Manitowoc Grove Crane AT635 SERIES SUPERSTRUCTURE Operator Manual PDF

OPERATOR’S AND SAFETY HANDBOOK

AT635 SERIES SUPERSTRUCTURE S/N_________________________

PUBLISHED: DECEMBER 1995

LIST OF EFFECTIVE PAGES Original . . . . . . . December 1995

ii

Page Numbers

Change In Effect

Title Page thru xiv 1−1 thru 1−3 2−1 thru 2−56 3−1 thru 3−14 4−1 thru 4−31 5−1 thru 5−22 6−1 7−1 thru 7−17

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.

Effective Date

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 WORLDWIDE CRANE PRODUCTS, EXCEPT THE MANUFACTURER’S WARRANTY AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP SET OUT BELOW: NEW CRANE PRODUCT WARRANTY The Manufacturer warrants each new Grove Worldwide crane product made by the Manufacturer to be free from defects In material and workmanship at the time of the product’s tender of delivery. The Manufacturer’s obligation and liability under this warranty are limited to (a) repairing or replacing (at the Manufacturer’s option) free of charge at its factory, any part proving so defective under normal use and service within twelve (12) months from the date of Initial sale, lease or rental, and (b) the reasonable labor cost of repair and/or replacement of said part or parts within six (6) months from the date of Initial sale, lease or rental, all providing the product is on record with the Manufacturer as being installed by the Distributor, Manufacturer further warrants for an additional nine (9) years the structural weldments described and Identified as the boom sections, turntable, carrier frame, boom extension, Jib and outrigger beams, to be free from defects In material and workmanship at the time of the product’s tender of delivery, The Manufacturer’s obligation and liability under this structural warranty are limited to repairing or replacing (at the Manufacturer’s option) free of charge at its factory any such structural weldment proving defective under normal use and service, but does not cover any labour or installment costs Incurred for the replacement of such structural weldment, If the product 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 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 new crane products of Grove Worldwide; 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. GROVE WORLDWIDE NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH SUCH PRODUCTS.

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, (0191) 5656281. (Address: Grove Worldwide Sunderland, England, SR3 3XR).

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

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

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 operators to visit our works for instruction and training. For details write to Product Support, 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

SECTION II SAFETY PRECAUTIONS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1 CRANING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−7 JIBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−24 WIRE ROPE AND SHEAVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−25 CONTROLLED FREE−FALL HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−30 ELECTRICAL HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−30 PERSONNEL PLATFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−42 COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−42 DON,T FORGET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−43 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−44 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−49

SECTION III CAB CONTROLS AND INDICATORS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 Engine Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 Battery Circuit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 Alternator Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 Low Oil Pressure Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 High Engine Temprtature Warning Light . . . . . . . . . . . . . . . . . . . . 3−2 Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Foot Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Hand Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Site Crane Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Swing and Telescope or Auxiliary Hoist Control Lever . . . . . . . 3−2 Boom Lift and Main Hoist Control Lever . . . . . . . . . . . . . . . . . . . . 3−3 Hoist Rotation Indicators − Optional . . . . . . . . . . . . . . . . . . . . . . . . 3−3 Telescope Control Pedal − Optional . . . . . . . . . . . . . . . . . . . . . . . . 3−3 x

Page Swing Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Swing Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Hoist Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Hoist Over Lower Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Axle Suspension Lock Switch (Spring Suspenion Only) . . . . . . 3−5 Axle Suspension Lock Warning Light (Spring Suspenion Only) 3−5 Suspension Locked Warning Light (Yellow) . . . . . . . . . . . . . . . . . 3−5 Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Auxiliary Hoist Selector Switch (Optional) . . . . . . . . . . . . . . . . . . 3−6 Warning Light (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Dual Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Low Air Pressure Indicator Warning Light (Red) . . . . . . . . . . . . . 3−6 Park Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Park Brake Indicator Warning Light (Red) . . . . . . . . . . . . . . . . . . . 3−6 Brake Foot Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Rear Steering Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 P.T.O. Warning Light (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Rear Steer Control (Orbitrol Steering) . . . . . . . . . . . . . . . . . . . . . . 3−7 Steer Control Switches (Electrical Tiller Steering) . . . . . . . . . . . 3−7 Rear Steer Indication Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Outrigger Selector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Safe Load Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Gearshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Panel Light Dimmer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Roof Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Heater Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Heater Control Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Windscreen Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Lights Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Rotating Beacon Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Armrest Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Heat Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Duty Selector Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10

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Page

SECTION IV OPERATING PROCEDURES PRE−STARTING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Signal and Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 Foot and Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Steering Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3 Hookblock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3 Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5 Idling the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5 Racing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−5 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6 CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6 CRANE TRAVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−7 Travelling General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−7 Moving the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−8 Superstructure Travel − Pick and Carry Duties . . . . . . . . . . . . . . . . . 4−9 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−9 Travelling Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−12 Travelling Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−13 Control Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−13 Preload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−13 USING YOUR LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−14 CRANE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−15 Setting the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−15 To Extend the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−18 To Retract the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−20 Remote Control Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−20 To Extend the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−21 To Retract the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−22 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−23 Operating Stabilizers Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−23 xii

Page Partial Outreach Extension − Optional . . . . . . . . . . . . . . . . . . . . . . . . 4−24 Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−26 Elevating and Lowering the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−27 Elevating the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−27 Lowering the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−27 Telescoping the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−28 Extending the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−28 Retracting the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−29 Lowering and Raising the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−29 Lowering the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−29 Raising the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−30 Emergency Boom Operating Procedures . . . . . . . . . . . . . . . . . . . . . 4−30 Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−31

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

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

SECTION VII SET UP AND INSTALLATION PROCEDURES GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING CABLE ON THE HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE REEVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEDGE AND SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7−1 7−1 7−2 7−3 xiii

Page 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−10 Setting the Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−13 Setting the Telescoping Extension Length . . . . . . . . . . . . . . . . . . . . 7−14 Extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−14 Retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−15

LIST OF FIGURES Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−3 Cab Controls and Indicators (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . 3−11 Cab Controls and Indicators (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . 3−12 Cab Controls and Indicators (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . 3−13 Cab Controls and Indicators (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . 3−14 Terms to Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−15 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−17 Lubrication Diagram (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18 Lubrication Diagram (Sheet 2 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−19 Lubrication Diagram (Sheet 3 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−20 Lubrication Diagram (Sheet 4 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−21 Lubrication Diagram (Sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−22 Installing Cable Anchor Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−2 Erecting and Stowing the Swingaway Boom Extension . . . . . . . . . . . 7−12 Swingaway Offset Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−17

xiv

SECTION I GENERAL INTRODUCTION This Handbook provides information for the operators of the Model AT635 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. Steering is power assisted utilising hydraulic steering cylinders fixed to the axles. The engine is mounted at the front of the crane and provides motive power through an 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. Alternatively a hydragas suspension system with hydraulic lockout and an automatic levelling system operated from the cab may be fitted.

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 fully powered boom. Additional reach is obtained by utilising a 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 super cab operator‘s seat with the superstructure facing rearward with the boom directly over the rear of the carrier frame.

1−1

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 Centre of Gravity 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.

1−2

Slinging Points 1−3

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 co− workers, 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.

Follow directions on all placards.

Know what they mean and follow their instructions.

Be prepared for the work day.

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.

2−2

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.

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.

2−3

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.

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.

2−4

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.

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.

2−5

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.

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.

WARNING NO RIDERS! ROTATING MACHINERY AND REVOLVING TIRES TO PREVENT DEATH OR SERIOUS INJURY, ONLY THE CRANE OPERATOR SHALL OCCUPY THE CRANE WHEN TRAVELING OR IN OPERATION2802 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.

2−6

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.

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.

2−7

Use the sight level bubble indicator to ensure crane leveling.

90 DEGREES

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.

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.

2−8

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 (HEADACHE BALL, BLOCK, JIB, ETC.) − ARE PART OF THE LOAD.

2−9

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.

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.

2−10

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.

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 accommodate 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 signalman 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.

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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.

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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.

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

Always move toward the load and move slowly. Use a tag line 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.

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.

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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.

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.

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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.

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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.

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.

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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.

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

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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.

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.

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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.

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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.

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 recom2−22

mended 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.

3.

Ensure the handbrake is applied and the slew lock engaged.

4.

Stop engine(s) and remove the ignition key(s), lock cab door(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.

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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.

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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 usable.

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.

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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.

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LIFT ONE LOAD AT A TIME. Do not lift two or more separately rigged loads atone 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.

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Ensure hoist cable (wire rope) is properly routed.

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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 antitwo−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.

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 hook block, etc.at least 12 inches (30.48 cm) away from the boom nose at all times.

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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.

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

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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.

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.

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− 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. IMPORTANT − Always consider the wire rope, hoist cable, pendant cables, tag lines, 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.

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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.

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! 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.

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

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.).

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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.

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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.

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.

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

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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.

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

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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.

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.

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− 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.

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.

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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.

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).

