Not Shown) A skylight wiper is available to remove moisture from the skylight. The wiper is available as either a manually operated wiper or as an electric motor driven wiper. The electric motor driven wiper is controlled by a switch on the motor.

3−14

Windshield Wiper Switch The windshield wiper (WIPER/WASHER) switch (48) is located on the left side of the front console at the bottom. The switch has three positions; off, low and high. In addition, pushing the switch energizes the motor on the windshield washer pump assembly. Positioning the switch to low energizes the wiper motor is low speed and positioning it to high energizes the motor for high speed. Positioning the switch to off stops the motor and causes the automatic park function of the wiper motor to return the wiper blade to the parked position.

Armrest Adjustment Lever The armrest adjustment lever (53) is located at the front of each armrest. When the adjustment lever is pushed, the armrest can be pulled our or pushed in to a length that is suitable to the operator.

Bubble Level Indicator The bubble level indicator (49) is located on the bottom of the front console. The indicator provides the operator with a visual indication for determining the levelness of the machine.

Heater Control Switch The HEATER control switch (51) is located on the right side of the front console.

It is a two position toggle switch with two placarded positions, ON and OFF. Positioning the switch to ON activates the heater to begin operation.

Heat Control Switch The HEAT control switch (52) is located on the right side of the front console. It is a two position toggle switch with two placarded positions. HI and LOW. Positioning the switch to HI activates the heater to produce full heat and positioning the switch to LOW switches the heater to the reduced heat mode.

3−15

42

43

39

A

15

6

41

27

28 54

32 19, 21

44 53

40

53

52 51

45

Superstructure Cab Controls and Indicators (Sheet 1 of 2) 3−16

20

12

33 8

22

56 11

25 18 30

9 17 38 37 3514

31

55 4 2 3 26 5 16 48

24 49 34

29

1

13 36 7

23

10

DETAIL A 1. Ignition Switch 2. Fuel Quantity Gauge 3. Engine Water Temp Gauge 4. Engine Oil Pressure Gauge 5. Voltmeter 6. Foot Throttle Pedal 7. Hand Throttle 8. Tachometer 9. Engine Distress Indicator 10. Diff Lock Control Switch 11. Diff Locked Indicator Light 12. Outrigger Selector Panel 13. Outrigger Ext / Ret Switch 14. Transmission Shift Lever 15. Swing and Tele Control Lever 16. Rear Steer Control 17. Rear Steer Indication Gauge 18. Rear Steer Indicator 19. Boom Lift & Hoist Control Lever 20. Fan Switch 21. Hoist Rotation Indicators 22. Crane Function Power Switch 23. Trans Range Selector Switch 24. Swing Brake Control 25. Low Air Pressure Indicator 26. Dual Air Pressure Gauge

27. Swing Brake Pedal 28. Brake Foot Pedal 29. Park Brake Control 30. Park Brake Indicator 31. Swing Lock Control 32. Swing Lock Control 33. Emergency Pump Switch 34. Rear Axle Steering Lock Control 35. Lights Switch 36. Panel Light Dimmer Control 37. Work Light Switch (Optional) 38. Boom Flood Lights Switch (Opt) 39. Cab Circulating Fan (Optional) 40. Horn 41. Turn Signal Lever 42. Four − Way Flasher Switch 43. Steering Column Tilt Lever 44. Steering Column Tele Control 45. Cab Dome Light 48. Windshield Wiper Switch 49. Bubble Level Indicator 51. Heater Control Switch 52. Heat Control Switch 53. Armrest Adjustment Lever 54. Fire Extinguisher 55. Trans Oil Temperature Gauge 56. Third Wrap Indicator

Superstructure Cab Controls and Indicators (Sheet 2 of 2) 3−17

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

FUEL SUPPLY. Ensure the fuel tank is full and the cap is on tight.

ENGINE OIL. Check oil level in the crankcase; fill to FULL mark on the dipstick. Do not over fill.

ENGINE COOLANT Check coolant level in the radiator, fill to proper level. Do not overfill. Check cap for security.

WARNING THE CAP SHOULD ONLY BE REMOVED WITH THE ENGINE COLD. SERIOUS INJURY COULD OCCUR IF THE ENGINE COOLANT IS HOT. THE PRESSURE IN THE SYSTEM WILL EJECT HOT STEAM. BATTERIES. Check each cell for the correct electrolyte level. Add only clean distilled water.

Do not over fill. Ensure the cables and clamps are tight and not corroded.

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

FOOT AND PARKING BRAKES. Check for proper operation.

4−1

DAILY LUBRICATION. Make certain that all components requiring daily lubrication have been serviced.

(Refer to Section V − Lubrication.

HYDRAULIC RESERVOIR Check hydraulic fluid quantity level gauge and check filter condition indicator.

Check breather for cleanliness and security.

TYRES. Check for severe cuts, foreign objects imbedded in treads, and for correct inflation pressures. A tyre inflation chart is provided to show the correct tire pressures.

WIRE ROPE. Sheaves, guards, guides, drums, flanges, and any other surfaces that come in contact with the rope should be inspected for any condition that could cause possible damage to the rope.

HOOKBLOCK. Visually inspect for nicks, gouges, cracks, and evidence of any other damage.

Replace a hook containing cracks or showing evidence of excessive deformation of the hook opening (including twist). Be sure the safety latch is free and aligned.

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

4−2

WARNING ENSURE THE STEERING MODE CONTROL IS IN THE PROPER POSITION FOR THE CAB THE CRANE IS TO BE OPERATED FROM. FAILURE TO HAVE THE CONTROL IN THE CORRECT POSITION WILL RESULT IN A LACK OF STEERING AND COULD CAUSE SERIOUS DAMAGE AND INJURY. STEERING MODE Ensure the steering mode control is in the correct position. When the control handle is pushed in the crane is in the carrier steering mode. When the control handle is pulled out the crane is in the superstructure steering mode. Turn the handle to the horizontal position to lock the cable in place.

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

4−3

STARTING PROCEDURE. WARNING BEFORE STARTING THE ENGINE, ENSURE THE TRANSMISSION IS IN NEUTRAL, PARKING BRAKE IS APPLIED, AND SWING LOCK IS ENGAGED. CAUTION NEVER CRANK THE ENGINE FOR MORE THAN 30 SECONDS DURING AN ATTEMPTED START. IF THE ENGINE FAILS TO START AFTER 30 SECONDS, ALLOW THE STARTER MOTOR TO COOL FOR APPROXIMATELY TWO MINUTES BEFORE ATTEMPTING ANOTHER START. CAUTION IF THE ENGINE FAILS TO START AFTER FOUR ATTEMPTS, CORRECT THE MALFUNCTION BEFORE ATTEMPTING ANY FURTHER STARTS. NOTE When starting a cold engine, ensure the hydraulic pumps are disengaged.

1 Turn the ignition switch to the start position (2) and release immediately when the engine starts.

2.

When the start has been accomplished, check the engine instruments for proper indications.

WARNING ENSURE BOTH AIR SYSTEM PRESSURES ARE IN THE NORMAL OPERATING RANGE PRIOR TO DISENGAGING THE PARK BRAKE.

4−4

CAUTION IF OIL PRESSURE AND/OR TEMPERATURE INDICATOR(S) DO NOT DISPLAY THE PROPER READINGS, SHUT DOWN THE ENGINE AND CORRECT THE MALFUNCTION BEFORE RESUMING OPERATION. 3.

Allow the engine to warm up at least five minutes before applying a load.

Do not race the engine for a faster warm up.

COLD WEATHER STARTING. The correct grade of oil for the prevailing temperature should be used in the crankcase to prevent hard cranking. Diesel fuel should have a pour point of 10 degrees F (−12 degrees C) less than the lowest expected temperature. In case of an emergency, white kerosene may be added to the fuel to bring the pour point down to the required temperature to prevent clogging of filters and small passages by wax crystals. The addition of kerosene is NOT recommended for general use. If low temperatures are ONLY expected at start−up, it is advisable to use starting aids such as preheating, starting aid compound metering equipment, or starting aid spray application into the air cleaner intake.

CAUTION AVOID OVERLOADING THE AIR BOX WITH HIGH VOLATILE FLUID WHICH COULD RESULT IN A MINOR EXPLOSION. To start the engine, position the ignition switch to the start position (2) and push the cold start button for one or two seconds and release. If the engine does not start within 30 seconds, allow the starter to cool at least two minutes and repeat the procedure.

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

4−5

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

RACING THE ENGINE. NEVER race the engine during the warm−up period. NEVER operate the engine beyond governed speed (as might occur in downhill operation or downshifting).

Engine bearings, pistons, and valves may be damaged if these precautions are not taken.

SHUTDOWN PROCEDURE. 1.

Allow the engine to operate at fast idle speed for approximately five minutes to avoid high internal heat rise and allow for heat dissipation.

2.

Position the ignition switch to the off position (0).

CAUTION CORRECT THE PROBLEM THAT CAUSED THE EMERGENCY SHUTDOWN BEFORE ATTEMPTING RESTART OF THE ENGINE.

CRANE OPERATION Hydraulic cranes should be warmed up to raise the hydraulic oil to the minimum operating temperature 20° C − 25° C when using oil recommended for temperate climates). This will prevent many mechanical failures of pumps due to cold viscous oil and will help the filters to operate efficiently.

To achieve the operating temperature the engine should be ran for a few minutes at engine idling speed with the Power Take Off engaged. The time to warm up will depend on the prevailing ambient temperature but generally the hydraulic tank should be ’just warm’ (20°C − 25°C) to the touch before operating crane motions. Avoid racing the engine for the first five minutes after the ’warm up’ period.

Do not attempt to operate heavily loaded motions at idling speed as this may cause the engine to stall and can also cause damage to the pumps. On the other hand, never run the engine at a speed higher than necessary to carry out the required movement, as to do so shortens the life of engine and pumps, may cause overheating of the hydraulic oil and results in excessive fuel consumption. In this respect it should be noted that on many machines the speed of certain motions, 4−6

particularly jib retraction and derricking out, does not increase with increasing the engine speed beyond a certain point, so that racing the engine on these motions is very wasteful of power.

