TMS800E OPERATOR’S MANUALOPERATING CONTROLS AND PROCEDURES

Lowering the Boom

To lower the boom, push the controller on the right hand armrest to the right and hold until the boom is lowered to the desired position.

Warning

Long cantilever booms can create a tipping condition even when unloaded and in an extended and lowered position.

Danger

Lower boom and let out cable simultaneously to prevent two-blocking.

Caution

The closer the load is to the boom nose, the more important it becomes to let out cable as the boom is lowered.

Telescoping The Boom

NOTE: When the crane is equipped with an auxiliary hoist the telescope function is controlled by a foot pedal. Extending The Boom (With Single Hoist) (Optional)

Warning

When extending the boom, simultaneously let out the cable to prevent two-blocking the boom nose and hook block.

Danger

Check the load chart for maximum load at given radius, boom angle, and length before extending boom with a load.

Push the controller on the left hand armrest to the left, and hold until the boom reaches the desired length.

Retracting The Boom (With Single Hoist) (Optional)

Warning

When retracting the boom, the load will lower unless the cable is taken in at the same time.

To retract the boom, push the controller on the left hand armrest to the right and hold until the boom retracts to the desired position.

Telescope Control Pedal

The telescope control pedal is used on cranes equipped with an auxiliary hoist. Push on the top of the pedal to extend the boom and push on the bottom of the pedal to retract the boom.

Lowering And Raising The Hoist Cable

Warning

Keep the area beneath the load clear of all obstructions and personnel when lowering or raising the cable (load).

Warning

Do not jerk controller when starting or stopping hoist. Jerking causes load to bounce, which could result in possible damage to the crane.

NOTE: When the load is stopped at the desired height, the automatic brake will engage and hold the load as long as the controller remains in neutral.

Lowering The Cable

Push the main hoist (right hand armrest) or auxiliary hoist (left hand armrest) controller forward, away from the operator, and hold until the hook or load is lowered to the desired height.

Raising the Cable

Pull the main hoist (right hand armrest) or auxiliary hoist (left hand armrest) controller, toward the operator, and hold until the hook or load is raised to the desired height.

Published 12-22-2008, Control # 107-09

Hoist Speed Range Selection

Danger

Do not change the hoist speed range with the hoist rotating.

To change the speed range of the hoist(s), press the top (high speed) or bottom (low speed) of the main hoist speed switch located on the right hand armrest or auxiliary hoist speed switch located on the left hand armrest.

Operational Aids

Danger

Electronic equipment on this crane is intended as an aid to the operator. Under no condition should it be relied upon to replace the use of capacity charts and operating instructions. Sole reliance upon these electronic aids in place of good operating practices can cause an accident.

Load Moment Indicator (LMI) System

The Load Moment Indicator (LMI) is an electro-mechanical sensing system designed to alert the crane operator of impending capacity when the system has been properly preset by the operator. The control panel is mounted in the front console of the operator’s 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.

Three additional features are included within the LMI system:

• Swing Angle Set Limitation

• Work Area Definition

• Anti-two Block Device

Swing Angle Set Limitation allows left and right swing angle to be preset. When the preset angle is reached, the system will provide an audible warning.

Work Area Definition allows the crane operator to describe the crane’s working area by setting up “virtual walls”. They are referred to as virtual walls because they exist in the system and are not real walls. The virtual walls represent obstacles (i.e. buildings, towers, poles, etc.) in the crane’s working range. They are set by defining points along the outer limits of the working area with the tip of the boom. Once the working area has been defined, the system will provide a visual and an audible warning if the boom approaches a virtual wall.

Caution

When defining virtual walls (s). always allow a safe working distance to any obstacles. Never work outside a safe working area as defined by common practice, standards, and manuals.

WARNING

There are no cut-outs associated with the swing angle set limitation or the work are definition features.

An Anti-two Block Device is also incorporated into the system to prevent the hook block or headache ball from coming into contact with the boom nose or boom extension. This condition will also cause a lockout of hoist up, boom down, and telescope out, and also provide a visual and an audible alarm.

Refer to the LMI Operator’s Handbook for more detailed information on the function of the LMI system.