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. OPERATING PRECAUTIONS WARNING IT IS DANGEROUS TO OPERATE ANY CRANE MOTIONS, WITH OR WITHOUT LOADS, WITH THE OUTRIGGERS IN THE STOWED POSITION. THEREFORE THE OUTRIGGER BEAMS MUST BE EXTENDED TO CORRECT FULL OR PARTIAL CENTRES AND THE CRANE SUPPORTED USING THE OUTRIGGER JACKS ON A FIRM, LEVEL AND UNIFORMLY SUPPORTING SURFACE WITH THE TYRES RAISED FREE OF THE GROUND. THE CRANE MUST BE ACCURATELY LEVELLED, USING THE OUTRIGGER JACKS BEFORE CRANE OPERATION. IT MAY BE NECESSARY TO HAVE STRUCTURAL SUPPORTS UNDER THE OUTRIGGER FLOATS TO SPREAD THE LOAD TO A LARGER BEARING SURFACE. THE TABULATED CAPACITIES SHOWN ON THE LOAD CHART IN THE OPERATORS CAB ARE VALID ONLY IF THE CRANE IS BLOCKED ACCORDINGLY. 2−44

WHEN OPERATING ‘FREE ON WHEELS’ THE MACHINE MUST BE ON A FIRM, LEVEL AND UNIFORMLY SUPPORTING SURFACE WITH THE TYRES INFLATED TO THE CORRECT PRESSURE AND THE SUSPENSION LOCKED. OPERATION MUST ONLY BE WITHIN LIMITS OF RADIUS OR ANGLE STATED ON THE LOAD CHART IN THE OPERATORS CAB. When operating ‘free on wheels’, over rear capacities must only be lifted with the boom centred over the rear of the crane, swing lock engaged and load restrained from swinging, and valid only up to a creep speed as specified on the cab load chart.

WARNING WITH THE 3.475 TONNE COUNTERWEIGHT NO MOTION MAY BE OPERATED UNLESS THE CRANE IS:− A) BLOCKED WITH THE OUTRIGGERS FULLY EXTENDED TO 6M JACK CENTRES. B) BLOCKED WITH THE OUTRIGGERS PARTIALLY EXTENDED TO 4.2M JACK CENTRES AND PINNED. C) IN THE FREE ON WHEELS CONDITION WITH THE BOOM DIRECTLY OVER THE REAR AND THE SLEW LOCK PIN ENGAGED. UNTIL THIS CONDITION IS REACHED, THE CRANE MUST BE BLOCKED WITH THE OUTRIGGERS IN CONDITIONS (A) OR (B).

WARNING WITH THE OUTRIGGERS FULLY EXTENDED AND THE 7.6M NON−OFFSETABLE EXTENSION IN THE WORKING POSITION, THE MAIN BOOM MUST BE FULLY RETRACTED FOR BOOM ANGLES LESS THAN THOSE SHOWN ON THE CAPACITY CHART. THIS WARNING ALSO APPLIES FOR BOOM EXTENSION ERECTION PURPOSES. 2−45

WARNING WITH THE OUTRIGGERS FULLY EXTENDED AND THE 7.6M FIXED LENGTH OFFSETABLE EXTENSION IN THE WORKING POSITION, THE MAIN BOOM MUST BE FULLY RETRACTED FOR BOOM ANGLES LESS THAN THOSE SHOWN ON THE CAPACITY CHART. THIS WARNING ALSO APPLIES FOR BOOM EXTENSION ERECTION PURPOSES. WARNING WITH THE OUTRIGGERS FULLY EXTENDED AND THE 7.6M TELESCOPIC EXTENSION IN THE WORKING POSITION, THE MAIN BOOM MUST BE FULLY RETRACTED FOR BOOM ANGLES LESS THAN THOSE SHOWN ON THE CAPACITY CHART. THIS WARNING ALSO APPLIES FOR BOOM EXTENSION ERECTION PURPOSES. WARNING WITH THE OUTRIGGERS FULLY EXTENDED AND THE 10.4 OR 13.1M EXTENSION IN THE WORKING POSITION, THE MAIN BOOM MUST BE FULLY RETRACTED FOR BOOM ANGLES LESS THAN THOSE SHOWN ON THE CAPACITY CHART. THIS WARNING ALSO APPLIES FOR BOOM EXTENSION ERECTION PURPOSES.

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WARNING WITH THE OUTRIGGERS PARTIALLY EXTENDED TO 4.2M CENTRES AND THE 7.6M NON−OFFSETABLE EXTENSION IN THE WORKING POSITION, THE MAIN BOOM MUST BE FULLY RETRACTED FOR BOOM ANGLES LESS THAN THOSE SHOWN ON THE CAPACITY CHART. THIS WARNING ALSO APPLIES FOR BOOM EXTENSION ERECTION PURPOSES. WARNING WITH THE OUTRIGGERS PARTIALLY EXTENDED TO 4.2M CENTRES AND THE 7.6M FIXED LENGTH OFFSETABLE EXTENSION IN THE WORKING POSITION, THE MAIN BOOM MUST BE FULLY RETRACTED FOR BOOM ANGLES LESS THAN THOSE SHOWN ON THE CAPACITY CHART. THIS WARNING ALSO APPLIES FOR BOOM EXTENSION ERECTION PURPOSES. WARNING WITH THE OUTRIGGERS PARTIALLY EXTENDED TO 4.2M CENTRES AND THE 7.6M TELESCOPIC EXTENSION IN THE WORKING POSITION, THE MAIN BOOM MUST BE FULLY RETRACTED FOR BOOM ANGLES LESS THAN THOSE SHOWN ON THE CAPACITY CHART. THIS WARNING ALSO APPLIES FOR BOOM EXTENSION ERECTION PURPOSES.

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WARNING WITH THE OUTRIGGERS PARTIALLY EXTENDED TO 4.2M CENTRES AND THE 10.4 OR 13.1M EXTENSION IN THE WORKING POSITION, THE MAIN BOOM MUST BE FULLY RETRACTED FOR BOOM ANGLES LESS THAN THOSE SHOWN ON THE CAPACITY CHART. THIS WARNING ALSO APPLIES FOR BOOM EXTENSION ERECTION PURPOSES. WARNING FOR PICK AND CARRY DUTIES ALWAYS TRAVEL WITH THE BOOM OVER THE REAR OF THE CARRIER, WITH THE (AXLES) SUSPENSION LOCKED AND WHERE POSSIBLE WITH THE BOOM TELESCOPED IN AND THE OUTRIGGERS EXTENDED AND JACKS JUST CLEAR OF THE GROUND. The crane load charts allow for wind speed of 20 mph on the crane structure but make no allowance for the effect of the wind on the load.

WARNING OPERATION OF THIS MACHINE WITH HEAVIER LOADS THAN THE CAPACITIES LISTED IN THE CAPACITY CHART IS STRICTLY PROHIBITED. MACHINE TIPPING WITH BOOM EXTENSION OCCURS RAPIDLY AND WITHOUT ADVANCE WARNING, REMOVE ALL REEVING/RIGGING ACCESSORIES FROM MAIN BOOM WHEN USING BOOM EXTENSION. 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 swingaway is fitted in the operating position, main boom capacities MUST be reduced. Refer to the load chart for load reductions.

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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 OR WITH A LOAD SUSPENDED FROM THE HOOK. WARNING IT IS MANDATORY THAT ALL HYDRAULIC HOSES AND FITTINGS BE CORRECTLY TAGGED AND IDENTIFIED BEFORE THEY ARE DISCONNECTED TO EFFECT REPAIRS OR SERVICE. FAILURE TO CORRECTLY TAG AND IDENTIFY HOSES AND FITTINGS CAN CAUSE WRONG CONNECTION, WHICH CAN RESULT IN DEATH OR INJURY TO PERSONNEL. FOLLOWING DISCONNECTION AND RECONNECTION ALL MOTIONS ARE TO CHECKED FOR CORRECT OPERATION.

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ADDITIONAL OPERATORS AND SAFETY HANDBOOK INSTRUCTIONS TO COMPLY WITH THE REQUIREMENTS OF THE MACHINERY DIRECTIVES 89/392/EEC AND 91/368/EEC. THE INTENDED USE OF THE CRANE IS THAT OF GENERAL HOOK DUTIES − NOT FOR CONTINUOUS SERVICE − GROUP A1. (REF. ISO 4301/1 AND /2 − CRANES AND LIFTING APPLIANCES − CLASSIFICATION − PART 1 − GENERAL AND PART 2 − MOBILE CRANES) THE EXPECTED LIFETIME OF THE CRANE LIES BETWEEN THE FOLLOWING CONDITIONS − 32000 OPERATIVE CYCLES (U1) WITH MODERATE STATE OF LOADING (Q2) 63000 OPERATIVE CYCLES (U2) WITH LIGHT STATE OF LOADING (Q1 (REF. − ISO 4301/1 AND /2)

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ABNORMAL USE − FOR USE OUTSIDE OF THE OPERATING CONDITIONS GIVEN, EG. WHERE THERE IS AN EXPLOSION OR FIRE HAZARD OR OFFSHORE USE SPECIAL PRECAUTIONS MUST BE TAKEN. THE ADVICE OF GROVE WORLDWIDE SHOULD BE SOUGHT IN SUCH CASES. OTHER LIMITING CONDITIONS OUTSIDE WHICH WOULD BE CONSIDERED ABNORMAL USE ARE: IN−SERVICE WIND SPEED THE MAXIMUM IN−SERVICE WIND/ SPEED FOR ALL BOOM LENGTHS IS 9M/S (20 MPH) (32KPH) FOR THE SPECIAL CASES WHERE CRANES ARE SUPPLIED TO NEN STANDARDS THE MAX. IN−SERVICE WIND SPEED FOR ALL BOOM LENGTHS IS 14 M/S (31 MPH) (50 KPH).