Crane motion should always be engaged slowly by operating the control levers with a slow, even pressure. Never jerk any control lever to stop a function, always return to neutral in a smooth even manner.

Hydraulic oil expands and contracts as its temperature rises and falls. For this reason over filling the hydraulic reservoir with cold oil should be avoided since it could overflow when the oil gets hot. Under filling must also be avoided as this will cause pump cavitation and allow air to be drawn into the hydraulic circuits.

The contraction of oil as it cools down allows extended rams to retract slightly.

This effect becomes noticeable if it is required to hold a load in a fixed position for some time using an extended boom. When such a lift is required it is recommended that the crane be worked as little as possible beforehand in order to keep the oil temperature down and thus prevent ram retraction due to cooling while the load is being ’held’.

CRANE TRAVEL OPERATION. TRAVELLING − GENERAL. CAUTION DISENGAGE THE HYDRAULIC PUMP FOR EXTENDED COLD WEATHER STARTING OR ENGINE CHECKS. AT cranes are subject to the same road regulations as any truck, regarding gross weight, width, and length limitations.

CAUTION FOR EXTENDED TRAVEL, CHECK THE COLD TYRE PRESSURE PRIOR TO START. (REFER TO TYRE INFLATION CHART.). THE TYRE LOAD RATING IS BASED UPON TRAVEL NOT EXCEEDING 45 MILES (72 KM) IN ANY ONE HOUR PERIOD. AT DESTINATION, THE TYRES MUST BE ALLOWED TO COOL TO AMBIENT TEMPERATURE BEFORE CRANE LIFTING ON RUBBER. 4−7

Although AT cranes are designed for rough terrain applications, the operator should be extremely cautious and aware of the terrain in which he is operating.

WARNING DO NOT DRIVE THE CRANE WITH THE BOOM OFF CENTER. WARNING DO NOT TRAVEL WITH AN EMPTY HOOK IN A POSITION WHERE IT CAN SWING FREELY. WARNING AVOID HOLES, ROCKS, EXTREMELY SOFT SURFACES, AND ANY OTHER OBSTACLES WHICH MIGHT SUBJECT THE CRANE TO UNDUE STRESSES OR POSSIBLE OVERTURN. CAUTION DO NOT DRIVE THE CRANE WITH THE LIFT CYLINDER BOTTOMED. POSITION THE BOOM SLIGHTLY ABOVE HORIZONTAL. WARNING ON OPEN GROUND, TOW OR PULL ONLY ON THE PINTLE HOOKS OR LIFT LUGS. CAUTION SHOULD THE CRANE BECOME MIRED DOWN, USE A TOW TRUCK OR TRACTOR TO FREE THE VEHICLE. SEVERE DAMAGE TO THE TRANSMISSION OR AXLES MAY OCCUR IF THE OPERATOR ATTEMPTS TO FREE THE CRANE UNASSISTED.

4−8

CAUTION THE TOWING SPEED SHOULD NEVER EXCEED 10 km/h (6.m.p.h) AND THE DISTANCE SHOULD BE NO LONGER THAN 10km (6 miles).

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

1.

Ensure all boom sections are fully retracted.

2.

Ensure the boom extension, if so equipped, is properly stowed and secured.

3.

Swing the boom to over−the−front and lower the boom slightly above horizontal.

4.

Position the SWING BRAKE control on the console to the engage position and engage the positive swing lock.

5.

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

6.

Ensure the outrigger stabilizers and outriggers are fully retracted and the floats are removed.

STEERING Steering is accomplished by the steering wheel and the rear steer control.

These controls, used singly or together provide front wheel steering, rear wheel steering, four wheel steering, and crabbing capabilities.

4−9

WARNING ENSURE THE STEERING MODE CONTROL IS IN THE PROPER POSITION FOR THE CAB THE CRANE IS TO BE OPERATED FROM. FAILURE TO HAVE THE CONTROL IN THE CORRECT POSITION WILL RESULT IN A LACK OF STEERING AND COULD CAUSE SERIOUS DAMAGE AND INJURY. Steering Mode Ensure the steering mode control is in the correct position. When the control handle is pushed in the crane is in the carrier steering mode. When the control handle is pulled out the crane is in the superstructure steering mode. Turn the handle to the horizontal position to lock the cable in place. Pull the flap down over the handle when either in or out has been selected.

Front Wheel Steering Conventional front wheel steering is accomplished with the steering wheel.

This method of steering should always be used when travelling at higher speeds.

4−10

WARNING WHEN OPERATING THE REAR STEERING FROM THE SUPERSTRUCTURE CAB, THE STEERING WHEEL IN THE CARRIER CAB WILL BE HYDRAULICALLY DRIVEN AND COULD CAUSE SEVERE INJURY IF THE CARRIER CAB IS OCCUPIED. WARNING OPERATE THE REAR STEER ONLY FOR ADDED JOB SITE MANEUVERABILITY. Rear Wheel Steering Rear wheel steering is controlled by the rear steer control. Actuating the control to the desired position activates the rear steer cylinders, thereby steering the crane in the selected direction.

Four Wheel Steering Four−wheel steering is accomplished by using both the steering wheel and the rear steer control. Depending upon which direction the operator wishes to travel, the steering wheel is turned in the same direction of the rear steer control position. This method of steering allows the crane to turn or maneuver in close, restricted areas.

Crabbing Crabbing is also accomplished by using both the steering wheel and the rear steer control. Depending upon which direction the operator wishes to travel (crab), the steering wheel is turned in the opposite direction in which rear steer control is positioned. This method permits driving the crane forward or in reverse at an angle from straight ahead in the crabbing manner.

FRONT−WHEEL

REAR−WHEEL

FOUR−WHEEL

CRABBING

Steering Methods 4−11

TRAVELLING − FORWARD WARNING ENSURE THE POSITIVE SWING LOCK IS ENGAGED BEFORE STARTING EXTENDED TRAVELLING. 1.

After the engine has warmed up, shift the directional control lever from neutral (N) to forward (F) position.

2.

Position the DRIVE AXLE switch to either high speed (2WD) or low speed (4WD).

CAUTION USE FOUR WHEEL DRIVE ONLY WHEN MORE TRACTION IS REQUIRED. 3.

Position the transmission shifting lever to first (1) gear position and release the parking brake; depress the foot throttle until maximum gear speed is attained.

4.

Shift the transmission lever to second (2) gear position; accelerate until the maximum gear speed is attained.

5.

Repeat the above procedure for the remaining gear positions until the desired travel speed is attained.

CAUTION DO NOT DOWNSHIFT TO A LOW GEAR IF CRANE IS TRAVELLING AT A GREATER ROAD SPEED THAN THE MAXIMUM SPEED OF THE LOWER GEAR. TRAVELLING − REVERSE CAUTION APPLY THE SERVICE BRAKES AND BRING THE CRANE TO A COMPLETE STOP BEFORE SHIFTING THE TRANSMISSION INTO REVERSE.

4−12

Travelling in reverse is accomplished the same way as travelling forward, except for shifting the directional control lever to reverse (R) position. (Refer to TRAVELLING − FORWARD).

INTER AXLE DIFFERENTIAL To lock out the inter−axle differentials and achieve maximum pulling power when approaching slippery or poor road conditions, adhere to the following.

CAUTION DO NOT ACTUATE THE SELECTOR SWITCH WHILE THE WHEELS ARE ACTUALLY SLIPPING OR SPINNING. 1.

Position the DIFF LOCK switch to the locked position while maintaining crane speed.

2.

Let up momentarily on the accelerator. This will engage the differential lock.

3.

Proceed over the poor road conditions cautiously.

When adverse conditions have passed, adhere to the following.

1.

Position the DIFF LOCK switch to the unlocked position while maintaining crane speed.

2.

Let up momentarily on the accelerator to allow the shift.

3.

Resume driving at a safe speed.

CONTROL LEVER OPERATION. The control lever operation for crane functions is standard, i.e., the closer the lever is to neutral (center), the slower the system responds. This applies to both forward and rear movement of the applicable lever. The control lever should be returned to neutral to hold the load. Never feather the hoist control to hold the load.

NOTE Always operate the control levers with slow,even pressure.

4−13

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

CAUTION OPERATE THE ENGINE AT OR NEAR THE GOVERNED RPM DURING PERFORMANCE OF ALL CRANE FUNCTIONS. NOTE Carefully read and become familiar with all crane operating instructions before attempting a preload check and operating the crane under load.

1.

Extend and set the outriggers.

2.

Raise, lower, and swing the boom right and left a minimum of 45 degrees.

3.

Telescope the boom in and out, extending and retracting the boom sections equally at all times.

4.

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

USING YOUR LOAD CHART. NOTE One of the most important tools of every Grove crane is the load chart found in the crane operator’s cab.

4−14

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

The load chart contains two on outriggers capacity charts; over front and 360 degrees. In addition, the load chart contains an on rubber capacity chart.

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

The chart shows the radius of the load in a column at the left. The radius is the distance between the center line of rotation of the crane and the centre of gravity of the load. Various boom lengths are listed across the top, ranging from fully RETRACTED to fully EXTENDED and with the swingaway extension in use.

The boom angle (in degrees) required for the given lift is shown in parenthesis below the maximum total weight which can be lifted. Note that the boom lengths in between the increments shown should always be treated as if the boom was extended to the next longer length. For example, if the load chart has capacities for 48 foot and 54 foot boom lengths and the actual length of the boom in use is 50 feet, then the maximum capacity will be listed under the 54 foot boom length because the boom is beyond 48 feet in length.

4−15

Another important section of the load chart is the range diagram. The range diagram illustrates the tip height which can be achieved at each boom length, angle and radius. If the operator knows the radius required for a specific lift and the tip height necessary, he can calculate the required boom length and angle needed for the lift. He then checks the capacity chart for the specific boom length and radius to find out if the crane is capable of performing the lift safely. Or, on the other hand, if the boom length and angle are known, the radius can be determined from the range diagram.

A lifting area diagram is included as part of the load chart to describe over side, over rear, and over front lifting areas. An examination of the lifting area diagram shows that the locations of the outrigger stabilizer cylinders in the fully extended position are used to mark the boundaries of the lifting areas.

A jib capacity chart and notes are also included as part of the load chart to list the capacities for the degree of offset and boom angle.