Control Lever Lockout System

The control lever lockout system consists of hydraulic solenoid valves located in the directional control valves. The valves are activated in such a manner as to prevent worsening the condition, i.e. boom down, telescope out, or hoist up. The control lever lockout system is used with the anti-two-block system or the load moment indicator (LMI) system. The LMI sends a signal to the canbus system which turns off the solenoids on the directional valves.

Crane Travel Operation

Active Restraints

Seat Belts

1. Before fastening a seat belt, always adjust the driver’s seat to the position in which you will drive.

2. Pull the belt across your lap and push the latch plate into the buckle until it clicks (Figure 3-9).

3. To reduce the risk of sliding under the belt during a collision, position the belt across your lap as low on your hips as possible and pull it toward the door to a snug fit so the retractor can take up the slack.

NOTE: The lap/shoulder belt is designed to lock only during a sudden stop or impact. At other times is should move freely.

4. If the shoulder belt is too snug, do the following: a. Pull the shoulder belt out (A) at least 130 mm (5 in) so that when it is left go, it returns to your chest (Figure 3-10). b. Then pull down on the shoulder belt (B) the least amount needed to ease pressure but no more than 25 mm (1 inch) and let go.

Traveling - General

Caution

Check cold tire pressure prior to extended travel. Refer to tire inflation decal on crane.

Caution

Job site travel with deflated suspension must be limited to 8 km/h (5 MPH). Attempting to travel at higher speeds may cause drive train component failure.

Caution

Before job site or off-highway travel or pick and carry, select auxiliary transmission LOW range to prevent clutch damage. Main transmission must be shifted in MANUAL mode when the auxiliary transmission is in LOW range.

Caution

If traveling with 10,900 kg (24,000 pound) counterweight installed, maximum travel speed is 2.5 mph. Suspension air bags should be inflated.

Do not move the crane until the superstructure has been secured as outlined below.

1. To ensure the axles and/or suspension are not overloaded, adhere to the following.

5. To reduce slack in the belt, pull the belt out as you did in step 4.a.

Danger

Keep any shoulder belt slack to a minimum, no more than 25 mm (1 inch). Belt slack beyond the specified amount could significantly reduce the amount of protection in an accident because the belt is too loose to restrain you as intended.

6. To unfasten the belt, push in on the button in the center of the buckle. To store the belt, pull out about 180 mm (7.1 in) and let go. The belt should retract when the buckle is unlatched. To help prevent damage to the seat belt and interior, before closing the door be sure the belt is fully retracted and the latch plate is out of the way.

a. For highway travel with 18,000 pounds (8170 kg of counterweight, install 8000 lb (3630 kg) of counterweight on the carrier. Check that front axle load does not exceed 49,200 lb (22,300 kg) and rear axle load does not exceed 60,000 lb (27,200 kg).

b. For highway travel with 14,000 lb (6350 kg) or 12,000 lb (5440 kg) of counterweight, install 4000 lb (1810 kg) of counterweight on the carrier. Check that front axle load does not exceed 49,200 lb (22,300 kg) and rear axle load does not exceed 60,000 lb (27,200 kg).

c. GVW should never exceed 109,200 lb (49,530 kg). Also refer to certification label on inside of cab door for Gross Axle Weight Ratio (GAWR).

NOTE: For 24,000 pounds (10,900 kg) counterweight job site travel without extension and/or inserts erected, the boom must be extended to a length of 50 feet (15 m).

2. Ensure all boom sections are fully retracted or set to whatever extension is necessary for balance load on the axles.

3. Ensure the boom is fully lowered into the boom rest.

4. Engage the swing brake.

5. Engage the swing lock.

6. Ensure the swingaway, if so equipped, is properly stowed and secured or removed from crane.

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

8. Ensure the outrigger stabilizers and outrigger beams are fully retracted and the floats are removed.

9. Ensure the center front stabilizer is fully retracted. Floats remain installed.

10. Ensure the stabilizer floats are properly stowed in their holding racks.

11. Ensure the cover doors on the outrigger control panels, battery box, and sling box are closed.

12. Close and/or install all superstructure cab windows and door.

NOTE: The electric-actuated variable geometry turbocharger causes the engine sound to vary at different times. This is normal. You may also hear a slight turbo whistle during idling.

