4 Operating Procedures

4.1 Breaking-in A New Carrier

Your new Manitowoc/Grove carrier has been thoroughly tested, adjusted, lubricated, and inspected prior to delivery. However, as road shock and crane operation occur, moving parts wear in, or gasket and hose connections take a set, an occasional oil, air, or coolant leak may develop. Immediate corrective action should be taken to avoid major repairs later. For detailed engine break-in, refer to the applicable engine manual.

Some important rules to follow to establish conditions for long service life are listed below.

1.Operate as much as possible in half to three-quarters throttle or load range.

2.Avoid long periods of operation at engine idle speeds or at continuous maximum horsepower levels.

3.Observe instruments often and shut down at the first indication of an abnormal reading.

4.Operate to a power requirement that allows acceleration to governed speed when conditions require more power.

5.Check all components frequently for proper operation, unusual noises, or excessive heating.

6.Check the engine oil and the coolant levels frequently.

These rules should not be considered as limitations in putting your equipment to work at maximum capacity, but rather to serve as a guide to familiarization and development of good operating habits.

4.2 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 ensure his crane is prepared for starting the day’s work.

4.2.1 Fuel Supply

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

4.2.2 Engine Oil

DO NOT OVERFILL THE ENGINE CRANKCASE.

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

4.2.3 Engine Coolant

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

4.2.4 Batteries

Currently some cranes use maintenance-free type batteries. When applicable, check the stateof-charge indicator on these type batteries. On cranes not using the maintenance-free batteries, check each cell for the correct electrolyte level. Add only clean, distilled water. Do not overfill. On either type battery, ensure the cables and clamps are tight and not corroded.

4.2.5 Seats

Adjust seat and mirrors for clear vision and safe driving.

4.2.6 Seat Belts

Seat Belt Maintenance

Seat belt assemblies are maintenance-free; however, they should be periodically inspected to ensure that they have not become damaged and they remain in proper operating condition, particularly if they have been subjected to severe stress.

Cleaning Seat Belt Webbing

To clean the webbing, wash with any mild soap or detergent. Do not clean seat belts with commercial solvents. Also, bleaching or re-dyeing the webbing is not recommended because of possible loss of webbing strength.

4.2.7 Signal and Running Lights

4.2.8

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

Foot and Parking Brakes

Check for proper operation.

4.2.9 Tires

Check pressure and condition of all tires before starting.

HFor tire inflation pressures, refer to the Tire Inflation Decal on the crane.

4.2.10 Wheels

Maintain proper torque on wheel lugs and check for proper wheel mounting.

4.2.11 Safety Equipment

Check all lights, windshield wipers, washers, washer liquid supply, horn, instruments, signaling devices, etc.

4.2.12

Daily Lubrication

Ensure all components requiring daily lubrication have been serviced. (Refer to Section 5, Lubrication).

4.3 Cold Weather Operation

The following recommendations are for operating Grove cranes in very low (i.e. sub-zero) temperatures.

Use particular care to ensure that cranes being operated in very cold temperatures are operated and maintained in accordance with the procedures as provided by Grove Worldwide. Cranes should have appropriate hydraulic oil, lubricants, and other auxiliary items required for operation in sub-zero temperatures. Individual crane functions should be operated to ensure they are sufficiently warmed prior to performing a lift.

Operation of cranes at full rated capacities in temperatures between zero (0) and -40° C (-40° F) or lower shall be accomplished only by competent operators who possess the skill, experience, and dexterity to ensure smooth operation. Shock loading shall be avoided. For cold weather operation, capacities shall be derated 2 percent of the rated load shown on the capacity charts for each degree below -40° C (-40° F).

4.4 Engine Operation

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

4.4.1 Starting Procedure

BEFORE STARTING THE ENGINE, ENSURE THE TRANSMISSION IS IN NEUTRAL, PARKING BRAKE IS APPLIED, AND SWING LOCK IS ENGAGED.

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.

IF THE ENGINE FAILS TO START AFTER FOUR ATTEMPTS, CORRECT THE MALFUNCTION BEFORE ATTEMPTING ANY FURTHER STARTS.

1.Turn the ignition switch to START and release immediately when the engine starts.

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

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

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.

4.4.2 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 5° C (10° F) 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 or starting aid compound metering equipment.

THE COLD START SYSTEM ON THE ENGINE OPERATES AUTOMATICALLY. IF THE ENGINE DOES NOT START IMMEDIATELY, AVOID OVERLOADING THE AIR BOX WITH HIGH VOLATILE FLUID WHICH COULD RESULT IN A MINOR EXPLOSION.

STo start the engine, position the ignition switch to START. If the engine does not start within 30 seconds, allow the starter to cool at least two minutes and repeat the procedure.

4.4.3 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.

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

4.4.4 Racing The Engine

NEVER race the engine during the warm-up period. NEVER operate the engine beyond governed speed (as might occur in downhill operation or downshifting). Engine bearings, pistons, and valves may be damaged if these precautions are not taken.

4.4.5 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 OFF.

GIF AN OVERHEATING CONDITION NECESSITATES AN EMERGENCY SHUTDOWN, USE CAUTION WHEN CHECKING THE RADIATOR. WHEN LOOSENING THE RADIATOR CAP TO RELIEVE PRESSURE, USE A HEAVY CLOTH OR GLOVES. ALLOW THE ENGINE TO COOL BEFORE REMOVING THE CAP FROM THE RADIATOR.

SCORRECT THE PROBLEM THAT CAUSED THE EMERGENCY SHUTDOWN BEFORE ATTEMPTING A RESTART OF THE ENGINE.