The last major portion of the load chart is the section concerning notes to lifting capacities. Be sure to read all notes carefully so you understand what each one means. The load chart also gives weight reductions for Grove load handling devices such as hookblocks, headache balls, boom extension sections, etc., which must be taken into consideration as part of the load. Remember, any other load handling devices such as chains, slings, or spreader bars must also be considered, and the weight of these devices must be added to the weight of the load.

CRANE FUNCTIONS. WARNING THE OUTRIGGERS MUST BE FULLY EXTENDED AND SET BEFORE ANY OTHER OPERATION OF THE CRANE IS ATTEMPTED,UNLESS LIFTING ON RUBBER. SETTING THE OUTRIGGERS 1.

Position the outrigger floats approximately 5 feet (1.5m) directly out from each outrigger.

4−16

CAUTION ALWAYS POSITION A SWITCH ON THE OUTRIGGER SELECTOR PANEL BEFORE POSITIONING THE OUTRIGGER EXTENSION / RETRACTION SWITCH TO EXTEND OR RETRACT. FAILURE TO DO THIS MAY CAUSE A HYDRAULIC LOCK AGAINST THE INDIVIDUAL SOLENOID VALVES, PREVENTING THEM FROM OPENING. 2.

Position the appropriate OUTRIGGER SELECTOR switch and position the outrigger extension / retraction toggle switch to EXTEND. The appropriate outrigger should begin to extend.

NOTE More than one outrigger may be extended at one time. However, to ensure that each outrigger is fully extended, each OUTRIGGER SELECTOR switch should be depressed individually and the outrigger extension / retraction switch momentarily positioned to EXTEND after multi − outrigger extension.

3.

After all four outrigger beams have been fully extended, position the appropriate STABILIZER switch and position the outrigger extension / retraction switch to EXTEND. 4.

Extend each stabilizer, positioning the float as necessary, until the locking levers of the float engage th stabilizer cylinder rod.

NOTE More than one stabilizer may be extended at one time.

5.

With each stabilizer float firmly touching the ground, depress the front STABILIZER switches and position the extension / retraction switch to EXTEND and extend the front stabilizers approximately 3 to 4 inches (7.6 to 10.2 cm).

6.

Depress the rear STABILIZER switches and position the toggle switch to EXTEND and extend the rear stabilizers approximately 3 to 4 inches (7.6 to 10.2 cm).

4−17

7.

Repeat the procedures in steps 5 and 6 until all wheels are clear of the ground and the crane is level, as indicated by the sight level bubble located on the front console. If suspected that the bubble level indicator is out of adjustment, verify and adjust it as follows. a.

Locate the crane on a firm level surface.

b.

Extend and set the outriggers. Level the crane, as indicated by the bubble level indicator, using the outriggers. c.

Place a miracle pointer, carpenter level, or similar type device on a machined surface such as the turntable bearing or bearing mounting surfaces. d.

Using the outriggers, level the crane as indicated on the device used in step c. e.

Using the mounting screws, adjust the bubble level indicator to show

level.

STOWING THE OUTRIGGERS. 1.

Position the rear STABILIZER switches and position the extension / retraction switch to RETRACT until the rear stabilizers have retracted several inches.

2.

Position the front STABILIZER push button switches and position the extension / retraction switch to RETRACT until the front stabilizers have retracted several inches.

3.

Repeat steps 1 and 2 until the crane is resting on all 4 wheels and the stabilizer floats are several inches off the ground.

WARNING KEEP FEET AND HANDS CLEAR OF THE FLOATS WHEN UNLOCKING THEM FROM THE STABILIZERS. 4.

Release the locking levers and allow the floats to drop to the ground.

5.

Continue to retract the stabilizers until they are fully retracted.

6.

Position the appropriate EXTENSION switch and position the extension / retraction switch to RETRACT to retract each outrigger.

4−18

NOTE More than one outrigger may be retracted at a time.

7.

Stow the outrigger floats.

SWINGING THE BOOM. WARNING BEFORE INITIATING ANY SWING OPERATIONS, ENSURE THE AREA IN THE SWING PATH OF THE HOOK AND/OR LOAD, AS WELL AS THE TAIL SWING AREA, IS CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL. WARNING WHEN SWINGING THE LOAD FROM OVER−THE−FRONT TO OVER−THE− SIDE OF THE CRANE, REFER TO THE OVER−THE−SIDE LOAD CHART TO MAKE CERTAIN THE APPLICABLE CAPACITY IS NOT EXCEEDED. TRAVELING WITH ANY LOAD OVER−THE−SIDE IS PROHIBITED. CAUTION ENSURE THE POSITIVE SWING LOCK IS DISENGAGED AND THE SWING BRAKE SWITCH IS IN THE DISENGAGE POSITION BEFORE ATTEMPTING TO SWING. CAUTION NEVER PUSH OR PULL THE SWING CONTROL LEVER THROUGH NEUTRAL TO THE OPPOSITE DIRECTION TO STOP SWING MOTION.

4−19

NOTE Automatic rear axle oscillation lockout will activate when the boom swings right or left of the crane centreline.

To swing the boom, the SWING control lever is pushed to the right for right swing and pushed to the left for left swing. Always operate the control lever with a slow, even pressure. With non−free swing, returning the lever to neutral stops rotation. With free swing, rotation is stopped utilizing the swing brake foot pedal.

When rotation is stopped, put the SWING BRAKE switch in the engage position to prevent further rotation.

ELEVATING AND LOWERING THE BOOM. Elevating The Boom.

WARNING BEFORE ELEVATING THE BOOM, ENSURE THE AREA ABOVE AND BENEATH THE BOOM IS CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL. To elevate the boom, the BOOM control lever is pushed to the left, and held until the boom reaches the desired elevation angle.

Lowering The Boom.

WARNING BEFORE LOWERING THE BOOM, MAKE CERTAIN THE AREA BENEATH THE BOOM IS CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL. WARNING LONG CANTILEVER BOOMS CAN CREATE A TIPPING CONDITION EVEN WHEN UNLOADED AND IN AN EXTENDED AND LOWERED POSITION.

4−20

WARNING WHEN LOWERING THE BOOM, LET OUT THE CABLE SIMULTANEOUSLY TO PREVENT TWO−BLOCKING THE BOOM NOSE AND THE HOOK BLOCK. CAUTION THE CLOSER THE LOAD IS CARRIED TO THE BOOM NOSE, THE MORE IMPORTANT IT BECOMES TO SIMULTANEOUSLY LET OUT CABLE AS THE BOOM IS LOWERED. WARNING BELOW 20° BOOM ANGLES, GREAT CARE MUST BE EXERCISED WHEN SLEWING OR DERRICKING DOWN TO AVOID DAMAGING CHASSIS EQUIPMENT E.G. CAB, EXHAUST, BOOM REST ETC. To lower the boom, the BOOM control lever is pushed to the right and held until the boom is lowered to the desired position.

EMERGENCY BOOM OPERATING PROCEDURES. Although highly improbable if proper maintenance and frequent inspections are made, there remains the possibility that the boom lift cylinder hydraulic line could fail. If this occurs, there are restricting devices provided that allow continued operation of the crane. All crane functions remain operable until the hydraulic oil in the reservoir is depleted. The most important thing is to get the boom in a safe position so that repairs can be made. The following procedures are recommended for getting the boom to a safe position.

1.

Remain at the operator’s station as all functions can be accomplished from this position.

2.

Accelerate the engine to normal operating rpm.

3.

Maintain the desired boom angle by pushing on the BOOM control lever to the left, as necessary.

4−21

4.

While maintaining the boom at this angle, activate swing, telescope in the boom sections, and operate the hoist(s) as necessary until the load is safely lowered to the ground.

5.

If over−the−side, telescope in as much boom as possible and then lower the boom. If over−the−front or over−the−rear, it will not be necessary to telescope in.

TELESCOPING THE BOOM. Extending The Boom.

WARNING WHEN EXTENDING THE BOOM, LET OUT CABLE SIMULTANEOUSLY TO PREVENT TWO−BLOCKING THE BOOM NOSE AND HOOK BLOCK. WARNING CHECK THE LOAD CHART FOR MAXIMUM LOAD AT GIVEN RADIUS, BOOM ANGLE AND LENGTH BEFORE EXTENDING BOOM WITH A LOAD. To extend the boom, the TELESCOPE control lever is pushed forward away from the operator, to the OUT position and held until the boom extends to the desired length.

Retracting The Boom.

WARNING WHEN RETRACTING THE BOOM, THE LOAD WILL LOWER UNLESS THE CABLE IS TAKEN IN SIMULTANEOUSLY. To retract the boom, the TELESCOPE control lever is pulled back, toward the operator, to the IN position and held until the boom retracts to the desired length.

NOTE When the crane is equipped with an auxiliary hoist the telescope function is controlled by a foot pedal.

4−22

LOWERING AND RAISING THE CABLE. WARNING BEFORE LOWERING OR RAISING THE CABLE (LOAD), ENSURE THE AREA BENEATH THE LOAD IS CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL. WARNING WHEN STARTING OR STOPPING THE HOIST, DO NOT JERK THE CONTROL LEVER. JERKING THE LEVER CAUSES THE LOAD TO BOUNCE, WHICH COULD RESULT IN POSSIBLE DAMAGE TO THE CRANE. NOTE When the load is stopped at the desired height, the automatic brake will engage and hold the load as long as the control lever remains in neutral.

Lowering The Cable.

To lower the cable, the MAIN hoist or AUX hoist control lever is pushed forward, away from the operator, to the down position and held until the hook or load is lowered to the desired height.

Raising The Cable.

To raise the cable, the MAIN hoist or AUX hoist control lever is pulled back, toward the operator, to the up position and held until the hook or load is raised to the desired height.

STOWING AND PARKING. WARNING NEVER PARK THE CRANE NEAR HOLES, OR ON ROCKY OR EXTREMELY SOFT SURFACES. THIS MAY CAUSE THE CRANE TO OVERTURN, RESULTING IN INJURY TO PERSONNEL. 4−23

After the crane is parked, complete the following.

1.

Remove the load from the hook.

2.

Remove or stow boom extensions if so equipped.

3.