OUT OF SERVICE WIND SPEED THE MAIN BOOM SHOULD BE RETRACTED AND LOWERED WITH THE SWING BRAKE SET IN WIND VELOCITIES OVER 20 M/S (45 MPH) (72 KPH).

AMBIENT TEMPERATURE THE MAXIMUM AMBIENT TEMPERATURE RANGE FOR CRANE OPERATION IS −20° C + 40° C (−4° F TO 104° F).

LIFTING OF PERSONS SEE PREVIOUS NOTES IN THIS SECTION. CARE IS TO BE TAKEN NOT TO SPILL DIESEL AND HYDRAULIC OILS. ANY SPILLAGE SHOULD BE CLEANED UP IMMEDIATELY USING SUITABLE MATERIALS.

2−51

WHEN WORKING AT NIGHT OR UNDER POOR LIGHTING CONDITIONS ADEQUATE ILLUMINATION IS TO BE PROVIDED TO GIVE A CLEAR VIEW OF LOADS, BOOM, THE GROUND AREA WITHIN THE SCOPE OF THE WORK BEING CARRIED OUT AND ANY OTHER EQUIPMENT OR BUILDINGS WHICH NEED TO BE ILLUMINATED TO ENSURE A SAFE OPERATION. THE WEIGHTS OF REMOVABLE COMPONENTS ARE SHOWN EITHER IN THE LOAD CHART BOOKLET OR ON A TRANSPORTATION DATA PLATE DECAL ON THE MACHINE. THE OUTRIGGER PAD LOADS ARE INCLUDED IN THE LOAD CAPACITY CHART BOOKLET. UNDER NO CIRCUMSTANCE SHALL THE LOAD MOMENT INDICATOR BE OVERRIDDEN DURING NORMAL CRANE USE, FOR THOSE PARTS INSIDE THE TELESCOPING BOOM WHICH CANNOT BE READILY EXAMINED DURING ROUTINE INSPECTIONS, E.G., TELESCOPING ROPES, IT IS RECOMMENDED THAT THEY BE CHECKED AT NO LONGER THAN 4 YEAR/4000 CRANING HOUR INTERVALS (WHICHEVER COMES FIRST) BY DISMANTLING THE BOOM AS REQUIRED. DAMAGED ROPES OR OTHER PARTS SHALL BE DISCARDED AND REPLACED. SOUND ROPES SHOULD BE CLEANED AND REDRESSED WITH SUITABLE LUBRICANT. IT IS RECOMMENDED THAT TELESCOPING ROPE BE REPLACED, IRRESPECTIVE OF VISIBLE CONDITION, AT NO LONGER THAN 8 YEARS/8000 CRANING HOUR INTERVALS (WHICHEVER COMES FIRST) 2−52

DURING CRANE OPERATIONS NO PERSON IS TO BE IN THE VICINITY OF THE HYDRAULIC SYSTEM EXCEPT THE CRANE OPERATOR WHO IS IN THE CRANE CAB. THERE IS SUFFICIENT VENTILATION IN THE OPERATOR’S CAB, EVEN WITH THE DOOR AND WINDOWS CLOSED, TO ALLOW NORMAL BREATHING FOR EXTENDED PERIODS OF TIME. WHERE MULTIPLE LIFTING (LIFTING A LOAD WITH TWO OR MORE CRANES OR TWO HOIST OPERATION WITH ONE CRANE) IS NECESSARY, GREATER ATTENTION TO PLANNING AND SUPERVISION THAN WHEN LIFTING WITH ONE CRANE OR HOIST IS ESSENTIAL. IT IS RECOMMENDED THAT THE CONDITIONS WHICH MAY INDUCE ADDITIONAL LOADING ON A CRANE BE CAREFULLY ASSESSED. DURING OPERATION NO PERSON IS TO GO NEAR TO: − THE BOOM WHEN TELESCOPING − OPENINGS IN THE BOOM − THE BOOM WHEN LUFFING − DANGER AREAS BETWEEN SUPERSTRUCTURE AND CARRIER − THE CARRIER WHEN LOWERING THE SUSPENSION − THE COUNTERWEIGHT WHEN SWINGING − THE HOIST DRUM WHEN THE CRANE IS OPERATING − OUTRIGGERS WHEN EXTENDING / RETRACTING.

2−53

THE HYDRAULIC SYSTEM CAN REACH TEMPERATURES OF UP TO APPROXIMATELY 80° C. (176° F) CARE SHOULD BE TAKEN NOT TO COME INTO CONTACT WITH HYDRAULIC COMPONENTS UNTIL IT CAN BE ESTABLISHED THAT IT’S TEMPERATURE IS LESS THAN 50° C (122° F) THE CRANE IS NOT INTENDED FOR USE IN AN EXPLOSIVE ATMOSPHERE. DO NOT WALK ON TOP OF THE BOOM. WHEN WORKING WITH DIESEL OR HYDRAULIC OILS SUITABLE PROTECTIVE CLOTHING IS TO BE WORN. WHEN DISPOSING OF USED OILS, THIS SHOULD BE CARRIED OUT IN A MANNER WHICH IS NOT HARMFUL EITHER TO PERSONS, ANIMALS OR TO THE ENVIRONMENT. UNDER NORMAL CRANE OPERATION WITH THE DOOR AND WINDOWS CLOSED THE NOISE AT THE OPERATORS STATION DOES NOT EXCEED AN EQUIVALENT CONTINUOUS A− WEIGHTED SOUND PRESSURE LEVEL OF 85 dBA. UNDER NORMAL CRANE OPERATIONS THE OPERATOR ARM AND WHOLE BODY VIBRATIONS ARE LESS THAN THE LIMITS IMPOSED BY THE MACHINERY DIRECTIVE. SPECIFICALLY, THESE ARE: 2.5 M/S/S − ARMS 0.5 M/S/S − WHOLE BODY THE LOAD MOMENT INDICATOR IS NOT SUSCEPTIBLE TO ELECTROMAGNETIC INTERFERENCE IN THE RANGE OF 30 TO 200 MHZ. 2−54

IN SOME CASES WORKING IN CLOSE PROXIMITY TO RADIO AND RADAR STATION TRANSMITTERS, THEIR EMISSIONS MAY AFFECT LMI OPERATIONS. IF LIFTING IS TO CONTINUE UNDER THESE CONDITIONS THE OPERATOR MUST USE OTHER MEANS TO ASSURE SAFE OPERATION. THE CAB HEATER IS DESIGNED TO MAINTAIN IN−CAB TEMPERATURE OF BETWEEN 15° C AND 30° C DURING OPERATION EXCEPT UNDER EXTREME EXTERNAL CONDITIONS. THE SERVICE BRAKE WILL HOLD THE MACHINE ON A 25% GRADE ON DRY CONCRETE. THE PARKING BRAKE WILL HOLD THE MACHINE ON A 15% GRADE ON DRY CONCRETE. THE OPERATOR MUST BE AWARE OF THESE BRAKE LIMITATIONS WHEN TRAVERSING UNEVEN TERRAIN. EMERGENCY CAB EXITS ARE PROVIDED, AS APPLICABLE, BY THE FOLLOWING MEANS: A) CRANE CAB i) BY OPENING WINDOW OR ii) BY POP OUT WINDOW B) CARRIER CAB i) BY SECOND CAB DOOR OR ii) BY POP OUT WINDOW C) CRANE AND / OR CARRIER CAB − BY MEANS OF SPECIAL HAMMER TO SHATTER THE WINDOW GLASS.

2−55

OPERATION IN A LIGHTNING ENVIRONMENT IS CAUSE FOR RETRACTION AND STOWAGE OF THE BOOM. IF THE CRANE WAS HIT BY LIGHTNING, A THOROUGH CRANE INSPECTION SHALL BE CONDUCTED FOLLOWING THE STORM TO DETERMINE ANY COMPONENT DAMAGE. PARTICULAR ATTENTION SHOULD BE GIVEN TO THE MACHINE ELECTRICAL / ELECTRONICS SYSTEMS, BOOM WEAR PADS AND WIRE ROPE. ANY DAMAGE SHOULD BE RECTIFIED PRIOR TO THE MACHINE GOING INTO SERVICE. ANY LOAD WHICH CANNOT BE HOISTED SHALL NOT BE LIFTED BY DERRICKING THE BOOM TO A SHORTER RADIUS. ALL LOADS SHOULD BE RAISED FROM THE GROUND BY HOISTING AND SHOULD NEVER BE RAISED BY BOOMING UP. THIS APPLIES WHETHER OR NOT THE INDICATOR SHOWS AN OVERLOAD CONDITION. WHENEVER POSSIBLE POSITION THE CRANE TO REDUCE LIFTING OVER THAT END OF THE MACHINE HAVING RESTRICTED VISIBILITY.

