Grove Crane AT 633B SUPERSTRUCTURE OPERATOR’S AND SAFETY HANDBOOK MANUAL

OPERATOR’S AND SAFETY HANDBOOK

AT 633B SUPERSTRUCTURE S/N_________________________

PUBLISHED: OCTOBER 1990

LIST OF EFFECTIVE PAGES

ii

Page Numbers

Change In Effect

Title Page thru xv 1−1 thru 1−9 2−1 thru 2−64 3−1 thru 3−15 4−1 thru 4−31 5−1 thru 5−21 6−1 7−1 thru 7−22

Original Original Original Original Original Original Original Original

Page Numbers

Change In Effect

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 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.

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Date Entered

Entered By

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iv

WARRANTY THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, MADE BY EITHER THE DISTRIBUTOR OR THE MANUFACTURER ON NEW GROVE EQUIPMENT, EXCEPT THE MANUFACTURER’S WARRANTY AGAINST DEFECTS, MATERIAL AND WORKMANSHIP SET OUT BELOW: NEW EQUIPMENT WARRANTY “The Manufacturer warrants each new product made by the Manufacturer to be free from defects in material and workmanship, its obligation and liability under this warranty being limited to replacing free of charge at its factory, any part proving defective under normal use and service within six (6) months from the date of initial sale, lease or rental, providing the equipment is on record with the Manufacturer as being installed by the distributor. If the machine is not on record as being installed by the distributor, the Manufacturer will consider the date of shipment from the factory as the date of initial sale, lease or rental. This warranty is in lieu of all other warranties, express or implied and the obligation and liability of the Manufacturer under this warranty shall not include any transportation or other charges or the cost of installation or any liability for direct, indirect or consequential damages or delay resulting from the defect. Any operation beyond rated capacity or the improper use or application of the product or the substitution upon it of parts not approved by the Manufacturer shall void this warranty.

This warranty covers only the products of Grove Manufacturing Company. The products of other Manufacturers are covered only by such warranties as are made by their Manufacturers.”

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY OTHER OBLIGATIONS OR LIABILITY ON THE PART OF THE MANUFACTURER, AND GROVE MANUFACTURING COMPANY NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH SUCH EQUIPMENT.

v

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 be for 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 vi

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. vii

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 operator‘s to visit our works for instruction and training. For details write to Training Office, Grove Cranes Sunderland, SR3 3XR. 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.

viii

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.

ix

TABLE OF CONTENTS Page

SECTION I GENERAL INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1 LIST OF SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−2

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 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−62 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−64

SECTION III DESCRIPTION GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 MAJOR COMPONENTS AND SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 Hydraulic System 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3 Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3 Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3 Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Main Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 x

Page Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Outrigger System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Swingaway Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 CAB CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Battery Circuit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Rear Wheel Steering Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Alternator Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Engine Distress Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Gearshift Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Cab Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Axle Suspension Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Boom Fourth Section Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Differential Lock Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Outrigger Selection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Rear Steering Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Low Fuel Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Axle Suspension Lock Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Hoist Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Free Slew Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Engine Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Slew Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Gearshift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Control Lever−Telescope/Slew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Control Lever−Hoist/Derrick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Accelerator Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Footbrake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Slew Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Steering Column Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Roof Windscreen Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 xi

Page Slew Speed Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duties Derate Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoist Drum Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windscreen Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3−11 3−11 3−11 3−12

SECTION IV OPERATING PROCEDURES PRE−STARTING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Signal and Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Foot and Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 . . Hydraulic Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Hookblock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Swingaway Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3 Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−4 Idling the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−4 Racing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5 CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5 CRANE TRAVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6 Traveling − General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6 Moving the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−8 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−9 Inter Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−15 Control Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−15 Preload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−16 USING YOUR LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−16 CRANE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−18 Setting the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−18 Extend the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−19 Retract the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−20 Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−24 xii

Page Elevating and Lowering the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−25 Elevating the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−25 Lowering the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−25 Telescoping the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−26 Extending the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−26 Retracting the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−27 Lowering and Raising the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−27 Lowering the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−28 Raising the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−28 Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−28 OPTIONAL EQUIPMENT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−29 Diesel Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−29 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−29 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−29 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−29 Propane Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−30 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−30 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−30 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−30

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

SECTION VI OPERATIONAL AIDS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1 LOAD MOMENT INDICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1 ANTI−TWO BLOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1

xiii

Page

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−8 POWER POSTIONED EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−11 Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−11 Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−11 MAN CARRYING BASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−15 Erecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−15 Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−16 Dismantling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−16 FLY JIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−19 Mounting the Fly Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−19 Dismounting the Fly Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−19 FLY JIB STOWAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−21

LIST OF FIGURES Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−7 Dimension Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−10 Cab Controls and Indicators (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . 3−13 Cab Controls and Indicators (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . 3−14 Cab Controls and Indicators (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . 3−15 Terms to Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−17 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−19 Lubrication Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−20 Lubrication Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−21 Installing Cable Anchor Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−2 Erecting and Stowing the Swingaway Boom Extension . . . . . . . . . . . 7−10 Extend and Retract the Power Positioned Ext(Sheet 1 of 2) . . . . . . . 7−13 Extend and Retract the Power Positioned Ext(Sheet 2 of 2) . . . . . . . 7−14 xiv

Page

LIST OF FIGURES (continued) Erecting the Man Carrying Basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−18 Fly Jib Erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−20 Fly Jib Stowage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−22

xv

SECTION I GENERAL INTRODUCTION This Handbook provides information for the operators of the Model AT633B Series Grove Crane.

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

The all terrain crane incorporates an all welded steel frame, using planetary drive axle to provide four−wheel drive. Axle steering is accomplished utilising hydraulic steer cylinders. The engine is mounted at the front of the crane and provides motive power through a 8 speed gearbox. Hydraulic sliding beam outriggers are integral with the carrier frame.

Suspension is provided by leaf springs with shock absorbers all round. Hydraulic axle lockout for on ‘rubber’ crane operation.

The superstructure is capable of 360 degrees rotation in either direction.All crane functions are controlled from the fully enclosed cab mounted on the superstructure. The crane is equipped with a four section boom, either 3 sections fully powered and a 4th section power positioned extension, or a 4 section fully powered boom. Additional reach is obtained by utilising an optional lattice extension (swingaway) and a fly jib (stinger section), lifting is provided by a main hoist and an optional auxiliary hoist.

NOTE Throughout this handbook, 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AT633B. Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . See Load Chart in cab Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 x 4.

Gross Weight . . . .

See lifting and transportation decal on cab door CAPACITIES (US Gallons/ Litres).

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 gallons (267 litres) Engine Lubrication System . . . . . . . . . . .

See Engine Specifications.

Hydraulic Tank (Reservoir Capacity) . . . . . .

110 gallons (418 litres) Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 gallons (11.5 litres) Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.73 galls (2.75 litres) Axle Planetary Ends . . . . . . . . . . . . . . . . . . . . . . 0.4 gallons (1.5 litres) Transmission and Torque Convertor . . . . . . . . .

5 gallons (19.0 litres) FIRE EXTINGUISHER. Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 BC Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.75 lbs (1.25 kg) TRANSMISSION. Speeds . . . . . . . . . . . . . . . . . ......................... ......................... ......................... .........................

Low range . . . . . . . . . . . . . High Range 9.94 . . . . . . . . . . . . . . . . . . . . . . . . . . 4.02 5.16 . . . . . . . . . . . . . . . . . . . . . . . . . . 2.09 2.98 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 1.84 . . . . . . . . . . . . . . . . . . . . . . . . . . 0.74

WHEELS AND TYRES. Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

480lb/ft (650 nm) For roading and lifting pressures, see the Tyre Inflation decal in the cab for various tire sizes and lifting pressures.

BRAKES. Type . . . . . . . . . . . . . . . . . . . . Front . . . . . . . . . . . . . . . . . .

Single Air . . . . . . . . . . . . . . . . . . . . . . . . . Rear . . . . . . . . . .

Single Wedge Air HYDRAULIC PUMP TRIPLE. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 GPM . . . . . . . . . . . . . . . . . . . . . . . .

1−45gpm (170 lpm), 1−39.7 gpm ......................

(150lpm),1−19.8gpm (75lpm) @ 2500 rpm 1−2

SWING MOTOR. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Orbit Displacement . . . . . . . . . . . . . . . . . . .

6.2cu.in (101.6 cu.cm) per rev SWING GEARBOX. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Reduction Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.98:1 BOOM. Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . −2 to +77 Optional Extensions . . . . . . . . . . . . . . . . .

24ft 6in (7.5m) Swingaway HOIST Grove Model HO−15F−20G Drum Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 inch (30.5 cm) Drum Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 inch (51 cm) Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13mm Cable Capacity . . . . . . . Useable . . . . . . . . . . . . . . . . . 365 feet (111 m) Stowable . . . . . . . . . . . . . . . 460 feet (140 m) Permissilble Line Pull . . . . . . . . . . . . . . Refer to Line Pull and Reeving Information Chart in the cab COUNTERWEIGHT Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bolt on Weight . . . . . . . . . . . . . . . . . . . .

(See Axle Weight Distribution Chart) OUTRIGGERS. Type . . . . . . . . . . . . . . . . . . . . .

Double Box Beam with Vertical Jack Extended Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18.0ft(5.5m) Retracted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8ft 2in(2.5m) AIR HYDRAULIC SWIVEL Air Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.

10.

ELECTRICAL SYSTEM. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single wire Ground.

System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24.

Starting Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(4.8kw) 24.

Alternator . . . . . . . . . . . . . . . . Rating . . . . . . . . . . . . . . . . 24v x 27amps.

CAB HEATER(S) Carrier.

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal Combustion.

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diesel.

Superstructure Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal Combustion.

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diesel.

1−3

ENGINE SPECIFICATION STANDARD ENGINE MAKE & MODEL

TYPE

BORE STROKE DISPLACEMENT GOVERNED RPM TORQUE (NET) COMBUSTION SYSTEM LUBRICATION SYSTEM WEIGHT

Deutz F6L413FR

6 CYLINDER,4 CYCLE Naturally Aspirated Air Cooled Diesel 4.92in (125mm) 5.12in (130mm) 9572 cm3 @ 2500rpm 2500 452lbs.ft (610NM) @ 1600 RPM Direct Injection 5.1 US galls (19.2L) 790 Kg

OPTIONAL ENGINE MAKE & MODEL TYPE

BORE STROKE DISPLACEMENT GOVERNED RPM TORQUE (NET) COMBUSTION SYSTEM LUBRICATION SYSTEM WITH FILTER CHANGE WEIGHT

1−4

Deutz BF6L513FR 6 CYLINDER,4 CYCLE Turbo Charged Air Cooled Diesel 4.92in (125mm) 5.12in (130mm) 9572 cm3 @ 2500rpm 2500 448lbs.ft (608 Nm) @1600 RPM Direct Injection 5.8 US galls (22L) 895Kg

SLINGING POINTS When it is required to lift a machine for shipment, rigging personnel shall be responsible for proper selection and placement of all slings and load handling devices. They must verify all dimensions as required for clearance and weight of machine of lifting.