Fully retract all boom sections.

4.

Lower the boom to normal travel position.

5.

Engage the swing brake and/or swing lock.

6.

Retract all stabilizer cylinders and outrigger beams.

7.

Park the crane on a stable surface.

8.

Apply the parking brakes and chock wheels.

9.

Ensure all operating controls are in neutral position.

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

11.

Remove the keys.

12.

Close and lock, if applicable, all windows, covers, and doors.

4−24

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

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

LUBRICANTS CAUTION CHASSIS GREASE LUBRICANTS MUST NOT BE APPLIED WITH AIR PRESSURE DEVICES AS THIS LUBRICANT IS USED ON SEALED FITTINGS. CAUTION THE MULTIPURPOSE GREASE INSTALLED DURING MANUFACTURE IS OF A LITHIUM BASE. USE OF A NON− COMPATIBLE GREASE COULD RESULT IN DAMAGE TO EQUIPMENT. Specific recommendations of brand and grade of lubricants are not made here due to regional availability, operating conditions, and the continual development of improved products. Where questions arise, refer to the component manufacturer’s manual and a reliable supplier.

5−1

SYMBOL DESCRIPTION MPG Multipurpose Grease.

Lubricating grease of such composition, structure, and consistency to meet the performance requirements for chassis grease, wheel bearing grease, universal joint grease, and other automotive uses of miscellaneous nature, such as fifth wheel service, should be inhibited to prevent rusting and have excellent resistance to both heat and water.

Higher quality EP−MPG multipurpose grease may also be used. See EP−MPG for recommended consistency grades EP−MPG Extreme Pressure Multipurpose Grease.

This is a lithium soap base grease with a high load carrying capacity. The following properties are recommended.

Timken OK Load Dropping Point Oil Viscosity Water Resistance

40 lb. Minimum 350°F (177°C)min.

75 SUS Minimum at 210°F (99°C) Excellent

Under normal operating conditions, the following consistency grades are recommended.

NLGI No. 0 or 00 for sub−zero Fahrenheit temperatures.

NLGI No. 1 or No. 2 for normal ambient temperatures.

NLGI No. 2 or No. 3 for temperatures over 100°F (38°C).

Unless otherwise specified, an EP−MPG containing molybdenum disulfide maybe used (see MPGM).

MPGM Extreme Pressure Multipurpose Grease Containing High Grade Molybdenum Disulfide Filler.

An extreme pressure multipurpose grease containing high grade molybdenum disulfide filler that imparts anti−friction properties especially well suited for conditions of heavy loading, particularly on slow oscillating or reciprocating bearing surfaces.

WBG Wheel Bearing Grease.

This grease is of such composition, structure, and consistency that it is suitable for long time use in anti−friction wheel bearings. It must have high resistance to the deteriorating effects of temperature and the separating effects of centrifugal 5−2

action. It shall not contain corrosive or abrasive materials and shall inhibit corrosion in the presence of moisture. NLGI Grade No. 2 is recommended where not otherwise specified.

RGL Regular Gear Lubricant.

This is a straight−mineral gear oil of relatively high viscosity for the lubrication of spiral−bevel and worm gear rear axles and most manual transmissions operating under low unit pressures and sliding velocities. API−GL−1 service classification. Unless otherwise specified, the following viscosity characteristics are recommended. Viscosity Index 85 minimum Summer Operation SAE 90 Winter Operation SAE 80 EPGL Extreme Pressure Multipurpose Gear Lubricant.

This gear lubricant is compounded to achieve high load carrying capacity and meet the requirements of either API−GL−5 or MIL−L−2105C. Unless otherwise specified, SAE 80W−90 viscosity may be used for year−round service. Low temperature usage is restricted as follows.

SAE Viscosity Number 75W 80W 85W 90 140 250

Minimum Ambient Temperature −°F (°C) −40 ( −40) −15 ( −26) +10 ( −12) +20 ( − 7) +40 ( + 5) +50 ( +10)

EPGL(SCL) Extreme Pressure Gear Lubricant,Sulpho Chloro−Lead.

This is a special gear lube formulated with EP additives of the sulfur chlorine− lead types. Usage is restricted to those component parts for which the manufacturer specifies a lubricant of this composition. (Refer Clark MS−8−Specification.)

OGL Open Gear Lubricant.

This is a special adhesive lubricant of heavy consistency for protection of wire rope and exposed gears where provision is not made for continuous lubricant replenishment. Select the viscosity that gives best protection and lubrication without peeling, scaling, or excessive throw off.

EO Engine Oil. Internal combustion engine lubricating oils are classified primarily by viscosity characteristics and on performance as determined by a series of tests called MS 5−3

test sequences. Lubricants marketed for heavy duty service consist of refined crude oil containing additives compounded to meet the desired engine performance levels. Use only good quality oil provided by a reputable supplier in accordance with the service classification and viscosIty requirements specified by the engine service manual.

ATF Automatic Transmission Fluid.

ATF shall meet the latest requirements for General Motors Dexron II specification.

HTF Hydraulic Transmission Fluid.

A fluid qualified to Detroit Diesel Allison (Div.of GMC) specification for Type C−3 transmission fluid, SAE 10W unless other−wise specified.

SBF Silicone Brake Fluid.

A silicone based hydraulic brake fluid, conforming to MIL−B−46176, for use in hydraulic brake systems at ambient temperature ranging from minus 67 degrees to plus 131 degrees F (−55 degrees to + 55 degrees C). It is intended to be used in braking systems fitted with cups and seals made from natural rubber, buna 5, polychloroprene or ethylene proplene diene monomer.

BF Brake Fluid.

A glycol ether fluid for use in hydraulic brake systems. Must meet or exceed SAE specification J1703.

THF Multipurpose Hydraulic/Transmission Oil. A high quality multipurpose hydraulic/transmission oil formulated to provide chatter − free performance of wet brake and wet clutches in addition to good gear lubrication and hydraulic performance. Should meet John Deere specification J20A, viscosity 20W−30 for general applications unless otherwise specified. When used as a hydraulic fluid (HYDO), refer to viscosity provisions under HYDRAULIC OIL RECOMMENDATIONS section.

GROVEXTRA HYDO High Performance Hydraulic Oil. Oil in a hydraulic system serves as the power transmission medium, system lubricant, and coolant. Selection of the proper oil is essential to ensure satisfactory system performance and life. (See HYDRAULIC OIL RECOMMENDATIONS.) GROVEXTRA HYDO may be further described using a suffix as follows: RO − Rust and oxidation inhibited oil.

5−4

AW − A premium oil with antiwear additive.

LT − Low temperature hydraulic oil.

WPG Water Pump Grease.

This is a multi−purpose high pressure lithium soap base grease. The following properties are recommended.

Dropping Point Water Resistance NLGI Grade

3405F (1715C) min.

Excellent NO. 2

WRL Wire Rope Lubricant.

Chemically neutral Wire Rope Lubricant used to prevent corrosion and reduce wear caused by internal friction. OGL is sometimes suitable. WRL should be selected and applied in accordance with operating conditions and recommendations of a reputable lubricant supplier. See WIRE ROPE LUBRICATION. HYDRAULIC OIL RECOMMENDATIONS. New cranes come from the factory with Grovextra Hydo high performance hydraulic oil.

Factory fill oil meets the optimum viscosity requirements through a temperature range from −20°C to 46°C (−4°F to 115°F). When replenishment of the oil becomes necessary, or when replacement of the oil is required as a result of contamination or operation outside the recommended temperature range for the factory fill oil, the following types of oil are suitable under most operating conditions: 1.

Tractor Hydraulic Fluids of suitable viscosity.

2.

Good quality anti−wear hydraulic oils of suitable viscosity and specifically formulated to provide chatter−free operation of wet brakes.

The most important factors in selecting an oil for hydraulic service are: 1.

Viscosity.

2.

Anti−wear additives.

Viscosity.

The oil must have proper viscosity to provide a lubricating film at system operating temperature.

Oil viscosity is important because it has a direct bearing on efficient transmission of power. An oil must flow readily through the system with a minimum of 5−5

pressure and flow loss. Positive lubrication depends on viscosity. The oil must be sufficiently light to get between the components machined surfaces, and maintain a lubricating film at system operating temperatures. Cold weather start−up procedures should allow for a gradual warm−up until the oil reaches a reasonably fluid state.

Oil that is too light may cause the following conditions in the system.

1.

Excessive leakage.

2.

Lower volumetric efficiency of the pump.

3.

Increased component wear.

4.

Loss of system pressure.

5.

Lack of positive hydraulic control.

6.

Lower overall efficiency.

Oil that is too heavy may cause the following conditions in the system.

1.

System pressure drop.

2.

Increases system temperature.

3.

Sluggish system operation.

4.

Low mechanical efficiency.

5.

Higher power consumption.

The following oil viscosity characteristics are recommended.

80 to 180 SUS optimum at system operating temperature 60 SUS minimum at system operating temperature 7500 SUS maximum at starting temperature 90 Viscosity Index (VI), minimum Pour point at least 20 degrees F (11 degrees C) below start−up temperature The following grades will usually meet the above viscosity requirements.

SAE VISCOSITY DESIGNATION 5W−20 10W 10W−30 5−6

TEMPERATURE −°F (°C) −10 to 180 (−23 to 82) +10 to 180 (−12 to 82) +10 to 210 (−12 to 99)

Arctic Conditions (Below 0 degrees F [−18 degrees C]).

In general, petroleum based fluids developed especially for low temperature service may be used with satisfactory results. However, certain fluids, such as hologenated hydrocarbons, nitro hydrocarbons, and phosphate ester hydraulic fluids, might not be compatible with hydraulic system seals and wear bands. If you are in doubt about the suitability of a specific fluid, check with your authorized Grove distributor or Grove Customer Services.

Regardless of temperature and oil viscosity, always use suitable start−up procedures to ensure adequate lubrication during system warm−up.

Anti −wear Additives.

Excessive wear in the system may cause a loss in volumetric efficiency, and may cause shutdowns for maintenance. An efficient anti−wear oil protects the components against rusting; resists oxidation and helps prevent wear.

LUBRICATION POINTS A regular frequency of lubrication must be established for all lubrication points.