13. If traveling on job site or off-highway, select auxiliary transmission LOW range to prevent clutch damage.

a. Push the auxiliary transmission low range switch located on the carrier right side console to the right to engage low range.

b. An amber indicator on the carrier left front console will illuminate when the auxiliary transmission is in low range.

c. The main transmission must be shifted in MANUAL mode if the auxiliary transmission is in LOW range.

14. If traveling with 24,000 pounds (10,900 kg) of counterweight installed, maximum travel speed is 2.5 mph. Suspension air bags should be inflated.

Traveling With Boom Extension And/Or Inserts

Erected

10 m (33 ft)/17 m (56 ft) Extension

Travel is permissible under the following conditions.

1. The 10 m (33 ft) or 17 m (56 ft) boom extension shall be erected at minimum offset. If traveling with just the 10 m (33 ft) extension, the stinger section must be stowed on the boom base section, not on the extension base section.

2. Jobsite travel only on firm, level surface.

3. Main boom shall be fully retracted.

4. Main boom angle: 3 degrees minimum, 30 degrees maximum.

5. Maximum travel speed: 4 km/h (2.5 mph).

6. Counterweight: a. With the boom over the front, the counterweight used can be from 0 kg to 8170 kg (18,000 lb) or 10,900 kg (24,000 pounds). b. With the boom over the rear, the counterweight used must be from 5440 kg (12,000 lb) to 8170 kg (18,000 lb).

7. Swing lock and pin shall be engaged.

8. Hookblock must be removed from main boom nose.

9. Headache ball may be reeved over boom extension, hanging 0.9 m (3 feet) below sheave.

10. Suspension air bags shall be inflated.

11. The tires shall be properly inflated.

10 m (33 ft)/17 m (56 ft) Extension Plus One or Two 6 m (20 ft) Insert(s

Travel is permissible under the following conditions.

1. The 10 m (33 ft) or 17 m (56 ft) boom extension shall be erected at minimum offset. If traveling with just the 10 m (33 ft) extension, the stinger section must be stowed on the boom base section, not on the extension base section.

2. Jobsite travel only on firm, level surface.

3. Main boom shall be fully retracted.

4. Main boom angle: 3 degrees minimum, 30 degrees maximum.

5. Maximum travel speed: 4 km/h (2.5 mph).

6. With the boom over the front, the counterweight used can be from 0 kg to 8170 kg (18,000 lb) or 10,900 kg (24,000 pounds). Travel with the boom over the rear is not permitted with insert(s) erected.

7. Swing lock and pin shall be engaged.

8. Auxiliary hoist or IPO counterweight must be installed.

9. Hookblock must be removed from main boom nose.

10. Headache ball may be reeved over boom extension, hanging 0.9 m (3 feet) below sheave.

11. Suspension air bags shall be inflated.

12. The tires shall be properly inflated.

UltraShift™ Transmission

The UltraShift™ is a fully automated mechanical Eaton® Fuller® transmission that provides automatic operation (no clutch pedal) using a manual transmission coupled with electronic modules that automate the shifts. The electronics direct the transmission to make each shift at the ideal engine speed.

Shifting Gears

Next to concern for safety, good shifting habits are probably the most important capability a driver can have. Knowing how and when to shift can return savings in trip time and operating expense.

Satisfactory engagement in 5th gear

Out of gear waiting for engine/ transmission rpm engagement in 6th gear

FIGURE3-12

Down arrows on the Gear Display indicate the transmission is waiting to verify decreased input shaft speed, before a gear engagement from Neutral can be completed.

R - Reverse

N - Neutral

D - Drive

M - MANUAL

L - LOW

FIGURE3-11

• R - Selects the reverse gear once vehicle speed is less than 2 mph.

• N - Neutral is selected.

• D - Selects the default starting gear and automatically selects gears between the starting gear and top gear.

• Manual - Allows the driver to hold current gear and manually select the appropriate gear for road condition using the up/down buttons.