2−56

SECTION III CAB CONTROLS AND INDICATORS 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. In addition to the normal craning functions, control for driving the crane on the job site are also located in the superstructure cab.

NOTE The following paragraphs describe the controls and indicators located in the cab. The numbers in parentheses ( ) represent the index number from the figure titled Superstructure Cab Controls and Indicators NOTE Any reference made to left, right, front and rear when describing locations from the superstructure cab is to be considered as viewed from the superstructure operator’s seat with the boom directly over the rear of the carrier.

ENGINE 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.

2.

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.

3−1

3.

Low Oil Pressure Warning Light

This light illuminates in the event of low oil pressure. Stop the engine immediately, ascertain cause and rectify the fault before continuing operations.

4.

High Engine Temperature Warning Light

This light illuminates in the event of high engine temperature. Stop the engine immediately, ascertain cause and rectify the fault before continuing operations.

5.

Fuel Quantity Gauge

Indicates the quantity of fuel in the fuel tank from 0 to 4/4.

6.

Tachometer

This gauge is calibrated in rpm x 100 with a reading from 0 to 40. It receives its signal from a sender unit on the engine.

7.

Foot Throttle Pedal

The foot throttle pedal is the right most pedal on the cab floor. The pedal is connected to a valve which pneumatically actuates the throttle cylinder on the engine to control engine speed.

8.

Hand Throttle

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

SITE CRANE CONTROLS AND INDICATORS 9.

Swing and Telescope or Auxiliary Hoist Control Lever

The swing and telescope or auxiliary hoist (SWING/TELE or SWING/AUX HOIST) control lever is located on the end of the left armrest. The lever controls the swing and telescope functions when the crane is not equipped with an auxiliary hoist. When equipped with an auxiliary hoist, the lever controls swing and auxiliary hoist functions and telescope functions are controlled through a foot pedal.

3−2

The lever when positioned to the left or right actuates a control valve through hydraulic pilot pressure to provide 360 degree continuous rotation in the selected direction. Positioning the lever forward actuates the control valve to telescope the boom out and pulling the lever back actuates the boom to telescope in. If equipped with an auxiliary hoist, positioning the lever forward actuates the control valve to let out hoist cable and pulling the lever back reels the cable in.

Moving the lever in a diagonal direction actuates the two functions simultaneously.

10.

Boom Lift and Main Hoist Control Lever

The boom lift and main hoist (LIFT/MAIN) control lever is located on the right armrest. The lever, when positioning to the left, actuates the control valve through hydraulic pilot pressure to raise the boom. Positioning the lever to the right lowers the boom. pushing the lever forward will let out the hoist cable and pulling back reels the cable in. Moving the lever in a diagonal direction actuates the two functions simultaneously.

Motion cut is operated by the Load Moment Indicator to prevent dangerous overload. When this occurs Hoist raise, Tele out or Derrick out motions are rendered inoperative, but any of these motions can be restored by operating in the opposite direction.

11.

Hoist Rotation Indicators − Optional

The hoist rotation indicators are located on the top of each hoist control lever.

The indicators are electronically driven by a signal from an electronic transmitter attached to each hoist frame. A pulsating signal is sensed by the operators thumb during operation.

12.

Telescope Control Pedal − Optional

The telescope control pedal is located on the left side of cab floor. The telescope control pedal is only used when the crane is equipped with an auxiliary hoist.

Pushing forward on the top of the pedal actuates a control valve through hydraulic pilot pressure to telescope the boom out. Pushing down on the bottom of the pedal will telescope the boom in.

WARNING THIS SWITCH (13) MUST BE RETURNED TO NORMAL SLEW AFTER FREE OPERATION. DO NOT VACATE THE CAB WITH SWITCH IN FREE (DISENGAGED) POSITION. 13.

Swing Park Brake Switch

The SWING BRAKE switch is located on the side of the console. This two position switch controls the brake. With the switch positioned to ENGAGED, the so3−3

lenoid valve is de−energised removing hydraulic pressure from the swing brake and allowing spring pressure to apply the spring brake, preventing swing as long as the switch is at ENGAGE. With the switch positioned to DISENGAGE, the solenoid valve is energized and closes the circuit allowing hydraulic pressure to overcome the mechanical spring pressure in the brake; causing the brake to be released. Swing is then controlled by the swing control lever and the swing brake pedal. An integral light illuminates with the swing in the DISENGAGE position.

14.

Swing Brake Pedal

The swing brake pedal is installed on the left side of the cab under the front console. The brake pedal is used to actuate the swing brake to slow or stop swing motion. Braking is proportional to pedal depression.

15.

Swing Lock Control

The purpose of the swing lock is to secure the superstructure in position. When the control handle is pulled up, the swing lock is disengaged and swing can be accomplished. Pushing down on the control handle engages the lock. The control lever is adjusted to require approximately 45 pounds (20.5 kg) force to move the handle into the engaged position.

16.

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.

17.

Hoist Boost

Engaging this switch will provide boost hoist speed on the main hoist barrel. An integral light will illuminate when the switch is in the ON position.

18.

Hoist Overlower Override Switch WARNING THE HOIST LOWER MOTION CUT OVERRIDE SWITCH MUST ONLY BE USED FOR SERVICING THE HOIST CABLE AND NOT FOR ANY OTHER PURPOSE.

Hoist Motion: If the hoist motion is operated to its over lower limit, the switch activates the hoist lower dump valve which dumps hoists lower. Move lever to hoist raise to restore motion within the limits.

This switch is used to override the over lower limit switch for servicing the hoist cable.

3−4

19.

Warning Horn

Press to sound audible warning as required, i.e. before starting engine and/or operating any crane motions.

20.

Axle Suspension Lock Switch (Spring Suspension Only) WARNING THE AXLE LOCKS MUST BE ENGAGED BEFORE SLEWING OVER THE SIDE WHEN ON TYRES.

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 (21) illuminates. To disengage the locks press the top part of the switch until fully disengaged.

The locks must be engaged before undertaking FREE ON WHEELS OR ON OUTRIGGER craning duties on site. When preparing the crane for ROAD TRAVEL or SITE TRAVEL (not pick and carry) the locks must be DISENGAGED (warning light extinguished).

21.

Axle Suspension Lock Warning Light (Red) (Spring Suspension)

Illuminates only when all the axle locks are engaged, operated by switch (20).

21.

Suspension Locked Warning Light (Yellow)(Hydragas Suspension)

This light illuminates when the suspension cylinders are hydraulically locked and not connected with the suspension accumulators.

22.

Differential Lock Switch

This switch controls 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 Illuminates when the differential lock is engaged.

It is intended to be engaged for TRAVELLING ON SURFACES THAT OFFER ADVERSE WHEEL GRIP. CAUTION DO NOT ACTUATE THE SWITCH WHILE THE WHEELS ARE ACTUALLY SLIPPING OR SPINNING. 3−5

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.

CAUTION DO NOT TRAVEL WITH THE LOCK ENGAGED ON A SURFACE THAT PROVIDES GOOD WHEEL ADHESION. 23.

Auxiliary Hoist Selector Switch (Optional)

Select when using auxiliary hoist.

24.

Warning Light (Green)

Illuminates to indicate power to the superstructure.

25.

Dual Air Pressure Gauge

The gauge is a direct reading pressure gauge with two indicating pointers, green for the primary system and red for the secondary. The gauge has a dual scale calibrated from 10 to 150 psi and 100 to 1000 kPa. The gauge is connected to each air system through tubing.

26.

Low Air Pressure Indicator Warning Light (Red)

The indicator is a red light that illuminates when the pressure in the air system(s) is below 75 psi (517 kPa). The indicator is controlled by two pressure switches electrically connected in parallel. In addition to illuminating the indictor, the pressure switches also energize a warning buzzer.

27.

Park Brake Control

The park brake control is a push−pull type air valve used to set and release the parking brake on the axle.

28.

Park Brake Indicator Warning Light (Red)

The indicator will illuminate when the park brake control is in the on position.

29.

Brake Foot Pedal

Depressing the pedal actuates an air valve to control application of the brakes.

3−6

30.

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.

31.

Power Take−Off Warning Light (Green)

The light illuminates when the PTO is engaged.

32.

Rear Steer Control (Orbitrol Steering) − Optional

The rear steer control is a three position, spring centered to off, toggle switch. By positioning the switch to the right, a control valve is actuated to turn the rear wheels to the left, which causes the crane to turn to the right. By positioning the switch to the left, a control valve is actuated to turn the rear wheels to the right, which causes the crane to turn to the left. Releasing the switch allows it to spring centre to the off position. With this system fitted the front wheels are controlled by a steering wheel.