Partially extended outriggers are used as lifting points.

The following procedure must be adhered to:− 1.

Ensure the parking brake is applied and the slew lock pin engaged with the Superstructure in line with the Carrier.

2.

Extend all four outrigger beams (approximately 12” (30.5cm).

3.

Use two spreader beams which are long enough to span the width of the machine and sufficient to give clearance to the machine for a vertical lift.

4.

The spreader beams to be positioned above the height of the machine and slings attached to the outrigger beams and the spreader beams as shown.

5.

The slings must be selected to suit the C of G to give a level lift.

WARNING DO NOT SLING ANY OTHER PART OF THE MACHINE FOR THIS OPERATION, OTHERWISE STRUCTURAL DAMAGE MAY OCCUR. ALWAYS ENSURE THAT SUITABLE DUNNAGE IS USED BETWEEN THE SLINGS AND THE OUTRIGGER BEAMS TO ENSURE THAT NEITHER THE SLINGS NOR THE BEAMS ARE DAMAGED DUE TO ABRASION BETWEEN THE SLINGS AND THE SHARP EDGES OF THE BEAMS.

1−5

SLINGING POINTS 1−6

AXLE WEIGHT DISTRIBUTION CHART POUNDS DESCRIPTION

Axle Loads Max Tyre Loads Allowed Carrier 4 x 4 Superstructure Boom 29.9ft−3 Section+4th Section power positioned Boom with all sections fully powered Counterweight 1,500 kg Counterweight 500 kg Complete Basic Machine (including: 4 x 4 Chassis with Deutz F6L413FR Engine: Kessler Front and Rear Axles 1400 x 24 Tyres:Clark Transmission: Grove HO15F−20G Main Hoist with 460ft of 1/2” Cable:Idler & Follower and full Hydraulic Tank With Fully Powered 4 Section Boom ADD Full Fuel Tank Spare Wheel stowage Spare Wheel Extra for 17.5 x 25 Tyres Extra for Spare Wheel17.5 x 25 Extra for 16.0 x 25 Tyres Extra for Spare Wheel 16.0 x 25 Hookblock Multifall (Stowed) Hookblock Multifall (Bumper) Hookblock 3 Fall (Stowed) Swingaway Extension and Stowage 6m Fly Jib (Stinger) Stowed

KILOGRAMS

GROSS LBS.

FRONT LBS.

REAR LBS.

GROSS KG.

FRONT REAR KG. KG.

51,592

26,008

25,584

26,023 5,734

13,316 4,876

11,802 2,832

6,039 5,763 2,408 −424

10,648 11,336 3,027 1,012

−847 −998 4,305 1,600

5,258 5,598 1,500 500

−418 −493 2,126 790

5,258 6,091 −626 −290

47,363 48,051

22,903 23,751

23,460 23,389 23,751 23,729

11,804 11,729

11,585 12000

220 84 561 154 38 956 239 830 830 304 1,187 608

77 −37 −373 77 −18 478 −115 960 1,460 350 −415 318

143 121 832 77 56 478 354 130 −630 −46 1,602 290

100 38 277 76 19 472 118 410 410 150 586 300

35 −17 −184 38 −9 236 −57 474 721 173 −205 157

65 55 411 38 28 236 175 −64 311 −23 791 143

203

0

203

100

0

100

1,316

−28

1,288

−650

−14

−664

11,797

11,605

SUBSTITUTE: Deutz BF6L513FR Engine REMOVE: Lift Cylinder

1−7

AXLE LOADING SPEED RESTRICTION CHART CAUTION MAXIMUM SPEED GIVEN FOR EACH CONDITION LISTED BELOW MUST NOT BE EXCEEDED

SPECIFICATION

COUNTER− AXLE LOADING FRONT REAR WEIGHT AXLES

AXLES

MAXIMUM SPEED KPH

2.0T

12.0T

12.0T

70

2.0T

12.75T

13.0T

65

A 4 X 4 drive,16.00 x 25 tyres 8.95 − 27.45m boom, 2 tonne counterweight. No swingaway’ fly jib, hookblocks or sparewheel

B As (A), plus swingaway, multifall, 3 fall and single fall hookblocks and spare wheel

1−8

11500mm (37ft 9in) 3715mm (12ft 2in)

Ground Clearance 370mm (1ft 2in)

1220mm (4ft)

1550mm (5ft 1in)

2600mm (8ft 6in)

3400mm (11ft 2in) 3260mm (10ft 8in) 8450mm (27ft 9in)

5170mm 570mm (16ft 11in) (1ft 10in) 3050mm (10ft)

Tailswing 3310mm (10ft 10in) 5500mm (18ft)

2500mm (8ft 2in)

4150mm Outreach (13ft 7in)

3730mm (12ft 3in)

3000mm (9ft 10in)

5860mm (19ft 2in) Kerb to kerb clearance radius 2−wheel steer 8400mm (27ft 6in) 4−wheel steer 4800mm (15ft 9in)

Dimensions refer to machine with standard tyres

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.

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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.

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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.

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

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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.

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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.

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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.

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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.

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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.

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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.

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OPERATING PRECAUTIONS

WARNING

IT IS DANGEROUS TO OPERATE ANY CRANE MOTIONS, WITH OR WITHOUT LOADS, WITH THE OUTRIGGERS IN THE STOWED POSITION EXCEPT WHEN OPERATING ’FREE ON WHEEL DUTIES’.

THEREFORE THE OUTRIGGER BEAMS MUST BE FULLY EXTENDED AND THE CRANE SUPPORTED USING THE OUTRIGGER JACKS ON A FIRM, LEVEL AND UNIFORMLY SUPPORTING SURFACE. THE CRANE MUST BE ACCURATELY LEVELLED, USING THE OUTRIGGER JACKS BEFORE CRANE OPERATION. THE TABULATED CAPACITIES SHOWN ON THE DUTY PLATE IN THE OPERATORS CAB ARE VALID ONLY IF THE CRANE IS BLOCKED ACCORDINGLY. WHEN OPERATING ’FREE ON WHEEL DUTIES’ THE MACHINE MUST BE ON A FIRM, LEVEL AND UNIFORMLY SUPPORTING SURFACE WITH THE TYRES INFLATED TO THE CORRECT PRESSURE AND AXLE LOCKS ENGAGED. OPERATION MUST ONLY BE WITHIN LIMITS OF RADIUS OR ANGLE AND SLEWING LIMITS STATED ON THE DUTY PLATE IN THE OPERATORS CAB.

Over front capacities must only be lifted within a maximum slewing angle of 2.5% either side of the crane centre line when operating ’free on wheel’, and valid only up to a creep speed of 5km/h.

Free on wheel static capacities for 1600 and 1750 tyres are also valid for 2km/h use if the inflation pressures are raised, see table in crane cab. The tyres must be returned to original pressure for highway travel.

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WARNING FOR PICK AND CARRY DUTIES ALWAYS TRAVEL WITH THE BOOM OVER THE REAR OF THE CHASSIS, WHERE POSSIBLE WITH THE BOOM TELESCOPED IN AND THE OUTRIGGERS EXTENDED AND JACKS JUST CLEAR OF THE GROUND. The crane duty tables allow for wind speed of 45 km/h on the crane structure but make no allowance for the effect of the wind on the load.

The crane is designed and manufactured for high load derricking capability. It is safe to attempt to derrick any load.

When lifting the safe working load for a given laden boom angle with the boom extended to the maximum length of the telescoping range, the maximum radius quoted for that laden boom angle must not be exceeded.

Capacities shown on the duty plate must not be derricked below 15− boom angle.

If a hookblock, is fitted to the main boom, the lattice extension/fly jib capacities must be reduced by the weight of the hookblock.

When the fly jib together with lattice extension is fitted in the operating position, main boom capacities MUST be reduced by 1150kg (1.15 tonne).

When lifting with power positioned extension and/or lattice extension or fly jib fitted and when main boom is NOT FULLY EXTENDED, capacities are determined by the laden boom angle given and NOT BY RADIUS. Radii quoted refer only to fully extended booms.

The boom MUST be fully retracted if a Lattice Extension Fly jib is fitted in the operating position when the boom angle is LESS than the minimum angle shown on the duty plate.

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HYDRAULIC SYSTEM WARNING THE HYDRAULIC SYSTEM ON THIS MACHINE SHOULD NOT BE TAMPERED WITH BY PERSONS WHO HAVE NOT BEEN TRAINED IN THE FUNCTIONS OF THE VARIOUS VALVES ASSOCIATED WITH THE CIRCUIT. EVEN WITH THE ENGINE STOPPED, BECAUSE OF THE USE OF COUNTERBALANCE AND LOCK VALVES, MANY COMPONENTS OF THE CIRCUIT MAY STILL BE IN A LOADED CONDITION. UNDER NO CIRCUMSTANCES SHOULD THE CIRCUIT BE BROKEN WITH AN ELEVATED BOOM OF WITH A LOAD SUSPENDED FROM THE HOOK.

2−64

SECTION III DESCRIPTION GENERAL. All crane functions are either electrically or hydraulically controlled and operated from the superstructure cab. 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 or from a remote control panel on either side of the carrier. In addition to the normal craning functions, control for driving the crane on the job site are also located in the superstructure cab.

MAJOR COMPONENTS AND SYSTEMS. CAB ASSEMBLY. The superstructure cab contains all of the controls and indicators necessary for craning operations and traveling on the job site and parking functions.

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 tinted safety glass window. The latch handle on the door must be used to both open and close the door. A lock is installed in the cab door to provide a means of locking the cab. Grab handrails are provided beside the door opening to aid the operator in getting into 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 on the window maintains the window in a closed and locked position.The cab has a skylight with a tinted safety glass window. The skylight is available as a stationary window or as an opening window. The opening skylight is held shut by two latches and hinges to the side when open. 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. The armrests 3−1

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, in addition, are also adjustable fore and aft to maximize operator comfort. Incorporated within 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 10BC rated, 2.75 pound (1.2 kg) dry type fire extinguisher is mounted in the cab in front of the operator’s seat on the floor.