• Low - Transmission downshifts at the earliest opportunity for maximum engine braking down to the lowest allowable gear, until MANUAL or Drive is selected.

• Up/Down Buttons - Used in the MANUAL mode to select upshifts and downshifts.

Gear Display

The Gear Display (Figure 3-12) shows the current gear position of the transmission. The Gear Display will flash the target gear position of the transmission when in neutral during a shift.

The “DASH” indicates the transmission may be torque locked in gear (see Locked in Gear in this section).

Start-up and Power Down Start-up

1. Turn the ignition to ON and allow the UltraShift™ to power-up. Engine cranking is delayed until the transmission power-up is complete and the gear display shows a solid “N”

2. Start the engine.

3. Apply the service brake.

NOTE: If the service brake is not applied while selecting a starting gear, the initial start gear will not be found and the driver will have to re-select neutral and press the brake while re-selecting the desired mode.

4. Select the desired mode and starting gear on the shift console.

5. Release the parking brake.

Published 12-22-2008, Control # 107-09

6. Release the service brake and apply accelerator.

NOTE: The transmission is not intended to provide hillhold capability. The service brakes should be used to stop and hold the machine on an incline. To prevent the machine from rolling when starting on an incline, place both feet on the brake pedal before sliding the right foot to the throttle pedal. Gradually back off the brake while applying as little throttle as necessary to move along the incline.

Power Down

1. Select Neutral (N) on the shift control.

NOTE: If gear display does not show solid (N), neutral has not yet been obtained.

NOTE: Neutral should always be reached before Ultrashift power down is performed, except in cases of emergency.

2. Set the machine parking brakes.

3. Turn the ignition switch to off (vertical position) and allow the engine to shut down.

Proper Starting Gear

Chose a starting gear appropriate for the load and grade conditions, while at a stop in Drive and MANUAL modes by using the up/down buttons. Refer to Drive Mode for detailed information.

Skip Shifting

Performed in MANUAL by pressing the shift button more than once.

Optimal Engine Braking

The LOW mode can be selected while moving. This initiates downshifts as soon as possible to maximize the effect of engine braking. Refer to LOW mode section for detailed information.

Skid Conditions

If a skid condition occurs, the UltraShift™ senses the vehicle speed dropping rapidly. In this case, the UltraShift™ delays downshifting.

Load Based Shifting

In Drive, the UltraShift™ will adapt to the changing conditions of the vehicle. Right after power-up or after changing loads, UltraShift™ needs to learn the new conditions. While learning, the transmission may hold a gear instead of upshifting. When this occurs simply push the Up button to start the upshift. It may take three or four shifts for the UltraShift™ to learn the new conditions. After that the transmission will complete upshifts and downshifts automatically.

Depending on conditions, the UltraShift™ can activate the engine brake in order to bring the engine down faster for an upshift. This can happen if the engine brake dash switch is off.

Coast Mode

When coasting to a stop in lower gears with your foot off the throttle, UltraShift™ may not finish downshifting until the driver gets back on the throttle. The system will automatically track vehicle and engine speed during this time and engage the appropriate gear when the throttle is re-applied. This is a normal condition for the UltraShift™ when in Drive “D” mode only.

Clutch Protection

Even though the crane does not have a clutch pedal, it still has a mechanical clutch. As you slowly increase and decrease engine RPM from a stop, the clutch is engaging and disengaging, just like slipping the clutch with an AutoShift or Manual transmission.

If you operate for long periods between engine idle and 1000 RPM during take off, you are slipping the clutch which, in turn, gets the clutch HOT.

Caution

If you see the (C) and then an (A) in the gear display during operation, stop the crane for at least 2 minutes and let the clutch cool down.

Continuing operation with the (C) and (A) flashing on the gear display will cause the clutch to get even hotter and the transmission may attempt to downshift into a lower start gear and/or limit the engine to idle speed until the clutch cools (approximately 3 minutes).

Repeated incidents of clutch abuse may cause the clutch to fail and the crane not to be able to move, resulting in extended down time.