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

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

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

On all hoists with a check plug in the drum, the fill plug shall be directly on top of the hoist, and the check plug level.

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

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

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

5−7

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

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

The following describe the lubrication points and gives the lube type, lube interval, lube amount, and application of each. Each lubrication point is numbered, and this number corresponds to the index number shown on the Lubrication Diagram.

1.

Steering Gearbox Lube Type − GROVEXTRA HYDO Lube Interval − Check every 1000 miles (1600 km) Lube Amount − 0.99 quarts (0.94 litres) Application − 1 grease fitting

2.

Steering Links and Tie Rods Lube Type − EP − MPG Lube Interval − 100 miles (1600 km) Lube Amount − Until grease extrudes Application − 1 fitting at each end of the rod

3.

Steering Cylinder Pivot Lube Type − EP − MPG Lube Interval − 100 miles (1600 km) Lube Amount − Until grease extrudes Application − 1 fitting at each end of each cylinder

4.

King Pins Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes Application − 2 fittings on each axle end

5−8

5.

Differentials.

Lube Type − EPGL−5 Lube Interval − 1.

Service after first 620 miles (1000 km) 2.

Drain and fill every 6000 miles (10000 km). When yearly mileage is less than 6000 miles (10000 km) change once a year Lube Amount − 21 quarts (20 litres) Application − Check/fill plug in differential housing.

6.

Planetary Axle Ends Lube Type − EPGL−5 Lube Interval − Service after first 620 miles (1000 km). Check every 1000 miles (1600 km). Change every 6200 miles (10000 km) Lube Amount − 1.4 quarts (1.5 litres) Application − Fill plug in axle end. The oil should be at the edge of the port opening.

Drain Plug Oil Fill and Oil Level Plug

7.

Engine Lube Type − EO Lube Interval − Check daily. Drain per the Engine Service Manual Application − Refer to the Engine Service Manual.

5−9

8.

Transmission Lube Type − HTF Lube Interval − 1.

Check daily with the engine running at 500 to 600rpm and oil at 180°F to 200°F (82.2°C to 93.3°C).

2.

Drain and refill every 500 hours with the oil at 180°F to 200°F (82.2°C to 93.3°C). a.

Replace oil filter and clean filter shell. b.

Fill to FULL mark on the dipstick c.

Run engine at 500 to 600 rpm to prime torque converter and lines. d.

Check the oil level with the engine running at 500 to 600 rpm and oil at 180°F to 200°F (82.2°C to 93.3°C). Add oil to bring level to FULL mark on the dipstick.

NOTE When checking the oil level, the oil temperature must be stabilized at 180°F to 200°F (82.2°C to 93.3°C) to properly check the oil level. Do not attempt an oil level check with cold oil. To bring the oil temperature to this range, it is necessary to either work the crane or stall the converter. Converter stall should be accomplished by engaging the shift levers in forward and high range with the brakes applied and then accelerating the engine to half or three−quarter throttle. Hold the stall until the desired converter temperature is reached and stabilized.

CAUTION FULL THROTTLE STALL SPEEDS FOR AN EXCESSIVE LENGTH OF TIME WILL OVER−HEAT THE CONVERTOR AND CAUSE SERIOUS DAMAGE. Lube Amount − 28 quarts (26.5 litres) Application − Through the fill pipe to the FULL mark on the dipstick.

9.

Drive Line Universals Lube Type − EP−MPG .

Lube Interval − 1000 miles (1600km)

5−10

Lube Amount − Until grease extrudes.

Application − 1 grease fitting per universal joint 10.

Drive Line Slip Joints Lube Type − EP−MPG .

Lube Interval − 1000 miles (1600km) Lube Amount − Until grease extrudes.

Application − 1 grease fitting per slip joint

11.

Outrigger Beams Lube Type − EP−MPG .

Lube Interval − As necessary Lube Amount − Thoroughly coat the area the wear pad moves on.

Application − By brush

12.

Swing Gear and Pinion Lube Type − OGL − Rotek Lube Type − EP−MPG−KEENE Lube Interval − 10 hours Lube Amount − Coat all teeth Application − Brush on

13.

Swing Box

A.

Gear Box Lube Type − EPGL−5H CAUTION WHEN CHECKING THE SWING GEARBOX OIL LEVEL, PLACE THE DIPSTICK INTO THE SLEEVE UNTIL THE CAP IS FLUSH WITH THE END OF THE SLEEVE. DO NOT SCREW THE CAP ONTO THE SLEEVE TO CHECK THE LEVEL. Lube Interval − Check every 50 hours Lube Interval − Drain 1st time after 250 hours and every 500 hours or 12 months thereafter.

Lube Amount − Capacity 50 ounces (1.5L) Application − Fill to fill plug

B.

Swing Gear and Pinion Lube Type − EP−MPG Lube Interval − 10 hours 5−11

Lube Amount − Coat all teeth Application − Brush on C.

Swing Brake Lube Type − GROVEXTRA HYDO Lube Amount − 0.5 pint (0.2 L) Application − Fill before installation

14.

Swing Bearing Lube Type − EP−MPG Lube Interval − 50 hours Lube Amount − Until grease extrudes the whole circumference of the bearing Application − 4 grease fittings. Rotate the turntable 90 degrees and apply grease to the fittings. Continue rotating 90 degrees and grease the fittings until the whole bearing is greased.

15.

Upper Lift Cylinder Pivot Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting

16.

Lower Lift Cylinder Pivot Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes Application − 2 grease fittings

17.

Hookblock Swivel Bearing Lube Type − EP − MPG Lube Interval − 100 Hours Lube Amount − Until grease extrudes Application − 3 grease fittings

18.

Hookblock Sheaves Lube Type − EP − MPG Lube Interval − 100 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting per sheave

19.

Lower Boom Nose Sheaves Lube Type − EP − MPG Lube Interval − 50 Hours

5−12

Lube Amount − Until grease extrudes Application − 1 grease fitting per sheave 20.

Upper Boom Nose Sheaves Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting per sheave

21.

Rooster Sheave (Optional) Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting per sheave

22.

Boom Extension Sheaves (Optional) Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting per sheave

23.

Telescope Cylinder Wear Pads Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Thoroughly coat the area the wear pad moves on.

Application − By brush. The wear pads are located on the cylinder support foot.

24.

Adjustable Wear Pads Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Thoroughly coat the area the wear pad moves on.

Application − By brush

25.

Non−Adjustable Wear Pads Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Thoroughly coat the area the wear pad moves on.

Application − By brush

26.

Telescope Cylinder Pivot Pins Lube Type − EP − MPG Lube Interval − 25 Hours 5−13

Lube Amount − Until grease extrudes Application − 2 grease fittings 27.

Extension Cable Sheaves Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting per sheave

28.

Retraction Cable Sheave Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Until grease extrudes Application − 2 grease fittings

29.

Boom Pivot Shaft Lube Type − EP−MPG Lube Interval − 10 hours Lube Amount − Until grease extrudes Application − 2 grease fittings, one on each side

30.

Jib Mast Lube Type − EP−MPG Lube Interval − 25 hours Lube Amount − Until grease extrudes Application − 1 grease fitting

31.

Jib Lower Cord Adaptor Lube Type − EP−MPG Lube Interval − 25 hours Lube Amount − Until grease extrudes Application − 1 grease fitting on each side

32.

Hydraulic Reservoir Lube Type − GROVEXTRA HYDO Lube Interval − Check daily. Drain as necessary Lube Amount − Capacity 65 gallons (246 L) Application − Fill through the cap on top of the tank. When tank is drained, clean the magnetic pipe plug.

33.

Hydraulic Reservoir Filter Lube Type − GROVEXTRA HYDO Lube Interval − Change the filter when the indicator is red

5−14

Lube Amount − N/A Application − N/A 34.

Oscillation Lockout Cylinder Lube Type − EP−MPG Lube Interval − 25 hours Lube Amount − Until grease extrudes Application − 1 grease fitting on each end of each cylinder

35.

Trunnion Bearings Lube Type − EP−MPG Lube Interval − 50 hours Lube Amount − Until grease extrudes Application − 1 grease fitting for each bearing

36.

Cardan Joint Lube Type − EP−MPG Lube Interval − 50 hours Lube Amount − Until grease extrudes Application − 1 grease fitting per joint

37.

Hoists Lube Type − EPGL−5H Lube Interval − Check every 250 hours Lube Amount − Capacity 12 quarts (11.5 litres) Application − The oil should be level with the bottom of the check/ fill plug when the crane is level.

38.

Pintle Hook Lube Type − EP−MPG Lube Interval − 50 hours Lube Amount − Until grease extrudes Application − 3 grease fittings

39.

Front Axle Torque Rod Lube Type − EP−MPG Lube Interval − 50 hours Lube Amount − Until grease extrudes Application − 2 grease fittings

40.

Swingaway Side Wear Pads Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Thoroughly coat the area the wear pad moves on Application − By brush 5−15

41.

Swingaway Rollers Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Thoroughly coat all sliding contact areas Application − By brush

42.

Hook Shank and Hex Nut Lube Type − MPG Lube Interval − 100 Hours Lube Amount − Apply a liberal coating to the hook shank threads and the top of the nut to prevent dust, water, etc. from entering the threads.

Application − By brush or hand

43.

Cable Follower Lube Type − EP−MPG Lube Interval − 50 hours Lube Amount − Until grease extrudes.

Application − 1 grease fitting on the roller arm.

44.

Door Hinge Lube Type − EP−MPG Lube Interval − 250 hours Lube Amount − Until grease extrudes.

Application − 1 grease fitting per hinge.

45.

Mitre Gear Lube Type − GROVEXTRA HYDO Lube Interval − Check every 1000 miles (1600 km).

Lube Amount − 0.5 quarts (0.47 litres) Application − Fill until running out of the fill hole.

46.

Vapour Corrosion Inhibitor Vapour Corrosion Inhibitors are fitted in the junction box. To retain efficiency the Vapour Corrosion Inhibitors should be replaced at least every 2 years.