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 push−pull control on the front console. A windshield washer system is also installed to spray a cleaning solution onto the windshield. It consists of two nozzles and a washer solvent container and pump assembly. The nozzles are located on each side of the wiper arm and the washer solvent container and pump assembly is mounted beneath the cab floor. The electric pump draws the solution from the washer solvent container and supplies it through a hose to the two nozzles that spray it onto the windshield. The washer solvent container can be refilled from inside the cab through an access hole in the left side of the cab floor.

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 the acc or on position, 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 volume for simultaneous operation of various crane functions.

Reservoir.

The reservoir, attached to the right side of the carrier frame, has a total capacity of 110 gallons (418 liters) including the air space. The all−steel reservoir has an internally mounted full−flow filter and integral baffles that help cool the oil and prevent oil foaming.

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 fan, and an electric motor.

The fan draws cool air through the cooling fins on the cooler.

3−2

A temperature switch installed in the return manifold controls the operation of the fan motor. When the temperature of the oil reaches 120 degrees F (48.8degrees C) the switch’s contacts close and energize the fan motor relay to actuate the fan motor.

Pumps and Disconnects.

The hydraulic pumps and their accompanying disconnects are mounted on drive pads on the torque converter.With the disconnects engaged and the engine and torque converter operating, the pumps provide oil to the hydraulically operated components.

The hydraulic pump is a gear−type pump, consisting of three sections. The pump provides a combined flow of approximately 105 gpm ( 395 lpm).

Directional Control Valves.

The directional control valves are four−way, three position, pilot operated 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 valve contains an integral load check valve to prevent back sliding of components which support heavy loads. Each bank contains a main relief valve, and additionally, certain crane functions are also protected by a circuit relief valve.

TURNTABLE ASSEMBLY AND SWING MECHANISM. An anti−friction ball bearing supports the superstructure on the carrier and allows 360 degrees of continuous rotation (swing) in either direction. Swing is accomplished by a hydraulically−driven motor driving a gearbox which in turn drives the ball bearing. A free−swing, 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 swing lock is provided.

Swing Motor.

The hydraulic swing motor is a low speed, high torque type. 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 of approximately 2.3 rpm.

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 3−3

superstructure cab through use of the swing brake foot pedal and the swing brake control valve.

BOOM ASSEMBLY. The boom assembly is a four section, full power,sequenced and synchronized, 29.5 to 90 foot (8.95 to 27.45 m) boom.For boom extension and retraction, the boom uses two sequenced telescope cylinders for the mid sections plus cable synchronization for the extension and retraction of the fly section. Boom lift is provided by a single lift cylinder and boom elevation is from −2 degrees to +77 degrees.

An optional auxiliary boom nose (rooster sheave) is available for the boom to simplify single part cable usage. The rooster sheave is installed on the main boom nose and is secured by pins that pass through the rooster shave and the main boom nose.

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.

STEERING SYSTEMS. The crane is equipped with two steering systems. One system is for roading the crane from the carrier cab and the other system is for craning operation from the superstructure cab.

OUTRIGGER SYSTEM. The outriggers are integral with the carrier frame and can be controlled from the superstructure cab or remotely from controls at either side of the carrier. 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 it’s maximum load capacity. Integral check valves and floats are standard equipment. A sight level bubble indicator is located in the superstructure cab and at each remote control station to ensure crane leveling.

ELECTRICAL SYSTEM. The electrical system is 24 VDC operation with 24 volt starting, consisting of an alternator and lead−acid batteries which are series−parallel connected. The system is the single wire−ground return type, utilizing the cranes’ structure as ground.

3−4

OPTIONAL EQUIPMENT SWINGAWAY BOOM EXTENSIONS An optional boom extension is available to obtain additional boom reach,it is a 24ft 6in(7.5m)swingaway The boom extension mounts directly to the boom nose utilizing a four point attachment HEATER The heater is located beneath the cab.The fuel tank is located on the rear of the cab.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

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 1.Battery Circuit Switch The switch positions are:− 1.OFF − and turning clockwise. 2.BATTERY CIRCUIT ENERGISED. 3.ENGINE START − against spring pressure.

When the switch is turned to position 3 and released it returns to position 2.

The engine cannot be started unless gearshift is in NEUTRAL position in both cabs.

2.Rear Wheel Steering Switch This spring loaded to OFF (centre) switch provides independent control of the steering functions of the rear axle. It is used in conjunction with the steering wheel to complete the alternative steering functions shown on the switch decal.

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For CRABBING movements, the wheels on both axles must be turned in the same direction whereas for REDUCED turning circle movements the wheels on one axle are turned in the opposite direction to the other.

To operate, select and hold switch as required then turn steering wheel accordingly. It is important to note that the rear wheels will turn until switch is released WARNING THE P.T.O. MUST BE ENGAGED AND THE REAR AXLE STEERING LOCK DISENGAGED BEFORE USING REAR AXLE STEERING FUNCTIONS 3.Warning Horn Press button to sound horn.

4.Alternator Warning Light (Red) This light will illuminate when the battery circuit switch (1) is turned on and the engine is stationary. If the lamp illuminates when the engine is running there is a fault in the alternator or charging circuits.

5.Engine Distress Light (Red) This light illuminates in the event of low oil pressure, high engine temperature or snapped vee belts. Stop the engine immediately, ascertain cause and rectify the fault before continuing operations.

6.Gearshift Warning Light (Green) With the battery circuit switch (1) turned ON, this light will illuminate when the Chassis/Superstructure change over switch in the chassis cab has been switched to superstructure control.

7.Cab Heater Switch This is a three position, centre OFF rocker switch which controls the cab ventilation and heating systems. Press top of switch for fresh air ventilation; press bottom of switch for cab heating. The switch is illuminated when HEAT position is selected and the heater is operating.

8.Axle Suspension Lock Switch This switch controls the axle locks on both axles. The locks are engaged by holding down the symbol (bottom) side of the switch until the engaged light (22) illuminates. To disengage the locks press the top part of the switch until fully disengaged.

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The locks must be engaged before undertaking FREE ON WHEELS craning duties on site. When preparing the crane for ROAD TRAVEL the locks must be DISENGAGED (warning light extinguished).

WARNING THE AXLE LOCKS MUST BE ENGAGED BEFORE SLEWING OVER THE SIDE WHEN ON TYRES 9.Boom Fourth Section Switch − Optional Under normal conditions with this switch in the off position movement of lever 31 forward or backward will cause the second and third synchronised sections to extend or retract. However, when this switch is in the on position, movement of lever 31 will cause the non−synchronised fourth section to extend or retract.

10. Differential Lock Switch This switch control the engagement and disengagement of the differential lock in the front and rear axles. The tractive effort of the crane is considerably improved when the locks are engaged.

It is intended to be engaged for TRAVELLING ON SURFACES THAT OFFER ADVERSE WHEEL GRIP. The locks should preferably be engaged when the crane is STATIONARY but may be engaged when moving if:− 1.the crane is moving very slowly or − 2.the wheels are NOT SPINNING at the same time of engagement.

When travelling with the locks engaged do not deviate from a straight path more than is necessary. Disengage the lock immediately conditions are suitable.

DO NOT TRAVEL WITH THE LOCK ENGAGED ON A SURFACE THAT PROVIDES GOOD WHEEL ADHESION. Outrigger Selection Switches 11.Right Hand Rear 12.Left Hand Rear 13.Right Hand Front 14. Left Hand Front 15.Beam/Jack 16.Extend/Retract For operational use of switches 11 to 16 inclusive refer to OUTRIGGER CONTROLS in this handbook.

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17.Rear Steering Warning Light (Red) Illuminates when the rear axle steering system is unlocked from the chassis cab. For road travel operations, the wheels must always be centralised and locked 18.Low Fuel Warning Light (Red) Illuminates when engine fuel tank level is LOW (approximately 42 litres − 9 gallons).

19.Spare Aperture May be used for optional equipment.

20.Spare Aperture May be used for optional equipment.

21.Spare Aperture May be used for optional equipment 22.Axle Suspension Lock Warning Light (Red) Illuminates only when ALL the axle locks are engaged, operated by switch (8).

23.Hoist Boost Engaging this switch will provide boost hoist speed on the main hoist barrel. Use this switch in conjunction with the control lever (32) only when LIGHT LINE LOADS are being handled or when hoisting/lowering an unloaded hook.

24.Free Slew Switch Depress this switch to select FREE SLEW condition with the brake controlled by foot pedal (36). For automatic operation of the slew brake, return the switch to NORMAL SLEW position.

WARNING THIS SWITCH MUST BE RETURNED TO NORMAL SLEW AFTER FREE OPERATION. DO NOT VACATE THE CAB WITH SWITCH IN FREE POSITION. 25. Engine Stop This is a spring biased to OFF switch which is used to stop the Engine. Turn the Battery circuit switch (1) to the OFF position to disconnect the electric supply to this switch.

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26.Override Switch Two conditions may arise in operation which will result in safety devices rendering the crane inoperative. These are: Hoist Motion: If the hoist motion is operated to its over lower limit, the switch activates the motion cut dump valve which dumps hoist lower. Move lever to hoist raise to restore hoist motion within its limits.

The overhoist limit (anti−two block) switch operates the motion cut dump valve.

It is then necessary to operate the ’hoist lower’ motion to restore the crane to normal operating conditions.

WARNING THE MOTION CUT OVERRIDE SWITCH MUST ONLY BE USED FOR SERVICING THE CABLE AND NOT FOR ANY OTHER PURPOSE. 27.Slew Lock Pin Used to lock the superstructure and prevent it slewing on its own accord on uneven ground conditions, wind pressure and the like. The pin should always be engaged except when using the slewing motions.

It is raised or lowered by the handle and is held in the selected position by a projection which engages in slots in a bracket. To lock, turn pin and lower into position.

28.Fuse Box Houses the fuses beneath removeable cover which protect the electrical circuits. The audible warning device is located adjacent to the fuse box.

29.Parking Brake Control To apply the parking brake pull knob fully. Push the knob down to release the brake. The control may also be used for emergency application of the brake.

30.Gear Shift Lever Refer to carrier handbook for shift pattern and procedures.

WARNING THE GEARSHIFT LEVER IN BOTH CABS MUST BE IN NEUTRAL POSITION BEFORE ENGINE CAN BE STARTED. 3−9

31.Control Lever When moved from centre (OFF) position, this lever controls the boom telescoping and slewing motions as under.

TELE OUT− move lever FORWARD SLEW RIGHT− move lever to RIGHT

TELE IN− move lever BACKWARD SLEW LEFT− move lever to LEFT

The speed of a motion is proportional to lever movement and the use of pedal (33). Refer to publication CRANE CONTROLS in this manual for further information.

If ’motion cut’ occurs due to an overload condition arising when telescoping OUT, reverse the lever to restore the crane to a safe condition.