32A. Steer Control Switches (Electrical Tiller Steering) − Optional Two paddle type switches fitted in the front of the armrests control the front and rear axle steering from the turntable cab. The right hand armrest is fiited with a yellow switch which controls the rear axle steering and the left hand armrest is fitted with a orange switch which controls the front axle steering. For further details see Section IV in the Superstructure Operator’s and Safety Handbook.

33.

Rear Steer Indication Gauge

The rear steer indication consists of a gauge with an indicator needle that shows the positioning of the rear wheels.

34.

Outrigger Selector Panel

For operational use of the outrigger switches refer to the OUTRIGGER CONTROLS in the Superstructure Operator’s and Safety Handbook.

35.

Safe Load Indicator Panel

Refer to manufacturers handbook for operational use of the Safe Load Indicator.

WARNING THE GEARSHIFT IN BOTH CABS MUST BE IN NEUTRAL POSITION BEFORE THE ENGINE CAN BE STARTED. 3−7

36.

Gearshift

Used to select range of gears in power−shift transmission. For shift procedures see instructions under Operation of Transmission in Section IV of the Carrier Operator’s Safety Handbook. Operation from the Super Cab is automatically in 4 wheel drive and low gear range.

ACCESSORY CONTROLS AND INDICATORS 37.

Panel Light Dimmer Control

When the light is positioned to the on position, rotating the panel light dimmer control knob controls the brightness of the panel light.

38.

Roof Wiper Switch

This switch controls the cab roof window wiper.

Instructions for Cleaning Polycarbonate Roof Window Avoid all cleaners that contain ammonia. Using a soft 100% cotton cloth or clean sponge wash surface with a mild liquid soap or domestic household detergent and lukewarm water. Follow cleaning with a thorough water rinse. Dry with a chamois, moist cellulose sponge or soft 100% cotton cloth.

Remove fresh paint, grease and glazing compounds with any of the following solvents, followed by a thorough water rinse. a) b) c) d)

Butyl cellosolve Aliphatic naphtha (VM & P or Super VM & P) Hexane, Haptane or Cyclohexane Denatures alcohol or isopropyl alcohol.

WARNING AVOID POLYCARBONATE CONTACT WITH ABRASIVE CLEANERS, SUCH AS STEEL WOOL, COMET, AJAX, ETC., HIGHLY ALKALINE CLEANERS, SQUEEGEES, SHARP INSTRUMENTS, RAZOR BLADES, PETROL, ACETONE, BENZENE, CARBON TETRACHLORIDE, TOLUENE, MEK, ACIDS OR ANY CLEANERS WITH AMMONIA. DO NOT CLEAN IN HOT SUN OR AT ELEVATED TEMPERATURE. DO NOT STICK ANY LABELS OR STICKERS TO THE POLYCARBONATED SURFACE.

3−8

USE ONLY APPROVED SOLVENTS TO CLEAN FRAMING. SOLVENTS RESIDUE AND FUMES CAN DAMAGE POLYCARBONATE EDGE AND CAUSE CRACKING OF THE POLYCARBONATE. ALL PRIMERS FOR FRAME AND/OR GLASS SURFACES MUST BE CHECKED FOR POLYCARBONATE COMPATIBILITY FOR THE SAME REASON. IF SETTING BLOCKS ARE GLUED IN PLACE, THE GLUE SHOULD CONTAIN ONLY THE ABOVE SOLVENTS, OR WATER 39.

Heater Switch (Optional)

The switch unit consists of an ON/OFF and a rotary heat control with integral thermostat. A green indicator light in the unit will illuminate when switched on and the fan will start after about 45 seconds of pre heat.

The fan will continue to run for about 250 seconds when the switch is turned off.

39.

Heater Control Panel (Optional)

With the heat control (47) pulled out to high move the switch on the control panel to ‘START’ and hold at that position, the green light will illuminate. When the amber light illuminates release the switch to the ‘RUN’ position, the amber light must stay on. The green light will cycle on when the fuel valve opens.

NOTE When switching the heater OFF do not immediately switch off the battery circuit switch. This would effectively interrupt the purging cycle off the feed to the cooling fan. The residual heat within the unit would then be sufficient to activate the thermal trip.

When the heater is switched off wait at least 5 minutes before switching off the battery circuit switch.

40.

Windscreen Wiper/Washer Switch

This is a dual switch. Position one operates the windscreen wiper, position two is a spring return which operates the washer.

3−9

41.

Cigar Lighter

Push the knob in − it will pop out when the element is hot enough.

42.

Test Switch

This switch is used to test the dash panel lighting.

43.

Lights Switch (Optional)

This is a two position switch. Position one controls the drive lights and position two the work lights.

44.

Rotating Beacon Switch (Optional)

This switch controls the rotating beacon light.

45.

Armrest Lever

This armrest slides back to allow access to the cab.

46.

Fire Extinguisher

Located below the seat at left hand side, it is a BC dry type extinguisher for emergency use.

47.

Heat Control(Optional)

The control must be pulled out to activate the heater to produce full heat and pushed in to switch the heater to the reduced heat mode.

48.

Duty Selector Switch(Optional)

This switch must be selected before undertaking FREE ON WHEELS OR ON OUTRIGGER craning duties on site. Lights (49) and (50) will illuminate to indicate duty selected.

3−10

35

8 36 11

15 10 32A

34 16 7

47

32A 39

32 27

39 29 46

12 14

9

45

32. Rear Steer Control (Opt) 7. Foot Throttle Pedal 32A. Steer Control Switches (Opt) 8. Hand Throttle 9. Swing & Tele or Aux Hoist Control Lever 34. Outrigger Selector Panel 35. Safe Load Indicator Panel 10. Boom Lift & Main Hoist Control Lever 36. Gear Shift Lever 11. Hoist Rotation Indicators − Optional 39. Heater Switch(Optional) 12. Telescope Control Pedal − Optional 39. Heater Control Panel(Opt) 14. Swing Brake Pedal 45. Armrest Lever 15. Swing Lock Control 46. Fire Extinguisher 16. Level Indicator 47. Heat Control(Optional) 27. Park Brake Control 29. Brake Foot Pedal

Superstructure Cab Controls and Indicators (Sheet 1 of 4) 3−11

24

30

31

13

17

40

21

25

5

6

5. Fuel Quantity Gauge 6. Tachometer 13. Swing Park Brake Switch 17. Hoist Boost 21. Suspension Locked Warning Light 24. Warning Light (Green) 25. Dual Air Pressure Gauge 30. Rear Steering Warning Light 31. Power Take−Off Warning Light 40. Windscreen Wiper/Washer Switch

Superstructure Cab Controls and Indicators (Sheet 2 of 4) 3−12

19

28

3

4

2

26

1

38

1. Battery Circuit Switch 2. Alternator Warning Light 3. Low Oil Pressure Warning Light 4. High Engine Temp Warning Light 19. Warning Horn 26. Low Air Pressure Ind Warning Light 28. Park Brake Ind Warning Light 38. Roof Wiper Switch

Superstructure Cab Controls and Indicators (Sheet 3 of 4) 3−13

33

49

23

50

18

48 43

41

44

22

18. Hoist Overlower Override Switch 20. Blank Aperture 22. Differential Lock Switch 23. Auxiliary Hoist Selector Switch 33. Rear Steer Indication Gauge 37. Panel Light Dimmer Control

42

37

20 41. Cigar Lighter 42. Test Switch 43. Lights Switch 44. Rotating Beacon Switch 48. Duty Selector Switch 49. Blocked Duty Light 50. F.O.W. Duty Light

Superstructure Cab Controls and Indicators (Sheet 4 of 4) 3−14

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

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

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

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

WARNING THE CAP SHOULD ONLY BE REMOVED WITH THE ENGINE COLD. SERIOUS INJURY COULD OCCUR IF THE ENGINE COOLANT IS HOT. THE PRESSURE IN THE SYSTEM WILL EJECT HOT STEAM. BATTERIES. 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.

4−1

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 Check hydraulic fluid quantity level gauge and check breather for cleanliness and security.

STEERING MODE

WARNING ENSURE THE STEERING MODE CONTROL IS IN THE PROPER POSITION FOR THE CAB THE CRANE IS TO BE OPERATED FROM. FAILURE TO HAVE THE CONTROL IN THE CORRECT POSITION WILL RESULT IN A LACK OF STEERING AND COULD CAUSE SERIOUS DAMAGE AND INJURY. 4−2

Ensure the steering mode control is in the correct position. When the control handle is pushed in the crane is in the carrier steering mode. When the control handle is pulled out the crane is in the superstructure steering mode. Turn the handle to the horizontal position to lock the cable in place.

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

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

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

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

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

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.

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

4−3

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 and release immediately when the engine starts.

2.

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

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

4−4

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.

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.

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 the off position.

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, 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

4−6

could overflow when the oil gets hot. Under filling must also be avoided as this will cause pump cavitation and allow air to be drawn into the hydraulic circuits.

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

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

CRANE TRAVEL OPERATION. TRAVELLING − GENERAL. CAUTION DISENGAGE THE HYDRAULIC PUMP FOR EXTENDED TRAVELLING, 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.