Excessive clutch slippage creates heat, which is detrimental to clutch life. If the system detects the clutch is being overheated, a warning tone will sound and the Gear display will flash a (C) than an (A) (Figure 3-13) signifying clutch abuse followed by the selected gear position. The alarm will continue until the clutch system cools, the throttle is released, or the clutch is fully engaged. If one of these is not done and the clutch heat continues to rise, the launch quality may be adversely affected and the clutch may be damaged. Selecting 1st gear (Figure 3-13) as the start up gear will reduce the risk of clutch abuse.

FIGURE3-13

Example of clutch abuse is listed in (Table 3-1) along with helpful hints on how to avoid.

Table 3-1

ExampleHow To Avoid

Use service brakes to hold on hill. To start moving, apply the throttle and release the brakes as you feel the crane start to pull.

NOTE: The transmission is not intended to provide hillhold capability. The service brakes should be used to stop and hold the vehicle on an incline. To prevent the vehicle from rolling when starting on an incline, place both feet on the brake pedal before sliding the right foot to the throttle pedal. Gradually back off the brake while applying as little throttle as necessary to move along the incline.

Reverse Mode

The vehicle speed must be less than 2 mph before Reverse is permitted. If the driver requests Reverse above 2 mph, the shift is not performed until the speed has dropped below 2 mph.

Depending on the transmission model, there may be a number of reverse gears available. Each time Reverse is selected from Neutral, the default reverse gear is engaged. While the vehicle is stopped in Reverse, the up/down buttons are used to change the reverse gear. This selection is used only until another mode is selected.

There is a speed limit on the reverse engagements, yet the driver can effectively rock the vehicle by moving the shift control from reverse to drive and drive to reverse.

Drive Mode

Depending on the transmission model and Shift Control configuration, there may be alternate forward starting gears available. While the vehicle is stopped in Drive, the up/down buttons are used to change the starting gear. This selection is used until it is changed again, or the UltraShift™ is powered down.

In Drive mode, all upshifts and downshifts are performed automatically based on vehicle and transmission conditions. The driver can advance a shift (by about 75 rpm) by pressing the proper up/down button (up for upshifts, down for downshifts) when the transmission is within 75 rpm of the load based shift point.

The Gear Display shows the status of the shift:

• The current gear is displayed solid.

• At the start of the shift, the current gear is displayed solid until the transmission is pulled to the neutral position.

• While the transmission is in neutral and synchronizing for the target gear, the target gear is flashed.

• When the shift is complete, the new current gear is displayed solid.

Cruise Control

If a shift is required while cruise control is active, cruise is temporarily interrupted while the shift is performed and then automatically resumes after the shift.

Manual Mode

Manual mode should be used whenever you want to select the shifts instead of letting UltraShift™ select them automatically for you. For example, when you are moving around the yard or on steep grade conditions.

Selecting From Neutral

As described above for Drive Mode, the starting gear can be changed in exactly the same way in Manual mode.

If Manual mode is selected from a stop, the starting gear is maintained - no automatic shifts are performed, except for conditions noted below.

The driver can request shifts using the proper shift button (up for upshifts, down for downshifts). The upshift or downshift is performed by the UltraShift™ provided the result in engine speed is not outside of defined limits. For upshifts, the resulting engine speed must be greater than 900 RPM; for downshifts, the resulting engine speed must be less than engine rated speed.

Selecting Manual from Drive or Low while Moving

FIGURE3-14

If Manual mode is selected while moving, the current gear is maintained - no shifts are performed, except for conditions noted below.

As described above, the driver can request shifts using the proper shift button (up for upshifts, down for downshifts) within the same limits described.

Transmission Manual Override

If the vehicle is being back driven and the engine is approaching a higher than normal level (approximately 300 RPM above rated speed), the UltraShift™ overrides the MANUAL position and performs an upshift to prevent engine damage.

If the gear being maintained is higher than starting gear, and the driver depresses the pedal, the UltraShift™ overrides the Manual mode and shifts to the best available gear.

Low Mode

LOW mode should be used any time you want to maximize engine braking and minimize the use of the brake pedal. For example, when driving down long grades or when coming to a stop.