31A. Tactile Display Button This button fitted in the top of the control lever (31) pulses to indicate the speed of the auxiliary hoist drum rotation.

32.Control Lever When moved from centre (OFF) position, this lever controls the hoisting and derricking motions as under: HOIST LOWER − move lever to FORWARD HOIST RAISE − move lever BACKWARD DERRICK OUT − move lever to RIGHT DERRICK IN − move lever to LEFT The speed of a motion is proportional to lever movement and the use of pedal (33). Obtain FAST speed on HOIST motion by selecting switch (23). Refer to publication CRANE CONTROLS in this manual for further information.

If ’motion cut’ (optional) occurs due to an overload condition arising with either hoist RAISE or derricking OUT motion engaged, reverse the lever to restore the crane to a safe condition.

32A. Tactile Display Button This button fitted in the top of the control lever (32) pulses to indicate the speed of the main hoist drum rotation.

33.Accelerator Pedal This pedal is used to control the engine speed.

34.Accelerator Fluid Reservoir Maintain fluid to level mark. Refer to Lubrication Schedule for approved fluid.

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35.Footbrake Pedal This pedal operates a graduated air valve which applies and releases the service brakes. The braking effect on the road wheels is proportional to the amount of pedal depression.

36.Slew Brake Pedal Depress this pedal progressively to apply the slew brake when FREE SLEW condition is selected by switch (24).

37.Steering Column Lock This foot operated lock is released to permit adjustment of the steering column.

38.Level Indicator This indicator is used to check that the crane is LEVEL prior to and at intervals during craning operations. The crane is level when the bubble is centralised.

39.Roof Windscreen Wiper Switch This switch is located on the motor.

40.Cab Lamp Provides illumination in cab. The switch is integral with lamp.

41.Operators Seat 42.Steering Wheel This is a conventional steering wheel with an integral knob for easy control when manoeuvring. Use the wheel in conjunction with steering switch 2, when required.

43.Slew Speed Control Valve This valve is factory set in the optimum position. Should a different setting be required turn the valve anti−clockwise to decrease and clockwise to increase the slewing speed.

44.Duties Derate Switch − Special Option Use to select 66 2/3% or 100% British Standard Duties. The key can only be removed in the 66 2/3 % position.

45.Hoist Drum Rotation − Optional to 32A Provides visual indication of hoist drum rotation.

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46.Windscreen Wiper Switch Controls the front windscreen wiper.

3−12

27. SLEW LOCK PIN 28. FUSE BOX 29. PARKING BRAKE CONTROL 30. GEAR SHIFT LEVER 31. CONTROL LEVER 31A. TACTILE DISPLAY 32. CONTROL LEVER 32A. TACTILE DISPLAY 33. ACCELERATOR PEDAL 34. RESERVOIR ACCLERATOR 35. FOOTBRAKE PEDAL

36. SLEW BRAKE PEDAL 37. STEERING COLUMN LOCK 38. LEVEL INDICATOR 39. ROOF WIPER SWITCH 40. CAB LAMP 41. SEAT 42. STEERING WHEEL 43. SLEW SPEED CONTROL 44. DUTIES DERATE SWITCH 45. HOIST DRUM ROT. IND.(OPTIONAL) 46. WINDSCREEN WIPER SWITCH

CAB CONTROLS AND INDICATORS (SHEET 1 OF 3) 3−13

YELLOW

19

RED

20

18

21

17

22

11

12

13

15

10

14 16

17. REAR STEER WARNING LIGHT 1. BATTERY CIRCUIT SWITCH 18. LOW FUEL WARNING LIGHT 2. REAR WHEEL STEER SWITCH 19. SPARE APERTURE 3. HORN 20. SPARE APERTURE 4. ALTERNATOR WARNING LIGHT 21. SPARE APERTURE 5. ENGINE DISTRESS LIGHT 22. AXLE SUSPENSION LOCK WARNING LIGHT 6. GEARSHIFT WARNING LIGHT 23. HOIST BOOST SWITCH 7. CAB HEATER SWITCH 24. FREE SLEW SWITCH 8. AXLES SUSPENSION SWITCH 9. BOOM FOURTH SECTION SWITCH 25. ENGINE STOP SWITCH 26. HOIST OVERRIDE SWITCH 10. DIFFERENTIAL LOCK SWITCH OUTRIGGER SELECTOR SWITCHES 11. RIGHT HAND REAR 12. LEFT HAND REAR 13. RIGHT HAND FRONT 14. LEFT HAND FRONT 15. BEAM/JACK 16. EXTEND/RETRACT

CAB CONTROLS AND INDICATORS (SHEET 2 OF 3) 3−14

9 8

23

7

24

6

25

5

26

4 1

2 3

17. REAR STEER WARNING LIGHT 1. BATTERY CIRCUIT SWITCH 18. LOW FUEL WARNING LIGHT 2. REAR WHEEL STEER SWITCH 19. SPARE APERTURE 3. HORN 20. SPARE APERTURE 4. ALTERNATOR WARNING LIGHT 21. SPARE APERTURE 5. ENGINE DISTRESS LIGHT 22. AXLE SUSPENSION LOCK WARNING LIGHT 6. GEARSHIFT WARNING LIGHT 23. HOIST BOOST SWITCH 7. CAB HEATER SWITCH 24. FREE SLEW SWITCH 8. AXLES SUSPENSION SWITCH 9. BOOM FOURTH SECTION SWITCH 25. ENGINE STOP SWITCH 26. HOIST OVERRIDE SWITCH 10. DIFFERENTIAL LOCK SWITCH OUTRIGGER SELECTOR SWITCHES 11. RIGHT HAND REAR 12. LEFT HAND REAR 13. RIGHT HAND FRONT 14. LEFT HAND FRONT 15. BEAM/JACK 16. EXTEND/RETRACT

CAB CONTROLS AND INDICATORS (SHEET 3 OF 3) 3−15

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.

BATTERIES. If the machine is equipped with a standard or low maintenance battery, check each cell for the correct electrolyte level. Add only clean distilled water. Do not over fill. If equipped with a maintenance free battery, check the state of charge indicator if applicable. On all batteries 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.

DAILY LUBRICATION. Make certain that all components requiring daily lubrication have been serviced. (Refer to Section V − Lubrication.

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

Check breather for cleanliness and security.

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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.

HOOK BLOCK. 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.

SWINGAWAY EXTENSION. WARNING FAILURE TO MAINTAIN THE CLEARANCE BETWEEN THE SWINGAWAY ANCHOR LUGS AND BOOM NOSE ANCHOR FITTINGS COULD CAUSE THESE FITTINGS AND LUGS TO COME INTO CONTACT WITH EACH OTHER DURING FULL RETRACTION OF THE BOOM. THIS ACTION COULD RESULT IN DAMAGE TO THE CRANE AND POSSIBLE SERIOU INJURY OR DEATH TO PERSONNEL. Check to ensure there is sufficient clearance between the boom nose anchor fittings and swingaway extension anchor lugs when the boom is fully retracted and the swingaway is properly stowed.

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

ENGINE OPERATION. Starting and shutdown procedures for most diesel engines generally follow the same pattern. Therefore, the following procedures can be applied, except 4−2

where specific differences are noted. (Refer to the applicable engine manufacturer’s manual for detailed procedures.

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. 4−3

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 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.

4−4

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 down hill 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, 4−5

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. TRAVELING − 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.

4−6

CAUTION FOR EXTENDED TRAVEL, CHECK THE COLD TYRE PRESSURE PRIOR TO START. (REFER TO TYRE INFLATION CHART.) REGARDLESS OF AMBIENT TEMPERATURE, AFTER EVERY ONE HOUR OF TRAVEL TIME, STOP AND ALLOW THE TIRES TO COOL OFF FOR AT LEAST A 30 MINUTE PERIOD. THE TIRE 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. 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. 4−7

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. 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 and stowed.

4−8

7.Ensure all four stabilizer floats are properly stowed.

STEERING Hydraulic power assistance is provided on each axle. Hydraulic power to the front axle is provided by a gear pump which is directly coupled to the torque convertor and is therefore energised immediately the engine is running. The normal road travel and ORBITROL steering systems are then operative.

Hydraulic power to the rear axle is obtained from the main hydraulic pump which is driven by a power take−off on the torque convertor, therefore assistance is available only when the power take−off is engaged.

Front Axle For normal road travel, the steering wheel in the CHASSIS cab controls this axle in the normal automotive manner via a wormbox with integral control valve. Before undertaking travel in this condition, the rear axle steering lock MUST be engaged.

The axle can also be controlled by the steering wheel in the SUPERSTRUCTURE cab via the orbitrol system for travel operations from that cab. Under this condition, normal instinctive steering is retained by a reversal valve which is operated automatically when the superstructure is slewed over the rear axle.

Rear Axle Independent control of the steering functions of this axle is provided by a biased OFF selector switch in EACH cab which is used in conjunction with the respective steering wheel to perform REDUCED turning circle or CRABBING functions. Rear wheel movements for these functions are shown on the switch instruction plate, the switch being held ON accordingly. Wheel movements are proportional to the duration of switch engagement.

WARNING IN ADDITION TO RELEASING THE REAR AXLE STEERING LOCK, THE POWER TAKE−OFF MUST BE ENGAGED BEFORE ATTEMPTING TO OPERATE THE STEERING FUNCTIONS OF THE REAR AXLE. Operation To undertake Highway Travel − Refer to Steering Controls Carrier Cab 4−9

1.

Complete normal pre−load travel checks ensuring that: a) CHASSIS CAB is selected by switch (1). b) REAR axle steering lock ENGAGED is selected by switch (10). c) Axle suspension locks are DISENGAGED. Light (11) extinguished.

WARNING CHECK VISUALLY THAT ALL LOCKS ARE DISENGAGED. d) 4 x 2 WHEEL DRIVE selected by switch (4). e) With engine STOPPED, select power take−off DISENGAGED by switch (2). f) NEUTRAL selected by gearshift lever (5).

2.

Start engine by turning switch (6).

3.

Check gauges and warning lights for any malfunction.

4.

Select required gear by lever (5).

5.

Move off by applying accelerator pedal (7) and releasing parking brake (8).

6.

Shift gears as required.

To Stop the Crane 7

Release accelerator pedal (7). Apply footbrake pedal (9).

8.

Move gearshift lever (5) to NEUTRAL. Apply parking brake (8).

To Prepare for Site Operations It is assumed that the crane has been travelled onto the site and is then to be worked in the mobile craning role driven entirely from the superstructure cab.

Carrier Cab − Refer to Steering Controls Carrier Cab 1.