5−16

WIRE ROPE LUBRICATION Wire rope is lubricated during manufacturing so the strands, and individual wires in strands, may move and adjust as the rope moves and bends. A wire rope cannot be lubricated sufficiently during manufacture to last its entire life. Therefore, new lubricant must be added periodically throughout the life of a rope to replace factory lubricant which is used or lost. The surface of some ropes may become covered with dirt, rock dust, or other material during their operation. This covering can prevent field applied lubricants from properly penetrating into the rope.

Therefore, these ropes should be cleaned before being lubricated. The lubricant applied should be light bodied enough to penetrate to the core of the rope. Lubricant may be applied effectively by various methods. It may be dripped on, sprayed on, or put on by brushing, but in any case it should be applied at a place where the rope is being bent, such as a sheave. It should be applied at the top of the bend, at the point the strands are spread by bending and are more easily penetrated. The service life of rope will be directly proportional to the effectiveness of the method used and amount of lubricant reaching the working parts of the rope. A proper lubricant must reduce friction, protect against corrosion, adhere to every wire and be pliable and not crack or separate when cold and yet not drip when warm. Special lubricant can be applied at the factory to meet usual conditions.

3851

Wire Rope Lubrication

5−17

Lubrication Diagram (Sheet 1 of 2) 5−18

30

31 41

Steering Gearbox 24.

Steering Links and Tie Rods 25.

Steering Cylinder Pivot 26.

King Pins 27.

Differentials 28.

Planetary Axle Ends 29.

Engine 30.

Transmission 31.

Drive Line Universals 32.

Drive Line Slip Joints 33.

Outrigger Beams 34.

Swing Gear and Pinion 35.

Swing Box 36.

Swing Bearing 37.

Upper Lift Cylinder Pivot 38.

Lower Lift Cylinder Pivot 39.

Hookblock Swivel Bearing 40.

Hookblock Sheaves 41.

Lower Boom Nose Sheaves 42.

Upper Boom Nose Sheaves 43.

Rooster Sheave (Optional) 44.

Boom Extension Sheaves (Opt) 45.

Telescope Cylinder Wear Pads 46.

22

41

41

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

40

Adjustable Wear Pads Non−Adjustable Wear Pads Telescope Cylinder Pivot Pins Extension Cable Sheaves Retraction Cable Sheave Boom Pivot Shaft Jib Mast Jib Lower Cord Adaptor Hydraulic Reservoir Hydraulic Reservoir Filter Oscillation Lockout Cylinder Trunnion Bearings Cardan Joint Hoists Pintle Hook Front Axle Torque Rod Swingaway Side Wear Pads Swingaway Rollers Hook Shank and Hex Nut Cable Follower Door Hinge Mitre Gear Vapour Corrosion Inhibitor

Lubrication Diagram (Sheet 2 of 2) 5−19

MILITARY EQUIVALENTS Lube Type

B.P. Recommended Lubricants

Temp Range

EO

Vanellus C3 Multigrade

−20°C to 46°C

No Direct Equivalent, would recommend OMD 80

HTF

Autran GM−MP

−20°C to 46°C

OMD55

BELOW−20°C

OMD80

Multigear FE80W/90

−10°C to 32°C

OEP 220

0−226

Multigear FE80W/140

−20°C to 46°C

None But OEP 38 is normally substituted

0−228

XG 279

G−403

−20°C to 46°C

OM33

−

BELOW−20°C

OM18

EPGL−5

EP−MPG MPG

Energrease LS−EP2

GROVE EXTRA HYDO

Grovextra Hydo

M.O.D. Spec

N.A.T.O. Code

−

Miscellaneous Lubricants

5−20

Battery Terminals

PX7

S−743

Anti−Freeze (Air System)

AL 14

−

Anti−Freeze (Cooling System)

AL 39

S−750

SECTION VI OPERATIONAL AIDS GENERAL. This Section provides a brief description of optional operational aids available on the crane.

LOAD MOMENT INDICATING SYSTEM. The load moment indicating system is an electro−mechanical sensing system designed to alert the operator of impending capacity lifts when the system has been properly preset by the crane operator. The control panel is mounted in the cab. When an overload condition is sensed, the system provides the operator with a visual and audible warning, and locks out the control levers to prevent lowering the boom, extending the boom, or raising the main or auxiliary hoist cables. Anti two−block devices are also incorporated into the system to prevent the hook block from coming into contact with the boom nose or jib. This condition will also cause a lockout of the above mentioned control functions. Boom angle indication is provided on the control panel.

ANTI TWO−BLOCK SYSTEM. The anti two−block system provides a warning to the operator of an impending two−block condition. The system consists of anti two−block switches, a relay, a buzzer, a warning indicator light, and the associated wiring. The number of switches used depends on the optional boom configuration, and ultimate boom nose tips. The switches are held in the closed position by a weight suspended on a chain from the switch. The closed switch maintains the relay energized, which silences the buzzer and prevents illumination of the indicator light. As the hook block comes closer to the boom tip, the weight is contacted and the switch is allowed to spring open. This action deenergizes the relay, which sounds the warning buzzer, and illuminates the TWO−BLOCK indicator light on the lower right side of the front console. This system is not installed if the load moment indicating system is provided.

CONTROL LEVER LOCKOUT SYSTEM The control lever lockout system consists of a hydraulic solenoid valve and three (four if auxiliary hoist is installed) hydraulic lockout cylinders. The cylinders are installed in the rod linkage between the control lever and the appropriate directional control valve. The cylinders are connected in such a manner as to prevent worsening the condition, ie. boom down, telescope out or, hoist up. With the solenoid valve energized (normal), its hydraulic valve is 6−1

closed, allowing 200 psi (1379 kPa) of hydraulic oil to be applied to the rod side of the cylinders, which provides a solid link in the control rods. Deenergizing the solenoid valve allows the valve to open and removes the hydraulic pressure from the cylinders. This removes the solid link from the control rods and allows the directional control valve to move in a direction that will improve the condition. the control lever lockout system is used with the anti two−block system or the load moment indicating system.

6−2

SECTION VII SET UP AND INSTALLATION PROCEDURES GENERAL. This section provides procedures for installing the hoist cable on the hoist drum, cable reeving, and erecting and stowing the swingaway boom extension.

INSTALLING CABLE ON THE HOIST. CAUTION IF CABLE IS WOUND FROM THE STORAGE DRUM, THE REEL SHOULD BE ROTATED IN THE SAME DIRECTION AS THE HOIST. NOTE The cable should preferably be straightened before installation on the hoist drum.

Install cable on the hoist drum in accordance with the following procedure.

1.

Position the cable over the boom nose sheave and route to the hoist drum.

2.

Position the hoist drum with the cable anchor slot on top.

3.

Insert the cable through the slot and position around the anchor wedge.

NOTE The end of the cable should be even with the bottom of the anchor wedge.

7−1

ANCHOR WEDGE

Installing Cable Anchor Wedge

4.

Position the anchor wedge in the drum slot; pull firmly on the free end of the cable to secure the wedge.

NOTE If the wedge does not seat securely in the slot, carefully tap the top of the wedge with a mallet.

5.

Slowly rotate the drum, ensuring the first layer of cable is evenly wound onto the drum.

6.

Install the remainder of the cable, as applicable.

CABLE REEVING. Within the limits of the load and range charts and permissible line pull, multi−part lines allow the operator to raise a greater load than can be raised with a single part line. Various cable reeving (part line) is possible with the boom nose and 7−2

hook block. This reeving should be accomplished by a qualified rigger using standard rigging procedures.

WEDGE AND SOCKET It is essential to use only a wedge and socket of the correct size for the rope fitted. Failure to do so may result in the rope pulling through the fitting as soon as the load is applied.

Mixing of components from different manufacturers should be avoided and the fitting of the wedge (with rope) in the socket should always be checked at the time of assembly.

When making up a termination, a dead−end length of rope not less than fifteen times the diameter of the rope should be left protruding from the socket e.g.

190mm rope.

When assembly is complete the boom should be raised to a working position and a load suspended to firmly seat the wedge and rope into the socket before the crane is used operationally.

The use of rope wedges and socket terminations is NOT recommended in any case where a crane hoist rope supports a man carrying skip or platforms.

Inspection The terminal fittings should be inspected weekly, particular attention should be paid to rope damage as might be evidenced by broken wires or deformation of the rope where it emerges from the socket; to the condition of the socket, i.e. that there are not cracks or deformation of the socket.

The socket and wedge and part of the rope lying inside the fitting should be examined at least every three months, damaged parts must be replaced.

Correct Method of Fixing the Rope to the Socket Fit the rope to the socket so that the working rope is at the straight side of the socket, the tail of the rope at the sloping side.

7−3

Loop the tail end of the rope so it can be clamped to the tail near the socket as shown. This clamp acts as a stop to prevent the rope becoming detached, even should slip occur.

Do not clamp the tail of the rope to the working rope as shown . If this is done it will prevent the wedge from gripping the rope in the socket, so that slip is possible.

Do not pass the rope through the socket as shown . Here the rope is not lying in a straight line with the anchor point. When is tension the rope bends as it leaves the socket and the edge of the socket will ’bite’ into the rope causing damage to the rope and possible eventual failure.

7−4

Both the incorrect methods can result in the rope slipping gradually through the socket and becoming free, with possible disastrous consequences.

Periodically inspect the socket. if the clamp is pulled up against the socket, reposition the rope to give clearance. Check that the rope is not kinked.

When anchoring the socket to the boom head ensure the flat face of the socket is in the position shown towards the boom sections.

CAUTION IF THE SOCKET IS NOT POSITIONED WITH THE FLAT FACE TOWARDS THE BOOM SECTIONS STRUCTURAL DAMAGE WILL OCCUR.

7−5

Single Hook and Pearweight Assembly Figure below shows the single hook and pearweight when assembled correctly for lifting duties.

During assembly it is very important to ensure that the hoist rope (1) is reeved through the wedge and socket (2) in strict accordance with the previous instructions.

The loop in the free end of the rope is then secured with rope clamp (3) as shown.

WARNING 1 Under no circumstances should the free end of the rope be clamped to the working end of the rope above the pearweight.

3 2

WARNING The rope clamp (3) should always be fitted as shown with the bridge on the working part of the rope and the ’U’ bolt on the rope tail or dead end of the rope.