Selecting Low From Neutral

If LOW mode is selected from Neutral while stopped, the starting gear is always 1st gear. The starting gear cannot be changed in LOW mode.

If LOW mode is selected from Neutral while stopped, 1st gear is maintained - no shifts are performed, except for conditions noted below.

Selecting Low From Drive or Manual While Moving

If LOW mode is selected while moving, no upshifts are performed, except for override conditions noted below. Downshifts are performed at higher RPM's than normal to enhance engine braking. The downshift point is chosen so engine speed after the shift is about 50 rpm below engine rated speed.

Transmission Low Override

If the vehicle is being back driven and the engine is approaching a higher than normal level (approximately 300 rpm above rated speed), the UltraShift™ overrides the LOW position and performs an upshift to prevent engine damage.

If the gear being maintained is higher than the starting gear, and the driver depresses the pedal, the UltraShift™ system will override the LOW mode and shift to the best available gear if the engine lugs excessively.

Locked In Gear

If the crane is shut down or stalls in gear, the UItraShift™ may become locked in gear. The transmission will attempt to get to Neutral during the next power up if the shifter is in Neutral. If Neutral is achieved, a solid "N" appears on the Gear Display. If Neutral can not be achieved, a "DASH" will appear on the display and the engine will not start. If a dash appears during power up and the lever is in Neutral try the following:

1. Turn the key OFF and let the transmission power down for a least 2 minutes.

2. Depress the brake pedal.

3. Release the parking brake.

Caution

Do not turn ignition key to off with transmission in gear.

4. Make sure the shifter is in Neutral.

5. Turn the key to the ON position.

6. The transmission will attempt to shift into Neutral once you turn the key ON, but you may have to slightly release the brake pedal to help let the torque off the driveline.

7. Once it reaches Neutral a solid "N" will appear on the Gear Display and the machine will start. If a dash still appears after this procedure, get the vehicle to a service center.

Diagnostics

NOTE: Refer to the Shop Reference and Maintenance Guide for fault code diagnostic procedures. If fault codes cannot be retrieved, contact your local distributor or Manitowoc CraneCARE.

In the event there is a problem with the UltraShift™, there are three primary tasks the driver should perform:

1. Note the driving condition under which the problem occurred.

2. Note the condition of the UltraShift™ under which the problem occurred (i.e. operation mode (Drive, MANUAL, LOW), current gear, engine speed, etc).

3. Reset the system.

Transmission Reset Procedure

In some cases, proper transmission operation can be restored by "resetting" the transmission Electronic Control Unit (ECU). Use the following procedure to reset the ECU:

1. When it is safe to do so, stop the vehicle.

Caution

Do not turn ignition key to off with transmission in gear.

2. Place the transmission shift lever in Neutral and turn the ignition key to the OFF position.

3. Wait at least 2 minutes.

4. Restart the engine.

5. If the problem continues, contact a service facility to have the vehicle and transmission system evaluated.

6. In most cases, depending on the engine and axle ratios, fuel can be saved by operating the crane at less than governed rpm while in 8th gear.

Auxiliary Transmission Operation

Caution

Before job site or off-highway travel or pick and carry, select auxiliary transmission LOW range to prevent clutch damage.

The auxiliary transmission low range switch is located on the carrier right side console.

1. Push the auxiliary transmission low range switch to the right to engage low range.

An amber indicator on the carrier left front console will illuminate when the auxiliary transmission is in low range.

Rear Tandem Inter-Axle/Cross-Axle Locks

Caution

Do not operate differential locks on dry roads.

To engage the inter-axle or cross axle differential locks for maximum pulling power when approaching slippery or poor road conditions, do the following:

Caution

Do not engage or disengage differential locks while wheels are spinning or at speeds over approximately 16 km/h (10 mph).

1. Stop the crane and position the switch to the lock position.

2. Proceed over the poor road conditions cautiously.

When adverse conditions have passed, do the following:

1. Stop the crane and position the switch to the unlock position.

2. Resume driving at a safe speed.

Service/Parking Brakes

For the most effective braking and maximum life from the brake system components, the following suggestions are made.