Complete cab change−over checks ensuring that: a) SUPERSTRUCTURE CAB selected by switch (1). b) NEUTRAL selected by gearshift lever (5).

4−10

c) Parking brakes applied by lever (8). d) Rear axle steering lock DISENGAGED selected by switch (10) if rear steering operations from superstructure cab are intended.

CAUTION IF THE STEERING LOCK FAILS TO DISENGAGE IMMEDIATELY DUE TO MALALIGNMENT OF THE WHEELS OR GROUND CONDITIONS, ENGAGE BIASED INTERLOCK OVERRIDE SWITCH (12) MOMENTARILY TO ASSIST DISENGAGEMENT. 2.

Battery circuit switch (6) turned OFF − engine stopped.. a) Power take−off ENGAGED selected by switch (2).

Superstructure Cab − Refer to Steering Controls Superstructure Cab 1.

Complete change−over checks ensuring that:

2.

a) Parking brake lever (1) is APPLIED. b) Gearshift lever (2) in NEUTRAL. Restart engine by turning switch (3).

3.

Check warning lights for any malfunction.

4−11

Carrier Cab

Superstructure Cab

STEERING CONTROLS

4−12

Site Operations from Superstructure Cab With the change−over checks completed and the crane preferably located on suitable LEVEL ground for the proposed operations, proceed as follows: On Outrigger Duties − Refer to Steering Controls Superstructure Cab 1.

For RATED duties fully extend the outrigger beams and jack up the crane to a LEVEL condition with road wheels clear of the ground. Note that viewed in the cab, the outrigger selection switches are grouped as follows: LEFT HAND FRONT LEFT HAND REAR

o o o o

RIGHT HAND FRONT RIGHT HAND REAR

2.

Remove slew lock pin (4) before engaging the slewing motion. .

Proceed with required craning operations on completion of normal checks.

Free on Wheels Duties − Refer to Steering Controls Superstructure Cab 1.

Engage the axle suspension locks using switch (5), light (7) should illuminate. Check tyre pressures.

2.

Remove slew lock pin (4) before engaging the slewing motion.

3.

When the boom over rear of crane, gear selections are the reverse of the normal pattern as follows: a) To Travel FORWARD − b) To travel BACKWARD −

select REVERSE gear select FORWARD gear

Note that in this condition, a cam switch on the collector column operates a steering reversal valve to maintain normal instinctive control of the steering system.

4.

With the boom over front of crane gear selections follows the normal pattern as follows: a) To travel FORWARD − b) To travel BACKWARD − 5.

select FORWARD gear select REVERSE gear

For travel and steering movements, proceed as follows:

a) For normal (two wheel) steering movements, use the steering wheel only in the instinctive automotive manner.

4−13

b) For reduced circle of crabbing (four wheel) steering movements, use the steering wheel in conjunction with selector switch (6) to manoeuvre the crane in the alternative directions shown on the switch instruction plate. To operate, turn switch and hold ON. CAUTION THE REAR WHEELS WILL CONTINUE TO TURN IN A SELECTED DIRECTION UNTIL SWITCH (6) IS RELEASED. c)

Position the load over the rear of the crane and engage slew lock pin.

6.

When travelling use accelerator pedal (8) and brake pedal (9) with care.

Maintain load close to the ground and DO NOT allow load to swing. If site conditions are suitable, extend the outriggers with jacks just clear of the ground. DO NOT TRAVEL ON A GRADIENT OR ON UNSTABLE GROUND. Site Operations to Road Travel Order Superstructure Cab − Refer to Steering Controls Superstructure Cab 1. le.

If necessary revert boom to basic configuration. Locate boom over rear ax-

2.

Erect optional boom rest. Lower fully retracted boom onto rest. Secure hoist rope.

3.

Check that parking brake (1) is applied. Gearshift lever (2) in NEUTRAL.

4.

Insert slew lock pin (4). If necessary, align all road wheels with chassis.

5.

If reverting from BLOCKED duties, fully retract and secure all the outriggers.

6.

If reverting from FREE ON WHEELS duties, use switch (5) to release axle suspension locks.

7.

Turn battery circuit switch (3) to OFF position − engine stopped.

Carrier Cab − Refer to Steering Controls Carrier Cab 8.

Complete change−over checks with engine stopped ensuring that: a) CHASSIS cab selected by witch (1).

4−14

b) c) d) e)

Power take−off DISENGAGED selected by switch (2).

4 x 2 WHEEL DRIVE selected by switch (4).

NEUTRAL selected by gearshift lever (5).

Parking brake applied by lever (8).

9.

Visually check that ALL axle suspension locks are disengaged. Warning light (11) will glow if one (or more) axle lock is still engaged.

10.

Re−start engine.

11. Having checked that rear wheels are aligned with chassis, select rear axle steering lock ENGAGED by switch (10).

12.

Complete the normal pre−road travel checks.

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 for4−15

ward, rear, or side 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.

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.

4−16

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

The load chart contains on outriggers capacity charts and on rubber capacity chart if applicable.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 center 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.

4−17

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 hook blocks, 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 Description Hydraulic power for the outrigger system is provided by the crane hydraulic system. The system comprises four graded outrigger beams, each beam being fitted with a double−acting ram for extension and retraction functions and at its extremity, a double−acting jack for levelling functions.

4−18

Each vertical jack incorporates a lock valve which hydraulically locks the jack in a selected position thus preventing closure of the jack in the event of a malfunction occuring in the equipment. Each jack can be individually adjusted to accurately level the crane.

Duplicate operating controls are provided. These comprises independent switch controls for extending and retracting each beam, located in the superstructure cab and a switch control panel duplicated on each side of the chassis.

Bubble level indicators are mounted adjacent to the control stations.

The outrigger controls are used to bring the crane to ON OUTRIGGERS condition with beams fully extended for RATED lifting duties. For rated FREE ON WHEELS duties, the tyres must be inflated to correct pressure and axle suspension locks engaged.

With the beams extended 300mm minimum, the crane may be jacked up for wheel changing or under chassis servicing. in this condition the superstructure MUST NOT be slewed.

The crane must be LEVELLED and remain LEVEL during operation.

Operation − Superstructure Control Panel WARNING BEFORE OPERATING OUTRIGGERS FROM EITHER SUPER CAB OR CHASSIS CONTROL STATIONS, IT IS ESSENTIAL THAT THE AREA IN WHICH THE OUTRIGGERS ARE TO BE EXTENDED OR RETRACTED IS CLEAR OF PERSONS(S) AND/OR OBSTRUCTIONS. To Extend the Outriggers − Refer to Outrigger Controls figure 1.

Position the crane as necessary in crane operation order shown with the engine running and power take−off engaged. Check that the parking brake is applied and the superstructure slew lock pin is engaged.

2.

Remove locking pin (1) from each outrigger.

3.

Select BEAM by pressing top lobe of switch (2).

4.

Select switch (3), (4), (5) or (6) as required for each outrigger. These 4−19

switches are biased to OFF position and may be operated one or more at at time.

5.

With switches (3), (4), (5) or (6) selected and held, hold top lobe of switch (7) until the beams are fully extended (or extended to required position) − see operating note. This switch is biased to centre (OFF) position.

6.

Place the elephants foot (8) under each jack and select JACK by pressing bottom lobe of switch (2).

7.

With switches (3), (4), (5) or (6) selected and held, hold top lobe of switch (7) until the jacks are located in the elephants feet.

8.

Secure the feet to jacks with locking pins (9) and spring clips.

9.

Using the level indicator (10), re−adjust each jack as necessary until the crane is properly levelled (bubbles centralised).

WARNING WHEN FULLY ’BLOCKED UP’ THE CRANE MUST BE ’LEVEL’ WITH THE WHEELS CLEAR OF THE GROUND. WARNING THE AUTOMATIC SAFE LOAD INDICATOR (IF FITTED) WILL ONLY CORRECTLY RECORD SAFE LOAD WHEN THE CRANE IS PROPERLY LEVELLED AND OUTRIGGER BEAMS ARE FULLY EXTENDED. 10. The crane is now ready for operations under ON OUTRIGGERS duty condition. If a safe load indicator is fitted the equipment will have to be set to suit the appropriate duties required.

To Retract the Outriggers 11. With the engine running and power take−off engaged, telescope boom fully ’IN’. Slew boom in line with chassis and engage slew lock pin. Check that parking brake is applied.

12.

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Remove locking pin (9) from each elephant foot.

13.

Select JACK by pressing boom lobe of switch (2).

14. With switches (3), (4), (5) or (6) selected and held, hold bottom lobe of switch (7) until the crane is on its wheels then fully retract each jack.

15.

Select BEAM by pressing top lobe, of switch (2).

16. With switches (3), (4), (5) or (6) selected and held, hold bottom lobe of switch (7) until all beams are fully retracted.

17. Insert locking pin (1) in each outrigger. Secure pin with spring clip provided.

18.

Stow elephants foot.

19.

If lifting operations are complete disengage power take−off.

Operation − Chassis Control Panel An outrigger control panel is located at each side of the chassis. Separate push buttons control the beams and jacks. Extend and retract functions are selected by the central control switch which is spring−biased to OFF position.

The push buttons control the respective front and rear outriggers as viewed at each panel.

To Extend the Outriggers − Refer to Outrigger Controls figure 1.

Position the crane as necessary in crane operation order with the engine running and power take−off engaged. Check that the parking brake is applied and superstructure slew lock pin engaged.

2.

Remove locking pin (1) from each outrigger,

3.

Turn control switch (11) to EXTEND position (A) and HOLD.

4.

Hold each control button (12) depressed, until all beams are fully extended (or extended to required position) − see operating note.

5.

Place elephants foot (8) under each jack. Extend the jacks by holding control buttons (13) with EXTEND selected until all jacks are located in elephants feet. Secure feet to jacks with locking pins (9) and spring clips.

6.

Continue progressively to re−adjust each jack as necessary until the crane is level. Check level indicator.

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WARNING WHEN FULLY ’BLOCKED UP’ THE CRANE MUST BE ’LEVEL’ WITH THE WHEELS CLEAR OF THE GROUND. 7.

Allow controls witch (11) to return to OFF (centre) position.

8.

The crane is now ON OUTRIGGERS.

To Retract the Outriggers 9.

With the engine running, check that power take−off is engaged and parking brake applied.

10.

Remove locking pins (9) from each elephants foot (8).

11.

Turn control switch (11) to RETRACT position (B) and HOLD.

12. Progressively retract the jacks by pressing each of the control buttons (13), in turn, until the crane is on its wheels then fully retract each jack.

13. With control switch (11) held, fully retract each outrigger beam by pressing each of the control buttons (12).

14.