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 CENTRE..

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.

4−7

CAUTION DO NOT DRIVE THE CRANE WITH THE LIFT CYLINDER BOTTOMED. POSITION THE BOOM SLIGHTLY ABOVE HORIZONTAL. WARNING THE HOIST ROPE/HOOKBLOCK STOWAGE PIN ON THE FRONT BUMPER MUST NOT BE USED FOR VEHICLE RECOVERY (TOWING).

TOWING OF THE CRANE OR BY THE CRANE MUST BE BY USE OF THE TOW/ TIE−DOWN LUGS ON THE FRONT OUTRIGGER HOUSING OR AT THE REAR OF THE CARRIER RESPECTIVELY 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.

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

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4.

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

5.

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

6.

Ensure the outrigger stabilizers and outriggers are fully retracted and suspension is unlocked. For pick and carry duties only the suspension must be locked.

SUPERSTRUCTURE TRAVEL − PICK AND CARRY DUTIES 1.

Swing the boom over the rear, engage swing lock and ensure suspension is locked.

2.

Boom should be derricked in or retracted proportionate to the capacity of the load chart.

3.

Travel where possible with the outriggers extended and the stabilizers just clear of the ground. Restrain the load from swinging.

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

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

With the crane in the operating position i.e. the boom over the rear, the rear axle wheels becomes the front wheel steering and the front axle wheels becomes the rear wheel steering.

WARNING ENSURE THE STEERING MODE CONTROL IS IN THE PROPER POSITION FOR THE CAB THE CRANE IS TO BE OPERATED FROM. FAILURE TO HAVE THE CONTROL IN THE CORRECT POSITION WILL RESULT IN A LACK OF STEERING AND COULD CAUSE SERIOUS DAMAGE AND INJURY.

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Steering Mode Ensure the steering mode control is in the correct position. When the control handle is pushed in the crane is in the carrier steering mode. When the control handle is pulled out the crane is in the superstructure steering mode. Turn the handle to the horizontal position to lock the cable in place. Pull the flap down over the handle when either in or out has been selected. .Front Wheel Steering (Rear Axle Wheels) With the crane in the operating position i.e. boom over the rear, front wheel (rear axle) steering is accomplished with the steering wheel.

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

WARNING WHEN OPERATING THE REAR STEERING FROM THE SUPERSTRUCTURE CAB, THE STEERING WHEEL IN THE CARRIER CAB WILL BE HYDRAULICALLY DRIVEN AND COULD CAUSE SEVERE INJURY IF THE CARRIER CAB IS OCCUPIED. WARNING OPERATE THE REAR STEER ONLY FOR ADDED JOB SITE MANOEUVERABILITY. Rear Wheel Steering (Front Axle Wheels) With the crane in the operating position i.e. boom over the rear, rear wheel (front axle) steering is controlled by the rear steer control. Actuating the control the desired position activates the rear steer cylinders, thereby steering the crane in the selected direction.

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

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

Electrical Tiller Steering − Optional Two paddle type switches fitted in the front of the armrests control the front and rear axle steering from the turntable cab. The right hand armrest is fitted with a yellow switch which controls the rear axle steering and the left hand armrest is fitted with a orange switch which controls the front axle steering.

With the crane in the operating position i.e. the boom over the rear, the rear axle wheels becomes the front wheel steering and the front axle wheels becomes the rear wheel steering.

WARNING ENSURE THE STEERING MODE CONTROL IS IN THE PROPER POSITION FOR THE CAB THE CRANE IS TO BE OPERATED FROM. FAILURE TO HAVE THE CONTROL IN THE CORRECT POSITION WILL RESULT IN A LACK OF STEERING AND COULD CAUSE SERIOUS DAMAGE AND INJURY. Steering Mode Ensure the steering mode control is in the correct position. When the control handle is pushed in the crane is in the carrier steering mode. When the control handle is pulled out the crane is in the superstructure steering mode. Turn the handle to the horizontal position to lock the cable in place. Pull the flap down over the handle when either in or out has been selected. .Front Wheel Steering (Rear Axle Wheels) With the crane in the operating position i.e. boom over the rear, front wheel (rear axle) steering is controlled by a yellow paddle switch fitted in the front of the right hand armrest. Moving the switch either to the left or right activates the rear axle steering cylinders, thereby steering the crane in the selected direction. With the boom over the front the steering is automatically reversed thus allowing the switch to be operated the same as with the boom over the rear.

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WARNING OPERATE THE REAR STEER ONLY FOR ADDED JOB SITE MANOEUVERABILITY. Rear Wheel Steering (Front Axle Wheels) With the crane in the operating position i.e. boom over the rear, rear wheel (front axle) steering is controlled by an orange paddle switch fitted in the front of the left hand armrest. Moving the switch either to the left or right activates the front axle steering cylinders, thereby steering the crane in the selected direction. With the boom over the front moving the switch to the left will steer the crane right and moving the switch right will steer the crane left.

Four Wheel Steering Four−wheel steering is accomplished by using both the left hand and right hand paddle switches. This method of steering allows the crane to turn or manoeuvre in close, restricted areas.

Crabbing Crabbing is also accomplished by using both the left hand and right hand paddle switches. This method permits driving the crane forward or in reverse at an angle from straight ahead in the crabbing manner.

FRONT−WHEEL

REAR−WHEEL

FOUR−WHEEL

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

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Allow the engine to warm up.

CRABBING

2.

Move the transmission lever directly forward away from the display to the detented position, upon selection of forward from neutral, 1st gear fwd is selected and L.E.D. 1 will light up ‘green’.

3.

Release the parking brake, depress the foot throttle until maximum gear speed is attained.

4.

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

5.

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

TRAVELLING − REVERSE CAUTION APPLY THE SERVICE BRAKES AND BRING THE CRANE TO A COMPLETE STOP BEFORE SHIFTING THE TRANSMISSION INTO REVERSE. 1.

Travelling in reverse is accomplished the same way as travelling forward except for moving the lever directly backwards towards the display to the detented position, upon selection of reverse from neutral, 1st gear rev. is selected and L.E.D. no. 1 will light up orange. (Refer to TRAVELLING − FORWARD).

CONTROL LEVER OPERATION. The control lever operation for crane functions is standard, i.e., the closer the lever is to neutral (centre), the slower the system responds. This applies to forward, 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.

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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.

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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 centre line of rotation of the crane and the centre of gravity of the load. Various boom lengths are listed across the top, ranging from fully RETRACTED to fully EXTENDED and with the swingaway extension in use.

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

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 4−15

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 stabilizer for levelling functions.

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

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A bubble level indicator is mounted in the operators cab.

WARNING THE CRANE MUST BE LEVELLED AND REMAIN LEVEL DURING OPERATION. 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 carrier servicing. in this condition the superstructure MUST NOT be swung.

Partial Outreach Outriggers On cranes fitted with optional partial outreach duties it is essential to correctly programme the load moment indicator to suit either the required full or partial outreach duties before operation of the crane.

WARNING IT IS POSSIBLE TO OPERATE ALL STABILIZERS FROM THE OPERATING STATION. SINCE NOT ALL OF THESE STABILIZERS WILL BE VISIBLE AT ONE TIME CARE MUST BE BE TAKEN THAT NO PERSON(S) CAN BE HARMED. WARNING USE THE OUTRIGGERS TO LEVEL THE CRANE, THE CRANE IS LEVEL WHEN LEVEL INDICATOR BUBBLES ARE CENTRALISED. CHECK AT INTERVALS DURING OPERATIONS THAT THE CRANE REMAINS LEVEL.

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WARNING BEFORE OPERATING OUTRIGGERS IT IS ESSENTIAL THAT THE AREA IN WHICH THE OUTRIGGERS ARE TO BE EXTENDED OR RETRACTED IS CLEAR OF PERSON(S) AND/OR OBSTRUCTIONS AND THE GROUND CONDITIONS ARE SUITABLE FOR THE OUTRIGGER LOADS TO BE APPLIED. WARNING WHEN THE OUTRIGGER CONTROLS ARE NOT BEING USED THE CONTROL STATION MUST BE LOCKED. Operation To Extend the Outriggers − Refer to Outrigger Controls figure NOTE Outrigger floats on standard cranes are permanently attached to the stabilizers.

Therefore procedures 2, 4 and 5 only apply to cranes fitted with optional outrigger float stowage.

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, the superstructure swing lock pin is engaged and ensure the suspension is locked from the carrier cab.

2.

Position the outrigger floats approximately 5 feet (1.5m) directly out from each outrigger. Locate stowage pin in to slot location for full beam extension.

CAUTION ALWAYS SELECT A STABILIZER/BEAM CONTROL BEFORE POSITIONING THE SELECTOR SWITCH TO EXTEND OR RETRACT. FAILURE TO DO THIS MAY CAUSE A HYDRAULIC LOCK AGAINST THE INDIVIDUAL SOLENOID VALVES, PREVENTING THEM FROM OPENING. 4−18

CAUTION THE ONLY WAY TO ENSURE THE BEAMS ARE FULLY EXTENDED IS VISUALLY. 3.