7−6

ERECTING AND STOWING THE SWINGAWAY BOOM EXTENSION. WARNING BEFORE ERECTING OR STOWING THE SWINGAWAY, READ AND ADHERE TO THE WARNING DECALS INSTALLED ON THE SWINGAWAY AND/OR STOWAGE BRACKETS. Erecting 1.

Extend and set the outriggers.

2.

Position the boom over the rear of the carrier.

3.

If extended, fully retract all the boom sections and lower to minimum elevation to permit ease of installation of pins and access to the boom nose.

NOTE The auxiliary boom nose (rooster sheave) does not have to be removed.

4.

Rig either the main hoist or optional auxiliary hoist cable for single part line with nothing but the becket on the end of the cable.

5.

Extend the boom enough to disengage the spring loaded boom extension stop blocks (14) from underneath the front of the mid section.

6.

Disengage the spring loaded boom extension slop blocks (14) and fully retract the boom.

7.

Remove the retainer clips (9) from the attach pins (10) stowed in the base of the swingaway and insert the attach pins (10) through the attach and anchor fittings on the right side of the boom nose. Install the retainer clips (9) in the attach pins (10).

8.

Remove the hitch pin (4) and pin (5) securing the swingaway to the rear stowage bracket (3).

9.

Attach a length of rope to the swingaway tip to aid in swinging the swingaway into place ahead of the boom nose.

10. Raise the boom to horizontal and extend the boom just enough to clear the swingaway stowage lugs (11) from the guide pins (12) and ramp (13) on the front and rear stowage brackets (2 and 3).

7−7

WARNING WHEN ERECTING, THE SWINGAWAY ENSURE ALL PERSONNEL AND EQUIPMENT ARE KEPT CLEAR OF SWING PATH. 11. Using the rope attached to the top of the swingaway, swing the swingaway into place ahead of the boom nose, engaging the anchor fittings (6) with the attach fittings (7) on the left side of the boom nose.

NOTE Step 12 applies only if there is difficulty in aligning the swingaway extensions attach points to the boom nose.

WARNING DO NOT MODIFY THE ATTACH POINTS TO PERMIT THE INSTALLATION OF THE ATTACH PINS. WARNING DO NOT PLACE BLOCKING UNDER THE SWINGAWAY SHEAVE WHEEL. 12. Place blocking under the swingaway nose and relieve the weight of the swingaway by a slight lowering of the boom.

13. Install the attach pins (10) and retainer clips (9) into the anchor (6) and attach (7) fittings on the left side of the boom nose.

14.

Lower the boom and remove the rope from the tip of the swingaway.

NOTE Refer to SETTING THE OFFSET in this Section to obtain a 15 or 30 degree offset with the swingaway.

NOTE Refer to SETTING THE TELESCOPING EXTENSION LENGTH in this Section for extending or retracting the telescoping extension section.

7−8

15. Lower the boom to minimum elevation and remove the cable retainer pins (18) from the tip of the swingaway.

16. Remove the cable roller clip pin (16) and pin (15) from the stowed position on the swingaway and raise the mast assembly (17) to an upright position. Reinstall the pin (15) and clip pin (16). Remove the cable retainer pins from the mast assembly.

17. Route the hoist cable over the center idler sheave on the main boom, over the mast assembly sheave and over the sheave on the swingaway tip. Install all the cable retainer pins.

18.

Rig the hoist cable.

STOWING NOTE The swingaway boom extension must be set at the minimum offset, and if used, the telescoping section must be fully retracted or replaced with the standard nose section in order to be stowed. Refer to SETTING THE OFFSET and / or SETTING THE TELESCOPING EXTENSION LENGTH in this Section.

1.

Extend and set the outriggers. Fully retract the boom and swing the boom over the rear of the carrier.

2.

Lower the boom to minimum elevation.

3.

Remove the cable roller pin (15) and clip pin (16) securing the mast assembly (17) in the upright position. Lay the cable roller over to the stowed position and install the cable roller pin (15) and clip pin (16).

4.

Remove the cable retainer pins (18) from the swingaway tip and remove the hoist cable from the swingaway sheave and boom nose idler sheave. Install the cable retainer pins (18).

5.

Attach a length of rope to the swingaway tip.

6.

Raise the boom to horizontal.

7.

Extend the boom enough so that the swingaway stowage lugs (11) will line up in front of the guide pins (12) and ramp (13) on the stowage brackets when the swingaway is positioned to the side of the boom.

7−9

8.

Ensure the hitch pin (4) and pin (5) are removed from the rear stowage bracket (5).

9.

Remove the retainer clips (9) and attach pins (10) from the anchor (6) and attach (7) fittings on the left side of the boom nose and stow them in the base of the swingaway.

WARNING WHEN STOWING THE SWINGAWAY, ENSURE ALL PERSONNEL AND EQUIPMENT ARE KEPT CLEAR OF THE SWING PATH. CAUTION DO NOT ALLOW THE SWINGAWAY TO SLAM INTO THE STOWAGE BRACKET WHEN SWINGING INTO THE STOWED POSITION. 10. Using the rope attached to the tip of the swingaway, swing the swingaway to the side of the boom.

11. Align the stowage lugs (11) on the swingaway with the guide pins (12) and ramp (13) on the stowage brackets and fully retract the boom.

12. Extend the boom enough to disengage the spring loaded boom extension stop blocks from underneath the front of the mid section.

13.

Disengage the stop blocks and fully retract the boom.

14. Install the hitch pin (4) and pin (5) securing the swingaway to the rear stowage bracket (3).

15. Remove the attach pins (10) and retainer clips (9) from the anchor (6) and attach (7) fittings on the right side of the boom nose and stow them in the base of the swingaway.

WARNING FAILURE TO MAINTAIN THE PROPER CLEARANCE BETWEEN THE SWINGAWAY ANCHOR FITTINGS AND THE BOOM NOSE ATTACH FITTINGS COULD CAUSE THESE FITTINGS TO CONTACT EACH OTHER DURING OPERATION OF THE BOOM. 7−10

16. Extend the boom to disengage the swingaway boom extension from the boom nose and ensure that the spring loaded boom extension stop blocks are engaged between the sections to prevent accidental contact between the boom nose and the swingaway during normal boom operations.

17. Rig the boom nose and hoist cable as desired and operate the crane using normal operating procedures.

SETTING THE OFFSET. WARNING ENSURE ANY BLOCKING MATERIAL USED IS ADEQUATE TO SUPPORT THE WEIGHT OF THE SWINGAWAY WITHOUT TIPPING OR FALLING. 1.

Extend and set the outriggers and swing the boom to over the front. Position the boom to above horizontal.

2.

Block up under the tip of the swingaway base section.

3.

To set the offset from zero (0) degrees to 15 or 30 degrees perform the following procedures.

CAUTION DO NOT OVERLOAD THE SWINGAWAY ANCHOR FITTINGS (6) OR THE SWINGAWAY BASE SECTION (1) WHEN LOWERING THE BOOM. a.

Slowly lower the boom until the pressure is relieved on the pin (19).

b.

Remove the pin (19) securing the offset links in the zero (0) degree offset position. If a 15 degree offset is desired, install the pin (19) in the second hole. If a 30 degree offset is desired, install the pin (19) in the third hole. c.

Slowly elevate and telescope the boom at the same time so that the swingaway does not move off of the blocking until the offset links (20) take the full weight of the swingaway. d.

Reeve the hoist cable over the mast sheave.

4.

To set the offset from 15 or 30 back to zero (0) degrees, perform the following procedures.

7−11

CAUTION DO NOT OVERLOAD THE SWINGAWAY ANCHOR FITTINGS (6) OR THE SWINGAWAY BASE SECTION (1) WHEN LOWERING THE BOOM. a.

Slowly lower the boom until the pressure is relieved from the pin (19).

b.

Remove the pin (19) and lower the boom until the holes for the zero (0) degree offset position align with the offset links. Install the pin (19). c.

Slowly elevate and telescope the boom at the same time so that the swingaway does not move off of the blocking until the offset links (20) take the full weight of the swingaway. d.

Reeve the hoist cable as outlined in step 3d.

SETTING THE TELESCOPING EXTENSION LENGTH. Extending 1.

Extend and set the outriggers and swing the boom to over the front.

NOTE Depending upon how well the swingaway is lubricated, it might be possible to pull the telescoping section to the desired length without setting the offset. If so, skip step 2 and continue with step 4. If it is not desirable to change the offset, perform step 3.

2.

Set the swingaway to maximum offset according to the procedures in SETTING THE OFFSET in this section.

3.

Loosen the side wear pads on the swingaway until the telescoping section is free.

4.

Within the limits of the load charts extend the boom to at least the length of telescoping swingaway to be extended and lower the boom until the swingaway sheave touches the ground or is as low as it will go.

WARNING BEFORE REMOVING THE HITCH PIN (21) AND PIN (22) SECURING THE TELESCOPING SECTION INSIDE THE BASE SECTION ENSURE THE TELESCOPING SECTION CANNOT SLIDE COMPLETELY OUT OF THE BASE SECTION. 7−12

NOTE Use the hoist cable to control the extension of the telescoping swingaway.

5.

Remove the pin (22) and hitch pin (21) securing the telescoping section to the base section.

6.

While controlling the extension of the telescoping swingaway section with the hoist cable, raise and / or retract the boom allowing the section to slide out of the base to the desired length.

7.

Install the pin (22) and hitch pin (21).

8.

If the wear pads were loosened, retighten the wear pads as necessary to ensure the telescoping section is straight with base section.

Retracting.

1.

Carefully hoist in cable until the headache ball or hookblock is almost two − blocked.

2.

Remove the pin (22) and hitch pin (21).

WARNING WHEN USING THE HOIST CABLE TO PULL THE TELESCOPING SECTION INTO THE SWINGAWAY BASE, DO NOT DAMAGE THE HOIST CABLE OR SWINGAWAY BY PULLING THE SECTION PAST ITS FULLY STOWED POSITION. NOTE If it was necessary to loosen the wear pads and to extend the section, it may be necessary to loosen them to retract the section.

3.

Slowly reel in the hoist cable until the headache ball contacts the swingaway sheave.

4.

Slowly reel in the hoist cable pulling the section into the swingaway base until the pin (22) and hitch pin (21) can be installed.