Allow control switch (11) to return to OFF (centre) position.

15.

Insert locking pin (1) in each outrigger.Secure pin with spring clip provided.

16. If operations are complete, disengage power take−off. Stow elephants feet.

Level Indicator Use the outriggers to level the crane. The crane is level when both bubbles are centralised. Check at intervals during operation that the crane remains level.

Operating Note The capacities given on the Duty Chart are for the crane working on firm, level ground. Duty chart capacities only apply to fully extended outriggers. Extreme caution should be exercised when operating with partially extended outriggers.

4−22

OUTRIGGER CONTROLS

4−23

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.

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.

4−24

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. CAUTION 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.

4−25

CAUTION WHEN LOWERING THE BOOM, LOWER THE CABLE AT THE SAME TIME TO PREVENT TWO−BLOCKING THE BOOM NOSE AND THE HOOK BLOCK. 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. 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. 4−26

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.

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.

4−27

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. 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.

4−28

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.

OPTIONAL EQUIPMENT OPERATION. DIESEL FUEL HEATER.

NOTE If the heater fuel tank is empty, it may be necessary to bleed the fuel system before the heater will start.

Starting.

1. Switch the AIR TEMP toggle switch to HI. 2. Pull the Heater ON/OFF switch to ON. This will actuate the automatic starting sequence.

Operating.

1. Switching the AIR TEMP toggle switch to HI raises the temperature and switching it to LO lowers the temperature.

Stopping.

1. Depress the HEATER ON/OFF switch.

2. The heater may not shut off immediately, since the heater controls incorporate circuits for a purge cycle. The blower will continue to run until all fuel in the burner is consumed and heat exchanger cools sufficiently to open the flame switch. When this occurs, the blower motor will stop.

Cold Weather Fuel Requirements.

When ambient temperatures drop below 0 degrees C, winter diesel fuel must be used or kerosene must be added to the winter diesel fuel according to the following table.

4−29

Temperature Range °C 0 to−15 −15 to −20 below −20

Winter Diesel (%) 100 70 0

Kerosene (%) 0 30 100

When changing to low−temperature fuels, heater must be run for 15 minutes to ensure the fuel pump and fuel lines are filled with new fuel.

PROPANE HEATER. Starting.

1. Pull the heater air temperature control knob out to the high temperature position.

2. Position the START−RUN−OFF switch to START. This will light the green HEATING indicator light. If the green HEATING indicator does not light immediately, refer to Troubleshooting.

WARNING IF THE HEATER FAILS TO PRODUCE HEAT WITHIN 30 SECONDS, TURN OFF POWER IMMEDIATELY TO PREVENT BUILD UP OF PROPANE IN THE BURNER HEAD.REFER TO TROUBLE−SHOOTING TO DETERMINE THE CAUSE OF MALFUNCTION. 3. Illumination of the amber FLAME SW indicator must be within 60seconds after ignition. After the FLAME SW indicator illuminates, release the START− RUN−OFF switch to RUN. Both lights will remain on until the burner cycles off under the control of the HI−LO microswitch.

Operating 1. Pulling the heater air temperature control knob out raises the temperature.

Pushing the heater air temperature control knob in lowers the temperature.

Stopping.

1. Move the START−RUN−OFF switch to the OFF position. The green heating indicator light should go out immediately.

4−30

2. The heater may not shut off immediately, since the heater controls incorporate circuits for a purge cycle. The blower will continue to run until all fuel in the burner is consumed and the heat exchanger cools sufficiently to open the flame switch. When this occurs, the blower motor will stop and the amber FLAME SW indicator light will go out.

4−31

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.

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 5−1

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 Resistance

40 lb. Minimum 350°F (177°C)min.

75 SUS Minimum at 210°F(99°C) Water 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 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 5−2

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 90Winter 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 5−3

a series of tests called MS 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.) 5−4

GROVEXTRA HYDO may be further described using a suffix as follows: RO − Rust and oxidation inhibited oil.

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

WRL

3405F (1715C) min.

Excellent NO. 2

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.

5−5

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 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 5−6

TEMPERATURE −°F (°C) −10 to 180 (−23 to 82)

10W 10W−30

+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.

5−7

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

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.

SUPERSTRUCTURE AND BOOM −See Lubrication Diagram(Sheet 2 of 2) 1 Throttle Reservoir Lub Type − BF. Lub Interval − Weekly or 50 hours or 1000 miles(1500km).

Lub Amount − 0.56 Litres.

Application − Filler cap.

2 Steering Column Lock.

Lub Type − EO. Lub Interval − 200 hours.

Lub Amount − Liberaly.

Application − Oil Can. 3 Brake Treadle Valve.

Lub Type − EO. Lub Interval − 200 hours.

Lub Amount − 2 or 3 Drops.

Application − Raise boot and apply oil to plunger.

4 Throttle Pedal Pivot.

Lub Type − EO. Lub Interval −200 hours.

Lub Amount − 2 or 3 Drops.

Application − Apply oil to pivot.

5−8

5 Swing Unit.

Lub Type − EPGL. Lub Interval − Monthly or 200 hours.

Lub Amount − 2.75 Litres.

Application − Remove filler plug and top up to the base of the apperture.

6 Swing Bearing.

Lub Type − EP−MPG. Lub Interval − 50 hours.

Lub Amount − Until grease extrudes from full circumference.

Apply grease and rotate through 90 degrees ,repeat as often as neccesary to achieve lub amount.

7 Swing Gear and Pinion.

Lub Type − EP−MPG. Lub Interval − 10 hours.

Lub Amount −Coat all teeth.

Application − Brush on.

8 Hoist Unit − HO15−20G NOTE THE CRANE MUST BE LEVEL BEFORE DRAINING OR TOPPING UP THE HOIST UNIT. Lub Type − EPGL. Lub Interval − 250 hours.

Lub Amount − 11.5 Litres Application − Remove the hoist rope, rotate the barrel until the filler plug is on the top and the level plug is at 3 o clock. Remove the filler and level plugs, add oil until the level reaches the lip of the level plug hole . Replace the plugs, and rewind on the hoist rope.

9 Hoist Barrel Lub type − EP−MPG. Lub Interval − 50 hours.

Lub Amount − Until grease extrudes.

Application − 1 Grease nipple.

5−9

10 Lift Cylinder Pivots.

NOTE When greasing the lift cylinder and boom pivot shafts, better distribution of gease within the shafts is obtained if the weight of the boom is removed from the shafts Lub Type − EP−MPG Lub Interval − 10 hours.

Lub Amount − Until grease extrudes.

Application − 2 grease nipples 11 No. 1 Boom Pivot NOTE When greasing the lift cylinder and boom pivot shafts, better distribution of gease within the shafts is obtained if the weight of the boom is removed from the shafts Lub Type − EP−MPG Lub Interval − 10 hours.

Lub Amount − Until grease extrudes.

Application − 2 grease nipples.

12 Teleram Anchor Pin. Lub Type − EP−MPG Lub Interval − 25 hours.

Lub Amount − Until grease extrudes.

Application − 1 grease nipple.

13 Sheave − No. 4 Boom Head Lub Type − EP−MPG Lub Interval − 50 hours.

Lub Amount − Until grease extrudes.

Application − 1 grease nipple.

14 Sheave Pin Boom Head Lub Type − EP−MPG Lub Interval − 50 hours.

5−10

Lub Amount − Until grease extrudes.

Application − 1 grease nipple.

15 Hook Block Pin Lub Type − EP−MPG Lub Interval − 50 hours.

Lub Amount − Until grease extrudes Application − 2 grease nipples.

16 Hookblock Crosshead.

Lub Type − EP−MPG Lub Interval − 50 hours.

Lub Amount − Until grease extrudes.

Application − 1 grease nipple.

17 Lifting Hook Release Lub Type − EO Lub Interval − 50 hours.

Lub Amount − Liberally. \application − Oil can.

18 Bottom Bearing Pads Lub Type − EP−MPG. Lub Interval − 25 hours.

Lub Amount − Coat underside of sections when telescoped out.

Application − Brush 19 Extension and Retraction Chains Lub Type − EP−MPG. Lub Interval − 25 hours.

Lub Amount − Liberally.

Application − By hand.

20 Boom Side Pads Lub Type − EP−MPG. Lub Interval − 25 hours.

Lub Amount − Coat side pads when telecsoped out.

Application − Brush.

21 Hoist Rope Lub Type − OGL Lub Interval − 200 hours.

5−11

Lub amount − Sufficient to coat the rope.

Application − Brush (See also rope maintenance) 22 Sheave − Swingaway (Optional Equipment).

Lub Type − EP−MPG. Lub Amount − Until grease extrudes.

Lub Interval − 50 hours.

Applicaton − Grease nipple. − Rollers −Swingaway(Optional Equipment).

Lub Type − EP−MPG Lub Interval − 25 hours.

Lub Amount − Thoroughly coat all sliding surfaces.

Application − By Brush.

23 Third Wrap Monitor Hoist Barrel Lub Type − EP−MPG. Lub Amount − Until grease extrudes.

Lub Interval − 50 hours.

Applicaton − Grease nipple.

24 Hookblock Nut and Threads Lub Type − EP−MPG. Lub Interval 1 − Monthly or 100 hours − Apply grease to the top of the nut to pre vent the ingress of moisture.

2 − Annualy − A combination of dust and moisture could enter the clearance between thread and nut. The effect of this combination, compounded by the swing of the hook results in abrasion and cor rosion of the threads, ultimately the threads weaken sufficiently to allow the hook to pull through the nut. this condition can remain undetected unless the nut is removed for a specific examination.

Therefore the hookblock should be dismantled annualy and the threads inspected for signs of deterioration, if in any doubt we strongly recommend new components be fitted. the threads should always be checked prior to the application of proof load tests.

During re−assembly a liberal coat of grease should be applied to the hook shank threads 5−12

WARNING UNDER NO CIRCUMSTANCES SHOULD GREASE CONTAINING MOLYBDENUM DISULPHIDE BE USED IN THIS APPLICATION. Lub Amount − Liberally Application − By hand.

25 N0 4 Section Tele Ram Anchor Pin Lub Type − EP−MPG Lub Interval − 50 hours.

Lub Amount − Until grease extrudes Application − 1 Grease Nipple CARRIER −See Lubrication Diagram(Sheet 1 of 2) 1 Engine Lub Type − EO Lub Interval − Check daily. Drain and refill as per the engine hand− book Application − Refer to the engine service manual.

2 Torque Convertor Lub Type − HTF Lub Interval − 1. Check Daily with the engine running at 500 to 600rpm and oil temperature at 180°F to 200°F (82.2°C to 93.3°C).