1. Air brakes have light pedal operation and the driver is cautioned to use extreme care in application until a good feel is achieved.

2. Use the engine as a brake when approaching a stop or going down a long grade. On a downgrade, use the same transmission gear as would be needed to go up the same grade.

3. When necessary to use brakes to reduce crane speed on downgrades, use a on-and-off application to minimize heat and wear. Do not hold a continuous brake application or slide the wheels.

4. When driving on slippery pavement or under icy conditions, alternately and smoothly apply and release the brakes to prevent skidding.

5. Keep the tires properly inflated. Improperly inflated tires can reduce the efficiency of the brakes.

6. After driving through water, dry the brakes by applying them lightly while maintaining a slow forward speed with an assured clear distance ahead until brake performance returns to normal.

Danger

Stop immediately if low air pressure warning sounds and determine cause of air loss, Stop by downshifting and use engine as a brake. Make final stop using a single brake pedal movement to avoid excessive loss of air and sudden engagement of parking brakes.

NOTE: If the pressure drops below 14 kPa (2psi) per minute with the engine stopped, have the air system checked for leaks.

7. Regularly check the air pressure gauge. System air pressure should never drop below 310 kPa (45 psi). If both systems drop below 310 kPa (45 psi), the automatic spring brakes will actuate. Normal operating pressure is 725 to 825 kPa (105 to 120 psi).

Published 12-22-2008, Control # 107-09

Danger

Do not use parking brake for stopping crane except in case of an emergency, as a severe sudden stop will occur.

Caution

Release brakes before moving crane, or drive train damage will result.

NOTE: Park brake must be set before outrigger controls can be operated.

8. The parking brakes are controlled by a push-pull knob on the front console. Pull the knob out to apply and push the knob in to release the parking brake.

Engine Braking

NOTE: Do not keep a foot lightly on the clutch pedal or the throttle pedal. This will cause the engine brake not to come on.

NOTE: Compression brakes are quieter on engines with the exhaust aftertreatment feature.

By energizing the engine brake, the power producing diesel engine, in effect, becomes a power absorbing air compressor. To retard a crane on a downgrade using the Engine Brake, the operator selects a gear which will provide a balance between engine speed and road speed, then engages the engine brake. If the engine speed exceeds maximum rated rpm for a desired speed, a lower gear can be selected or intermittent use of the service brakes can be made. This selection of a lower gear will generally allow complete control of the crane by the engine brake leaving the service brakes in reserve to be used for emergency stops. With the engine brake turned on, the engine brake will not be energized until the momentum is driving the engine.

1. Position the engine brake On/Off switch to on (push top of switch).

2. Position the engine brake switch to either high (press top of switch) or low (press bottom of switch) position, depending on the amount of braking desired.

3. Leave off the throttle to activate the engine braking system and slow the crane.

NOTE: The engine braking system will automatically deactivate when the throttle is depressed.

Caution

Before engaging engine brake on slippery roads, be sure crane is maintaining traction.

Stowing and Parking

Danger

Never park crane near holes, on rocky surfaces, or on soft spots. This may cause crane to overturn, resulting in injury or death to personnel.

When parking the crane, do 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, swing lock pin, and 360 degree swing lock.

6. Retract all stabilizer cylinders and outrigger beams.

7. Turn the crane function power switch to the off position (press bottom of switch).

8. Park the crane on a stable surface.

9. Apply the parking brakes and if necessary, chock wheels.

10. Ensure all operating controls are in neutral position.

11. Shut down engine following proper procedures specified in this handbook and the applicable engine manual.

12. Remove the keys.

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

Crane Shutdown Procedures

The following procedures will extend serviceable life of various crane components, reduce vandalism, and accidents during crane shutdown periods or anytime the crane is left unattended.

1. Perform the procedures found under Shutdown Procedure in this handbook.

Danger

Never park crane near holes, on rocky surfaces, or on soft spots. This may cause crane to overturn, resulting in injury or death to personnel.

2. Park the crane on a proper surface with the outrigger stabilizers and beams fully retracted. Do not park in a location where it may become frozen to the ground or settle unevenly and overturn.