7−13

Erecting and Stowing the Swingaway Boom Extension (Sheet 1 of 2) 7−14

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Swingaway Base Front Stowage Bracket Rear Stowage Bracket Hitch Pin Pin Swingaway Anchor Fitting Boom Attach Fitting Boom Nose Retainer Clip Attach Pin Stowage Lug

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

Front Guide Pins Ramp Boom Extension Stop Mast Pin Clip Pin Mast Assembly Cable Retainer Clip Adjustment Link Pin Offset Link Hitch Pin Attach Pin

Erecting and Stowing the Swingaway Boom Extension (Sheet 2 of 2) 7−15

MAGNET EQUIPMENT General Description − refer to illustration.

The self contained Generating set (1) supplies the electrical power for the magnet (2) via the engine control station (4), control panel (6), magnet control station (3) and reeling drum (5).

Starting and Stopping generator set.

1.

Check fuel level in tank. Access to the tank is by using the ladder positioned against the rear of the counterweight.

2.

Move the battery switch (7) to start. The positions are (i) battery circuits energised and (ii) start against spring pressure. Warning light (8) will illuminate when the switch (7) is turned on. If it illuminates when the engine is running there is a fault in either the alternator or charging circuit.

3.

An oil pressure warning light (10) will illuminate to indicate low oil pressure.

4.

To stop the engine press button (9).

Sequence of Magnet Operation.

1.

Start the generating set.

2.

Select Magnet duties on the LMI.

3.

The magnet is controlled by three push buttons ON (11), OFF (12) and VR (13) voltage reduction. An indicator light (14) will illuminate to indicate when the magnet is ON. The VR (13) button is used when the crane is attempting to lift an overload, when this button is pressed a voltage reduction occurs and subsequently the load will be reduced.

4.

Always make sure the magnet has been lowered on to the load and the lifting chains are slack before the magnet is switched on. This is the way to ensure maximum lift, especially when handling swarf or heavy, medium or fragmentised scrap. Press button (11) to switch the magnet ON. 5.

After completion of crane cycle to drop position, operate OFF button (12) to demagnetize.

6.

Repeat procedure for each cycle.

OPERATION WARNINGS AND PRECAUTIONS. WARNING ON NO ACCOUNT MUST A MAGNET BE USED TO TRANSPORT LOADS OVER AN AREA OCCUPIED BY PERSONS AT WORK OR REST. 7−16

1.

Maximum lift on loose material can only be obtained when the pile of material is sufficient to encompass the complete magnetic field. It is worthwhile making several small lifts to form a large pile in order to obtain a single good lift for main transport.

2.

After switching on the magnet allow approximately 6 seconds for the current to reach maximum value before hoisting. Crane drivers should not switch on before the magnet is lowered on to the load. This procedure does not give maximum lift.

3.

Wait until magnet and load are clear of the scrap heap before increasing hoist speed. A load dragged quickly out of a heap is more likely to be dislodged.

4.

When discharging a load, a slight pause is recommended at OFF before moving into DROP position. This removes a possibility of closing the DROP contactor before the LIFT contactor arcing is fully quenched, and will help to prolong the life of the contact fingers.

5.

The button will need to be held in OFF position for 2 to 4 seconds for full discharge depending on the density of the load.

6.

Many crane drivers form the bad habit of switching on again immediately after releasing the load. This is extremely bad practice and must be strongly discouraged. Lifting magnets are normally rated either for a 50% ON / 50% OFF, or 75% ON / 25% OFF duty. In either case energizing the magnet immediately after releasing a load and keeping it energised for the whole of the return crane journey back to the place of lifting will eventually overheat the magnet and result in premature breakdown. The practice is also bad in that it is wasteful of electricity and reduces the average lifting capacity of the magnet during a working day, since lift reduces as the magnet heats up.

7.

When handling steel slabs or plates, maximum lift will only be achieved when the load covers the complete area of the inner and outer pole shoes.

Reduced lifting capacity will be inevitable if slabs or plates are heavily scaled or otherwise covered with any material able to prevent good physical contact between the magnet and the true magnetic steel face of the load.

8.

Lifting capacity will also be reduced if a plate is bent or buckled in such a way that contact is not being made with the plate over the full magnet pole area.

Care must be taken when handling long thin plates that excessive handling does not result in the plates being in contact with only the centre pole. This does not constitute a safe lift.

9.

When handling a ‘‘raft” of billets, that is a layer of billets lying neatly side by side, a safe lift will generally only be obtained on those billets making contact simultaneously with the centre and outer pole shoes.

7−17

10. Lifting magnets are sometimes used for handling hot slabs approaching red heat. The rate of conduction of heat from the load to the magnet may be comparable or exceed the electrical rate of heating in the coil. To ensure the coil does not attain a temperature above a safe limit for the insulation, the operational cycle must be restricted.

11. Never use the magnet as a ‘‘drop−ball” or ‘‘skull−cracker ball”, ie. never lower it quickly onto a load or steelworks slag, for example, for the purpose of breaking the load into smaller pieces. This practice imposes unnecessary stress on the bumping plate as well as the electrical coil.

12. Never swing the magnet for the purpose of knocking down buildings or shunting railway wagons.

13. Never submerge the magnet in water for retrieving material from soaking pits etc. Water ingress into the coils cavity is one of the most common causes of electrical failure. Every care should be taken to ensure that the magnet remains dry whenever possible.

14. Never allow the magnet to be submerged in water or hosed down for cooling after a prolonged period of operation. This imposes undue stress on the casting and welding and may allow water to penetrate into the coil cavity.

15. When the magnet is not in operation, for example, overnight or at weekends, try to ensure that it is stored above ground level by resting it on a wooden cradle or old rubber tyres. This will reduce the tendency for moisture from wet ground to be drawn into the magnet as it cools. Preferably the magnet should be stored under cover.

16. NEVER DISCONNECT THE PLUG AND SOCKET CONNECTOR WHEN THE MAGNET IS ON. This is a very dangerous practice. The magnet is a source of high inductive energy and if the circuit is broken other than by the proper control gear, many thousands of volts can be generated across the terminals. This can damage magnet insulation and be fatal to the operator making the disconnection.

17. Do keep the power off when not lifting, a magnet gradually heats up due to normal usage; this results in less current being taken and consequently a drop in excitation ampere turns, the outcome being reduced payload.

18. For general scrap work a magnet performs at its best when working on deep stock piles. By doing this, a greater payload is taken as the magnet has a chance to get a good bite.

19. DO NOT SWITCH OFF THE ENGINE WHEN THE LOAD IS SUSPENDED BY THE MAGNET. 20.

7−18

Do not use the magnet for compacting material.

PICK AND CARRY DUTIES WITH MAGNET. 1.

The boom must be centred over rear of the machine with swing lock engaged and load restrained from swinging.

2.

Travel speed is up to 4 kph with loads within the lifting capacity chart with Magnet.

3.

Travel speed should be reduced to creep speed of 1.6 kph for capacities close to maximum ratings and movement not over 61m in any 30 minute period.

MAINTENANCE. 1.

Regular inspection of cable condition is essential. Examine all connections and glands at least once a day.

2.

Check condition of cable drum, slip rings and brushes at least once a month.

3.

Check insulation resistance between magnet terminals and magnet shell (with supply cable removed) at least once a month. Any value over 2 megohms is satisfactory.

Before despatch all magnets are subject to a flash test of 2000 volts rms A.C. for 1 minute between terminals and shell.

NOTE An earth terminal is provided in the terminal box. Most D.C. supplies are isolated from earth. If a 3 core cable is adopted, the earth lead may be used for earth leakage monitoring.

4.

When cold the magnet current should agree with the nameplate marking, (inside the terminal box lid). After several hours operation a drop of approximately 30% may be expected.

5.

Ensure that the terminal box lid is always securely fixed in position. This is an item which is surprisingly often ignored. Absence of the lid affords easy entry for water into the terminal box with resultant lowering of terminal installation and possible tracking between terminals.

6.

Check the operation of all control gear, in particular the contactor bringing in the discharge resistor. Examine all contacts; ensure they are clean, not pitted and that arcing during switching is promptly quenched. Clean or renew contacts as necessary.

7−19

7.

At least once a week, check that the tie bolts securing the centre pole shoe are tight. Examine the pole shoes for wear and replace if necessary.

NOTE The lifting capacity of the magnet when handling scrap will not be impaired by the loss of the centre pole shoe. It is not unknown, in a badly organised workplace, for a crane driver to be unaware that he is operating without a centre pole shoe, excessive wear having caused it to drop off. Continued operation in this condition is likely to cause considerable damage to the coil; at the very least the bumping plate is sure to be so distorted as to make replacement essential.

On magnets having a bolted outer pole shoe, check the tightness of the bolts at least once a week.

8.

After a long period of operation and excessive wear on the outer pole shoes, the centre pole shoe may be proud of the outer. This will result in a reduction in lift when handling flat loads, eg. plates. Re−machining the poles level is the only remedy.

9.

On “all welded” and partially welded magnets, examine all welding at least once a month, particularly that securing the outer pole to the shell. If any cracks appear, the weld should be ground off and new weld deposited.

10. At least once a month, examine the sling chains including the egg link or ring and the hardened bushes in the magnet lifting lugs. Replace whenever excessive wear is evident.

Graphite is recommended as a lubricant; grease retains grit, causing greater wear.

11. The manganese bumping plate is a hard wearing durable item. Nevertheless, occasional inspection is advised to ensure early detection of distortion or (rarely) cracking.

12. The cable drum rotates on sealed ball races and the springs are pre− packed with grease on assembly and do not require any further attention.

Brush pressure should be checked every 6 months and adjusted when necessary to maintain a positive contact with the slip rings.

13.

7−20

For maintenance of the engine refer to the Deutz Operators Handbook.

5

A

2

A

10

8 IGN

9

11

OIL ENGINE STOP

14 ON

13 ON

V/R

12

OFF

3

START

LIFTING MAGNET

MAGNET CONTROL STATION (MOUNTED ON TOP OF CONSOLE AT LHS)

7 DIESEL ALTERNATOR

4

ENGINE CONTROL STATION (MOUNTED ON RHS CONSOLE)

6

1

SECTION ‘AA’ 7−21