2. Drain and refill every 500 hours with the oil at 150°F to 200°F (65.6°C to 93.3°C).) a) Remove and clean the sumpscreen. Replace screen using a new gasket. b) Replace the oil filter and clean filter the filter shell, tighten to 30lbs/ft (4.15kg/m). c) Fill to high level plug. d) Run the engine at 500 to 600 rpm to prime the torque convertor lines. e) Check oil level with the engine running at 500 to 600 rpm add oil at 180°F to 200°F(82.2°C to 93.3°C). Add oil to bring level back to high level filler plug brim.

5−13

NOTE When checking oil level, the oil temperature must be stabilised at 180 degrees to 200 degrees F (82.2 degrees C to 93.3 degrees 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 convertor. Convertor stall should be accomplished by engaging the shift levers in forward and high range with the brakes applied and then accelerate the engine to half or thee − quarter throttle, hold the stall until the desired convertor temperature is reached and stabilised.

CAUTION FULL THROTTLE STALL SPEEDS FOR AN EXCESSIVE LENGTH OF TIME WILL OVER−HEAT THE CONVERTOR AND CAUSE SERIOUS DAMAGE. Lub Amount − 19 Litres.

Application − Through the high level plug in the side of the gear box.

3 Gearbox See torque convertor.

4 Rear Axle Differential.

Lub Type − EPGL−5 Lub Interval − 1600km(1000 miles) Lub Amount − 10.5 Litres Application − Check filler/level plug..

5 Rear Axle Hubs.

Lub Type − EPGL−5 Lub Interval − 1600km(1000 miles) Lub Amount − 1.5 Litres.

Application − Locate level mark and level plug in horizontal posi 5−14

tion, remove plug and add oil up to the lip of the aperture. Refit the level plug.

6 Front Axle Differential.

Lub Type − EPGL−5 Lub Interval − 1600km(1000 miles) Lub Amount − 10.5 Litres Application − Check filler/level plug.

7 Front Axle Hubs.

Lub Type − EPGL−5 Lub Interval − 1600km(1000 miles) Lub Amount − 1.5 Litres.

Application − Locate level mark and level plug in horizontal posi tion, remove plug and add oil up to the lip of the aperture. Refit the level plug.

8 Steering Wormbox Automatically lubricated from the sreering hydraulic system.

9 King pin Trunnions Lub Type − EP−MPG Lub Interval − 1600km(1000 miles) Lub Amount − Until grease extrudes.

Applicarion − 4 grease nipples per axle.

10 Steering and Tie Ball Joints Lub Type − EP−MPG .

Lub Interval − 1600km(1000 miles).

Lub Amount − Until grease extrudes.

Application − 6 grese nipples located at the ends of the tie rods.

11 Front Spring Pins Lub Type − EP−MPG .

Lub Interval −.

Lub Amount − Until grease extrudes.

Application − 2 grese nipples, 1 per spring.

12 Front Spring Pins Lub Type −EP− MPG .

Lub Interval −1600km(1000 miles).

5−15

Lub Amount − Until grease extrudes.

Application − 2 grese nipples, 1 per spring.

13 Steering Ram Ball Joints Lub Type − EP−MPG .

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

Application − 8 grease nipples, 4 per axle.

14 Propshafts Lub Type − EP−MPG .

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

Application − 9 grease nipples, 3 per shaft.

15 Axle Universal Joints.

Lub Type − EP−MPG .

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

Application − 4 grease nipples, 1 per joint.

16 Axle Lock Hook Pivot Pin. Lub Type − EP−MPG .

Lub Interval − 1600km(1000 miles).

Lub Amount − Liberally.

Application − By hand 17 Front and Rear Springs Lub Type − EO Lub Interval − 1600km(1000 miles).

Lub Amount − Liberally.

Application − Oil Can. 18 Outrigger Ram Pivot Pins Lub Type − EP−MPG .

Lub Interval − 50 hours or 1600km(1000 miles).

Lub Amount − Liberally.

Application − By hand to the 8 pins, 2 per ram.

19 Steering Column Ball Joint Lub Type − EP−MPG .

Lub Interval − 1600km(1000 miles).

5−16

Lub Amount − Until grease extrudes.

Application − Grease nipple.

20 Hydraulic Oil Tank Lub Type − GROVEXTRA HYDO Lub Interval − Daily Lub Amount − 418 Litres Application − Filler cap, add oil to level of sight gauge.

21 Steering Lock Wedge Lub Type −EP− MPG Lub Interval − 1600km(1000 miles) Lub Amount − Liberally.

Application − By hand 22 Engine Fuel Tank Lub Type − Diesel Lub Interval − Daily Lub Amount − 267 litres Application − Filler Cap 23 Steering Bevel Box Lub Type − EP−MPG Lub Interval − During Overhaul Lub Amount − 0.5 Litres 24 Steering Shift Ball Lub Type − EP−MPG Lub Interval − 50.000km(30,000 miles) Lub Amount − Until grease extrudes.

Application − 2 Grease nipples.

25 Hydraulic Oil Filter Lub Type − GROVEXTRA HYDO − Fed from the hydraulic tank Lub Interval − 1 − On commission of a new crane daily.

2 − 50 hours, Replace element after 50 hours.

Lub Amount − Supplied from the hydraulic tank.

Application − Element should be changed at 600 hours or when the red poppet extends, whichever occurs first.

5−17

NOTE When the hydraulic oil is cold the pressure may be great enough to push out the poppet. If the poppet extends, push it in when normal operating temperature is obtained, if the poppet stays in the element is satisfactory, otherwise if the poppet comes out again the element needs renewing. On systems with an indicator light on the dashpanel, if illuminated when the engine is started wait until normal temperature is reached, the light should extinguish, if not the element should be renewed.

26 Transmission Oil Filter (See torque convertor.

27 Steering Tank Lube Type − GROVEXTRA HYDO Lub Interval − Daily Lub Amount − 27 litres Application − Filler Cap 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 5−18

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

5−19

19

23

24

24

11 6 9

8

16 17 3

7

14 15

26

10 20

14 2

1

16

12 15 21 4 18 2 10 5 9

13 4

8 10 9 15 6 7 14 27 1. ENGINE 2. TORQUE CONVERTOR 3. GEARBOX 4. REAR AXLE DIFFERENTIAL 5. . REAR AXLE HUB 6. FRONT AXLE DIFFERENTIAL 7. FRONT AXLE HUB 8. STEERING WORMBOX 9. KING PIN TRUNNIONS 10. STEER AND TIE BALL JOINTS 11. FRONT SPRING PINS 12. REAR SPRING PINS 13. STEER RAM BALL JOINTS 14. PROPSHAFTS

25

22 14

15. AXLE UNIVERSAL JOINTS 16. AXLE LOCK HOOK PIN PVOT 17. FRONT AND REAR SPRINGS 18. OUTRIGGER RAM PIVOT PINS 19. STEER COLUMN BALL JOINT 20. HYDRAULIC OIL TANK 21. STEERING LOCK WEDGE 22. ENGINE FUEL TANK 23. STEERING BEVEL BOX 24. STEERING SHAFT BALL 25. HYDRAULIC OIL FILTER 26. TRANSMISSION OIL FILTER 27. STEERING TANK

LUBRICATION DIAGRAM (SHEET 1 OF 2) 5−20

10 13 18

13

20

14

25

21

12

18

15

24

19

11

22

16 17

7

6

5

8

4

10 1 3

9

2

1 Throttle Reservoir 2 Steering Column Lock 3 Brake Treadle Valve 4 Throttle Pedal Pivot 5 Slew Unit 6 Slewing Ring (Swing Bearing) 7 Slew Rack and Pinion 8 Hoist Unit 9 Hoist Barrel 10 Derrick Ram Pivots 11 No 1. Boom Pivot 12 Teleram Anchor Pin 13 Sheave No. 4 Boom Head

23

14 Sheave Pin Boom Head 15 Hookblock Pin 16 Hookblock Crosshead 17 Lifting Hook Release 18 Bottom Bearing Pads 19 Extension and Retraction Chains 20 Boom Side Pads 21 Hoist Rope 22 Sheave Lattice Extension 23 Third Wrap Monitor (When Fitted) 24 Hookblock Nut and Hook Threads 25 N0.4 Section Tele Ram Anchor Pin

LUBRICATION DIAGRAM (SHEET 2 OF 2) 5−21

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. Antitwo−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.

ANTITWO−BLOCK SYSTEM. The antitwo−block system provides a warning to the operator of an impending two−block condition. The system consists of antitwo−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 positionby 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.

6−1

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

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.

Installing Cable Anchor Wedge 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 7−2

part line. Various cable reeving (part line) is possible with the boom nose and 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 (1/2”) 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 very 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 instructions given on page 1.

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

Under no circumstances should the free end of the rope is clamped to the working end of the rope above the pearweight.

IMPORTANT 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 ATTEMPTING TO ERECT OR STOW THE SWINGAWAY, READ AND STRICTLY ADHERE TO ALL WARNING DECALS INSTALLED ON THE SWINGAWAY AND STOWAGE BRACKETS. Erecting 1.

Fully extend and set the outrigger beams and jacks, ensuring the crane is level.

2.

Swing the boom over the rear.

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.

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.

Detach spring clips (1) and remove the attach pins (2) from the swingaway anchor fittings − see view A. WARNING DO NOT REMOVE THE PIN (11) SECURING THE SWINGAWAY TO THE FRONT STOWAGE BRACKET (15) AT THIS TIME. 6.

Pull the latch pin (3) on the rear stowage bracket (16) and swing the latch plate (4) down 90 degrees to the position shown in vies B and C. 7.

Release the latch pin (3) locking the latch plate (4) in position.

WARNING ALWAYS INSERT PINS (2) FROM THE TOP OF THE JOINTS AS SHOWN. NEVER INSERT IN THE REVERSE ORDER.

8.

Pull the extension nose (5) outward towards the latch (4) until the extension anchor fittings (6) are fully engaged with the boom nose attach fittings (7).

Insert the attach pins (2) and clip pins (1) − See View D. 7−7

9.

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

10.

Elevate the boom to horizontal.

11. Remove the padlock (90 at the front stowage bracket (15). With the safety latch (10) held upwards, lift pin (11) from the recess; then turn and lower until stop (12) abuts the block (13) on the front stowage bracket (15). See View E. 12. At the rear stowage bracket (16) retract the latch pin (3) to release the latch (4), and allow it to be lowered out of the way. − See View F. WARNING IT IS IMPORTANT THAT THE LATTICE EXTENSION IS RESTRAINED BY THE CONTROL ROPE AFTER RELEASE FROM THE SUPPORT BRACKETS AND WHILST BEING SWUNG AROUND TO ITS OPERATING POSITION. THE ROPE SHOULD BE USED ONLY WHEN STANDING AT GROUND LEVEL. 13. Using the rope attached to the extension tip, swing the extension into place ahead of the boom nose, engaging the anchor fittings with the attach fittings on the boom nose. − See Views G and H. 14. Insert the attach pins (2) into the anchor and attach fittings on the boom.