Rotate switch (13) to each individual outrigger beam position, hold switch (14) in the EXTEND position in turn for each beam until they are fully extended.

4.

After all four outrigger beams have been fully extended, position each float under each stabilizer and with switch (13) rotated to the JACK position, hold switches (15), (16), (17) or (18) depressed in turn while holding switch (14) in the EXTEND position until the stabilizer rods are located in the floats.

5.

Secure floats (6) to each stabilizer rod with locking latches (7).

6.

Using the level indicator (8), readjust each stabilizer as necessary until the crane is properly levelled (bubble centralised).

WARNING WHEN FULLY ’BLOCKED UP’ THE CRANE MUST BE ’LEVEL’ WITH THE WHEELS CLEAR OF THE GROUND. WARNING THE LOAD MOMENT INDICATOR WILL ONLY RECORD SAFE LOADS IF IT IS CORRECTLY SET FOR REQUIRED DUTIES WITH THE CRANE PROPERLY LEVELLED. 7.

The crane is now ready for operations under ON OUTRIGGERS duty conditions. If a load moment indicator is fitted it will have to be set to suit the appropriate duties required.

8.

Rotate switch (13) to the locked position.

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To Retract The Outriggers.

NOTE Outrigger floats on standard cranes are permanently attached to the stabilizers.

Therefore procedures 3 and 7 only apply to cranes fitted with optional outrigger float stowage.

1.

Position the crane in normal travelling order with the engine running and power take−off engaged. Check that the parking brake is applied, the superstructure swing lock pin is engaged.

2.

With switch (13) rotated to the JACK position, hold switches (15), (16), (17) or (18) depressed in turn while holding switch (14) in the RETRACT position until the crane is on its wheels and the stabilizer floats are several inches off the ground.

WARNING KEEP FEET AND HANDS CLEAR OF THE FLOATS WHEN UNLOCKING THEM FROM THE STABILIZERS. 3.

Release the locking levers (7) and allow the floats (6) to drop to the ground.

4.

Continue to retract the stabilizers until they are fully retracted.

5.

Rotate switch (13) to each individual outrigger beam position, hold switch (14) in the RETRACT position in turn for each beam until they are fully retracted.

6.

Rotate switch (13) to the locked position.

7.

Stow the floats in their holding brackets.

8

If the crane is being made ready for road travel unlock the suspension.

9.

If outrigger operations are complete, stop engine and disengage power take−off.

Remote Control Outriggers − Refer to Outrigger Controls figure On cranes fitted with optional remote control outriggers a control unit is plugged into the rear of the carrier fame. The unit is activated by a toggle switch (10) which illuminates lamp (11).

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Operation WARNING BEFORE OPERATING OUTRIGGERS, 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 NOTE Outrigger floats on standard cranes are permanently attached to the stabilizers.

Therefore procedures 2, 4 and 5 only apply to cranes fitted with optional outrigger float stowage.

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, the superstructure swing lock pin is engaged and ensure the suspension is locked from the carrier cab.

2.

Position the outrigger floats approximately 5 feet (1.5m) directly out from each outrigger. Locate stowage pin in to slot location for full beam extension.

CAUTION ALWAYS SELECT A STABILIZER/BEAM CONTROL BEFORE POSITIONING THE SELECTOR SWITCH TO EXTEND OR RETRACT. FAILURE TO DO THIS MAY CAUSE A HYDRAULIC LOCK AGAINST THE INDIVIDUAL SOLENOID VALVES, PREVENTING THEM FROM OPENING. CAUTION THE ONLY WAY TO ENSURE THE BEAMS ARE FULLY EXTENDED IS VISUALLY. 3.

Position the appropriate switch (1), (2), (3) or (4) to beam position and position the switch (5) to EXTEND. The appropriate beam should begin to extend.

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4.

After all four outrigger beams have been fully extended, position each float under each stabilizer and position the appropriate switch (1), (2), (3) or (4) to stabilizer position and switch (5) to EXTEND until stabilizer rods are located in the floats.

5.

Secure floats (6) to each stabilizer rod with locking latches (7).

6.

Using the level indicator (8), readjust each stabilizer as necessary until the crane is properly levelled (bubble centralised).

7.

Allow control switch (5) to return to OFF (centre) position, during each movement prior to relieving the switches (1), (2), (3) and (4).

WARNING WHEN FULLY ’BLOCKED UP’ THE CRANE MUST BE ’LEVEL’ WITH THE WHEELS CLEAR OF THE GROUND. WARNING THE LOAD MOMENT INDICATOR WILL ONLY RECORD SAFE LOADS IF IT IS CORRECTLY SET FOR REQUIRED DUTIES WITH THE CRANE PROPERLY LEVELLED. 8.

The crane is now ready for operations under ON OUTRIGGERS duty conditions. If a load moment indicator is fitted it will have to be set to suit the appropriate duties required.

To Retract The Outriggers.

NOTE Outrigger floats on standard cranes are permanently attached to the stabilizers.

Therefore procedures 3 and 7 only apply to cranes fitted with optional outrigger float stowage.

1.

Position the crane in normal travelling order with the engine running and power take−off engaged. Check that the parking brake is applied, the superstructure swing lock pin is engaged.

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2.

Position the appropriate switch (1), (2), (3) or (4) to stabilizer position and position the switch (5) to RETRACT until the crane is on its wheels and the stabilizer floats are several inches off the ground.

WARNING KEEP FEET AND HANDS CLEAR OF THE FLOATS WHEN UNLOCKING THEM FROM THE STABILIZERS. 3.

Release the locking levers (7) and allow the floats (6) to drop to the ground.

4.

Continue to retract the stabilizers until they are fully retracted.

5.

Position the appropriate switch (1), (2), (3) or (4) to beam position and position the switch (5) to RETRACT. The appropriate beam should begin to retract.

6.

Continue to retract the beams until they are fully retracted.

7.

Stow the floats in their holding brackets.

8

If the crane is being made ready for road travel unlock the suspension.

9.

If outrigger operations are complete, stop engine and disengage power take−off.

Level Indicator.

Use the outriggers to level the crane. The crane is level when bubbles are centralised. Check at intervals DURING operations that the crane remains level.

Operating Stabilizers Only.

WARNING THE SUPERSTRUCTURE MUST NOT BE SWUNG FROM THE ROAD TRAVEL POSITION WHEN THE CRANE IS JACKED UP FOR SERVICING. UNDER NO CIRCUMSTANCES MUST ANY CRANING OPERATIONS BE CARRIED OUT IN THIS CONDITION.

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For servicing the carrier only, the outrigger stabilizers may be used to lift the crane after first extending the beams 300mm minimum.. To operate the stabilizers only follow the instructions given for operating the stabilizers.

Partial Outreach Outrigger Extension − Optional.

The procedures for extending and stowing the outriggers for partial outreach outrigger duties is the same as for full outreach except that the beams are pinned in the intermediate position.

WARNING THE OUTRIGGER BEAMS MUST BE PARTIAL EXTENDED WITH THE PINS (9) IN THE LOCKED POSITION AND THE FOUR MAIN AND FRONT STABILIZERS FULLY EXTENDED AND SET BEFORE OPERATING PARTIAL EXTENDED OUTRIGGER DUTIES. Lift the pins (9) from the stowed position (short slot) and turn to position in the long slot. Partially extend the beams until the pins (9) locate in the beams, locking them to the housing. Indicator marks on the side of the beams facilitate location of the holes in the beams.

The outrigger duties must be selected for the required full or partial outreach duties from the load moment indicator.

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15

17 13 18

8

14

16

11

10 1 3

5 2 4

7

6

9

Outrigger Controls 4−25

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 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.

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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. WARNING WHEN LOWERING THE BOOM, LET OUT THE CABLE SIMULTANEOUSLY TO PREVENT TWO−BLOCKING THE BOOM NOSE AND THE HOOK BLOCK. CAUTION THE CLOSER THE LOAD IS CARRIED TO THE BOOM NOSE, THE MORE IMPORTANT IT BECOMES TO SIMULTANEOUSLY LET OUT CABLE AS THE BOOM IS LOWERED.

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WARNING BELOW 20° BOOM ANGLES, GREAT CARE MUST BE EXERCISED WHEN SLEWING OR DERRICKING DOWN TO AVOID DAMAGING CHASSIS EQUIPMENT E.G. CAB, EXHAUST, BOOM REST ETC. To lower the boom, the BOOM control lever is pushed to the right and held until the boom is lowered to the desired position.

TELESCOPING THE BOOM. Extending The Boom.

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

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

When a telescope boom control foot pedal is fitted push down on the top of the pedal and hold until boom extends to desired length.

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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.

When a telescope boom control foot pedal is fitted push down on the bottom of the pedal and hold until the boom retracts to the desired length.

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

Lowering The Cable.

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

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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.