Install the safety clips (1) in the pins. Remove the rope.

NOTE Insertion of the pins may be assisted by inserting the pins into the joint and applying a shaking action to the head of the extension.

15. Route the hoist cable over the center idler sheave on the main boom nose and the sheave on the extension tip.

16.

Install the rope guard (8) and clip pin (14).

Stowing 1.

7−8

Fully retract the boom and swing to over the rear.

2.

Lower the boom to minimum elevation.

3.

Remove the clip pin (14) securing the rope guard (8).

4.

Reel to the hoist cable, removing it from the extension tip and boom nose idler sheaves. Lay the cable off to the side of the boom.

5.

Raise the boom to the horizontal position.

6.

Attach a length of rope to the extension tip.

7.

Remove the two pins (2) from the side of the boom nose opposite the swingaway stowage brackets (15 and 16).

CAUTION

DO NOT ALLOW THE SWINGAWAY TO IMPACT THE STOWAGE BRACKET WHEN SWINGING INTO POSITION.

8.

Using the rope, swing the extension away from the boom nose. Ensure the swingaway rollers run up to the ramp on the rear stowage bracket (16). To assist positioning the swingaway into the stowage bracket, elevate the boom (approximately 65 degrees as necessary.

9.

Retract the latch pin (3) and swing the latch plate (4) to the horizontal position. Lock the plate in this position. − See View F. 10. With the safety latch (10) held upward, lift the pin (11), then turn and lower into the recess in the bracket. Release the safety latch and install the padlock (9).

11. Remove the two remaining attach pins (2) from the side of boom nose. − See View D. 12. Push the extension into place in the rear bracket (16). Pull the spring loaded pin (3) and position the latch plate (4) in the locked position. − See View J. 13. Install the pins (2) and clip pins (1) into the swingaway anchor fittings (6).

Remove the rope.

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

7−9

SWINGAWAY STOWING AND ERECTING

7−10

POWER POSITIONED EXTENSION To Extend Power Positioned Extension a) With the boom fully retracted and horizontal detach end of extension rope from boom head at 1 (A) by removing ’R’ clip 6(A) and attach it to the boom section at 2(A), using pin 7(A) and ’R’ clip 8(A). (Note an alternative mounting is shown in inset). b)

Remove ’R’ clip 4(A) and locking pin 3(A).

c) Telescope out. When the high bearing area location block 9(B) reaches the roller 5(B) insert locking pin 3(B) and fit ’R’ clip 4(B). d) Remove end of extension rope from bottom section at 2(A) and re−stow it to the stowage point at 1(A) using ’R’ clip 6(A). e)

Stow erection rope in spring clip 10(C).

To Retract Power Positioned Extension There are two alternative methods of retracting the extension.

Method 1 a) With the boom fully retracted and horizontal remove extension rope from stowage clips. b) Derrick−in and attach hookblock to attachment point 12(D) on rear of crane (front on Husky cranes). c)

Derrick boom down to horizontal position.

d) With the hoist rope slack, remove the power positioned extension locking pin 13(E). e)

Hoist in slowly until the extension is retracted and fit locking pin 13(E).

f)

Restow extension rope.

Method 2 a) With the boom in the horizontal position remove the extension rope from its stowed position in spring clips 10(C). b)

Derrick the extension rope from its stowed position 1(A) and attach to an7−11

chor point 2(A), using pin 7(A) and ’R’ clip 8(A). c) Telescope out until extension rope is just taut, then check that the extension rope is located in groove 11(B). d)

Remove ’R’ clips 4(B) and locking pin 3(B).

e) Derrick ’IN’ until the high bearing area location block 9(B) is released from the roller 5(B). It may be necessary to actuate the Derrick Lever so that a gentle rocking motion is induced to facilitate release of the extension location block from the roller. f)

Telescope ’IN’ until the extension is fully retracted.

g)

Fit locking pin 3(A) and ’R’ clip 4(A).

h)

Re−fit end of extension rope to stowage point 1(A) using ’R’ clip 6(A).

CAUTION IT IS EXTREMELY IMPORTANT THAT THE EXTENSION ROPE IS TAUT AS DESCRIBED AT (C) BEFORE DERRICKING ’IN’ AT (E).

THE FLY JIB, IF FITTED, MUST BE REMOVED BEFORE RETRACTING THE POWER POSITIONED EXTENSION.

7−12

POWER POSTIONED EXTENSION AND RETRACTION (Sheet 1 of 2) 7−13

E

TO RETRACT

13 12

D

POWER POSITIONED EXTENSION AND RETRACTION (Sheet 2 of 2)

7−14

MAN CARRYING BASKET ERECTING With the Man Carrying Basket completely assembled and resting on the ground, the procedure to mount to Boom Head is as follows:− Remove the hookblock and store Hoist Rope on barrel.

On cranes fitted with an anti two block this must be unplugged and removed from the Boom Head.

1.

With the Boom fully retracted, derrick down to the horizontal position and align the mounting bracket (1) to the Boom Head holes and insert pin (2), lock with linch pin (3). Insert locking pins (4) and lock with plate (5), nut (6) and split pin (7).

WARNING MOUNTING BRACKET (1) SHOULD NOT BE SECURED TO BOOM HEAD OTHER THAN WITH THE PINS, BOLTS AND FITTING PROVIDED. 2.

Remove dummy electrical plugs (8) and connect the electrical plugs (9) to the sockets (10).

WARNING FAILURE TO DO THIS WILL PROHIBIT THE OPERATION OF THE EMERGENCY STOP SYSTEM,.

3.

Ensure clips (17), pin (16) and detach support (18) after ensuring the support is unloaded. Note the support (18) is an optional fitting therefore if not supplied a suitable alternative support must be used to keep the basket mounting bracket (1) in position to facilitate connection to the Boom Head.

5.

The basket should be inspected and tested at intervals in accordance with National and Local crane/basket regulations.

The safe working load is 250 kgs.

WARNING REFERENCE MUST BE MADE TO THE BASKET RADIUS PLATE IN THE CAB FOR SAFE WORKING RADII. 7−15

Before putting into service and also after a proof test thoroughly inspect pins, bolts and nuts (2) to (7) (12) and (13) for security and the basket (14) and mountings (1) for any signs of structural defects.

Ensure the basket is free to self level and check emergency stop is operational, see notes below.

6.

Check before derricking for overhead cables and obstructions etc, see General Precautions publication in this manual.

7.

Derrick the boom to desired operating position and lock the Basket (14) by tightening hand lever (11) to prevent swing. The handlever (11) MUST be loosened before derricking again.

Emergency If the Engine stops for ANY reason it must be restarted unless authorised by the personnel in the basket, the crane operator and personnel should be made aware of this before lifting the basket. in an emergency the crane engine can be stopped by pressing button (15) in the basket (14). If this happens ascertain why, rectify and reset when safe.

To reset start the engine pull button (15) out.

Dismantling Procedure − generally the reverse of Erection:− 1.

Loosen handlever (11) and derrick boom down to horizontal.

2.

Tighten handlever (11).

3.

Disconnect electrical plugs (9) from sockets (10) and insert dummy plugs (8).

WARNING FAILURE TO DO THIS WILL PROHIBIT STARTING OF THE ENGINE. 4.

Ensure basket is resting on the ground. At this stage personnel get out of the basket.

5.

Fit support (18) with pin (16) and clip (17) to mounting bracket (19). Note this is an optional fitting therefore if not supplied a suitable alternative support must be used to keep the basket and mounting supported while they are detached from the Boom Head.

7−16

6.

Remove split pin (7), nuts (6), keep plate (5) and pins (4). Remove linch pin (3) and pin (2) to disconnect the basket from the Boom Head.

7−17

MAN CARRYING BASKET

7−18

FLY JIB Mounting the Fly Jib 1.

Derrick the boom down as far as possible.

2.

Position the fly jib in line with and below the lattice extension with the hoist rope attached to the shackle (1) − See A. 3.

Operate the hoist motion to lift the end of the fly jib so that it can be positioned between the side plates (2) on the lattice extension and in contact with the stops (3), the other end of the fly jib resting on the ground − see B. 4.

Push the pilot pin (4) through the side plates and fly jib boss. The flexibility of the extension will allow sufficient relative movement to be obtained to help ease the pin into position.

5.

With the pin fully in position, secure it with safety clip (5).

6.

Hoist in to lift the end of fly jib to allow tie ropes (6) to be connected to the anchor points (7) on the lattice extension after detaching the ends from stowage point (8) − see C, and caution below for the Rope Centres.

7.

Lower the fly jib until it is supported by the tie ropes and detach the end of the hoist rope from or shackle (1) . Pass it over the fly jib pulley after removing rope guide (9). Re−fit the rope guide and attach the required hookblock.

Dismounting the Fly Jib The fly jib is dismounted by reversing the mounting procedure.

CAUTION USE ONLY THE FLY JIB, AND THE ROPES SUPPLIED WITH THE CRANE TO ENSURE CORRECT OFFSET ANGLE AS SHOWN ON THE DUTY CHART. FAILURE TO DO SO WILL RESULT IN AN UNSAFE OPERATING CONDITION.

7−19

FLY JIB ERECTION

7−20

FLY JIB STOWAGE The fly jib is stowed on the chassis platform as shown and MUST be removed before the crane can be slewed through 360 degrees.

To remove the fly jib, proceed as follows: 1.

Apply crane parking brake.

2.

Fully extend all four outrigger beams and jacks.

3.

After unstowing the hookblock, derrick UP and fully retract the boom.

4.

Remove slew lock pin and slew over the side as shown; it is important to slew in the correct direction (RIGHT) away from the stowed fly jib.

5.

Attach main hookblock using suitable sling (1) to the fly jib.

6.

Remove locking pins (2) and (3).

7.

Lift fly jib clear of brackets and lower to ground.

8.

Replace locking pins in brackets for safe keeping.

To replace the fly jib, reverse the removal procedure.

NOTES The tie ropes should remain stowed on the fly jib sides when lifting the fly jib from the platform; this ensures a balanced lift.

When stowing the fly jib ensure that no part of the fly jib extends beyond the front or rear of the chassis platform.

7−21

FLY JIB STOWAGE

7−22