EMERGENCY BOOM OPERATING PROCEDURES. Although highly improbable if proper maintenance and frequent inspections are made, there remains the possibility that the boom lift cylinder or telescope cylinder hydraulic lines could fail. If this occurs, there are restricting devices provided that allow continued operation of the crane. All crane functions with the exception of that with the failure remain operable until the hydraulic oil in the reservoir is depleted. The most important thing is to place the load in a safe location and get the boom in a safe position so that repairs can be made with the minimum spillage of hydraulic oil. 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.

With a suspended load decide where the load can be safely placed and how this can be achieved with minimum operation without using the failed motion.

3.

Accelerate the engine to the minimum rpm necessary to carry out the function to be used and place the load in a safe location.

4.

If it is not possible to carry out the necessary repairs with the crane as positioned, proceed to place the boom in a safe position where repairs can be carried out, using the failed motion as little as possible to minimise spillage of hydraulic fluid.

5.

Boom or boom and extensions should be retracted until it is safe to lower the boom.

6.

4−30

With telescope cylinder failure lower the load to the ground.

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.

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.

13.

Disengage the battery isolator switch.

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 automotive uses of miscellaneous nature, such 5−1

as fifth wheel service, should be inhibited to prevent rusting and have excellent resistance to both heat and water.Higher quality EP−MPG multipurpose grease may also be used. See EP−MPG for recommended consistency grades EP−MPG Extreme Pressure Multipurpose Grease.

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

Timken OK Load Dropping Point Oil Viscosity Water Resistance

40 lb. Minimum 350°F (177°C)min.

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

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

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

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

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

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

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

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

WBG Wheel Bearing Grease.

This grease is of such composition, structure, and consistency that it is suitable for long time use in anti−friction wheel bearings. It must have high resistance to the deteriorating effects of temperature and the separating effects of centrifugal action.It shall not contain corrosive or abrasive materials and shall inhibit corrosion in the presence of moisture. NLGI Grade No. 2 is recommended where not otherwise specified.

RGL Regular Gear Lubricant.

This is a straight−mineral gear oil of relatively high viscosity for the lubrication of spiral−bevel and worm gear rear axles and most manual transmissions operating under low unit pressures and sliding velocities. API−GL−1 service classifi5−2

cation. 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

Minimum Ambient Temperature °F (°C)

75W 80W 85W 90 140 250

−40 ( −40) −15 ( −26) +10 ( −12) +20 ( − 7) +40 ( + 5) +50 ( +10)

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

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

OGL Open Gear Lubricant.

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

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

5−3

HTF Hydraulic Transmission Fluid.

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

SBF Silicone Brake Fluid.

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

BF Brake Fluid.

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

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

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

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 5−4

3405F (1715C) min.

Excellent NO. 2

WRL Wire Rope Lubricant.

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

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

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

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

2. Anti−wear additives.

Viscosity.

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

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

5−5

2.

Lower volumetric efficiency of the pump.

3.

Increased component wear.

4.

Loss of system pressure.

5.

Lack of positive hydraulic control.

6.

Lower overall efficiency.

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

1.

System pressure drop.

2.

Increases system temperature.

3.

Sluggish system operation.

4.

Low mechanical efficiency.

5.

Higher power consumption.

The following oil viscosity characteristics are recommended.

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

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

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

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

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

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

5−6

Anti −wear Additives.

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

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

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

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

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

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

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

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

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

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, 5−7

and this number corresponds to the index number shown on the Lubrication Diagram.

1.

Hookblock and Swivel Bearing

Lube Type − EP − MPG Lube Interval − 100 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting 2.

Hookblock Sheaves

Lube Type − EP − MPG Lube Interval − 100 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting 3.

Lower Boom Nose Sheave

Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting per sheave 4.

Upper Boom Nose Sheave

Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting per sheave 5.

Aux. Boom Nose Sheave (Optional)

Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes Application − 1 grease fitting per sheave 6.

Retraction Cable Sheave NOTE The boom sections must be extended to gain entry through the access holes in the boom.

Lube Type − EP − MPG Lube Interval − 50 Hours 5−8

Lube Amount − Until grease extrudes Application − 1 grease fitting 7.

Telescope Cylinder Wear Pads NOTE The boom sections must be extended to gain entry through the access holes in the boom.

Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Thoroughly coat the area the wear pad moves on Application − By brush 8.

Boom Section Wear Pads NOTE The boom sections must be extended to gain entry through the access holes in the boom.

Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Thoroughly coat the area the wear pad moves on Application − By brush 9.

Adjustable Wear Pads

Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Thoroughly coat the area the wear pad moves on Application − By brush 10.

Non Adjustable Wear Pads

Lube Type − EP−MPG Lube Interval − 25 hours Lube Amount − Thoroughly coat the area the wear pad moves on Application − By brush 11.

Rear Pad Pivot

Lube Type− EP−MPG Lube Interval − 50 hours 5−9

Lube Amount − Until grease extrudes Application − 2 grease fittings 12.

Lifting Hook Release

Lube Type − Release Lube Type− EO Lube Interval − 50 hours Lube Amount − Liberally Application − Oil Can 13.

Hoist Rope

Lube Type − OGL Lube Interval − 200 hours Lube Amount − Sufficient to coat the rope Application − Brush (see also rope maintenance) 14.

Hookblock Nut and Threads

Lube Type − EP−MPG Lube Interval 1 − Monthly or 100 hours − Apply grease to the top of the nut to prevent the ingress of moisture.

2 − Annually − 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 corrosion 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 annually 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.

WARNING UNDER NO CIRCUMSTANCES SHOULD GREASE CONTAINING MOLYBDENUM DISULPHIDE BE USED IN THIS APPLICATION. Lube Amount − Liberally Application − By hand 15.

Lift Cylinder

Lube Type − EP − MPG Lube Interval − 50 Hours 5−10

Lube Amount − Until grease extrudes Application − Top and bottom lift cylinder trunnions −4 grease nipples 16.

Swing Bearing

Lube Type − EP − MPG Lube Interval − 50 Hours Lube Amount − Until grease extrudes the whole circumference of the bearing Application − Front 2 grease fittings on the front side of the superstructure.

Ensure the entire bearing is lubed by rotating the superstructure 10 degrees and apply grease to the fittings. Continue rotating 10 degrees and greasing through the fittings until the whole bearing is greased.

17.

Telescope Cylinder Trunnion

Lube Type − EP − MPG Lube Interval − 25 Hours Lube Amount − Until grease extrudes Application − 2 fittings 18.

Swing Box

Lube Type − EPGL90 Lube Interval − Check every 50 hours Drain 1st time after 250 hours and every 500 hours or 12 months thereafter Lube Amount − Capacity 4.3 litres Application − Fill to mark on dipstick. Gain access to dipstick and drain through the rear access plate.

19.

Swing Brake

Lube Type − GROVEXTRA HYDO Lube Interval 1.Check weekly 2.Drain and refill twice a year Lube Amount − Approx. 0.22 litres (0.5 pints) Application − The oil should be level with the top of the elbow.

NOTE The crane must be level before draining or topping up the hoist units.

Hoist Main 20.

Model HO−15G− (Main)

Lube Type − EPGL Lube Interval − 250 Hours 5−11

Lube Amount − Capacity 11.5 litres (3 Gallons) Application − The oil should be level with the bottom of the check fill plug when the crane is level.

21.

Model HO−15G (Auxiliary)

Lube Type − EPGL Lube Interval − Check every 250 Hours Lube Amount − Capacity 11.5 litres (3 Gallons) Application − The oil should be level with the bottom of the check fill plug when the crane is level.

22.

Boom Pivot Shaft NOTE When greasing the lift cylinder and boom pivot shafts, better distribution of grease within the shafts is obtained if the weight of the boom is removed from the shafts.

Lube Type − EP − MPG Lube Interval − 10 Hours Lube Amount − Until grease extrudes Application − 2 grease fittings, one on each side.

23.

Third Wrap Monitor Hoist Barrels

Lube Type − EP−MPG Lube Amount − Until grease extrudes Lube Interval − 50 hours Application − Grease nipple 24.

Engine

Lube Type − EO Lube Interval − Check daily. Drain and refill as per the engine handbook Lube Amount − 22.4 litres (5.8 gallons) Application − Refer to the engine service manual.

25.

Transmission Gearbox and Torque Convertor

Lube Type − HTF Lube Interval − Daily 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). Maintain oil level to full mark.

5−12

2. Every 1000 hours drain and refill system − see Service Manual for instructions.

Lube Amount − 22 Litres (6 gallons) Application Procedure − Remove the breather from the upper face of the transmission. Open the LOWER level indicator at the side of the gearbox and add the specified quantity of lubricant through the breather. Add or drain further oil until the lubricant just flows from the LOWER level indicator. Tighten this indicator and refit the breather, then start and IDLE the engine for 2 minutes to prime the system.

With the engine at IDLE, recheck the level at the LOWER indicator and add lubricant until again it just flows from the indicator. Tighten the indicator.

Stall the convertor, to bring the lubricant temperature to between 82° C and 93° C (180 ° F and 200 ° F). IDLE the engine with the lubricant at this temperature and open the UPPER level indicator. Add or drain lubricant as necessary until it just trickles from the UPPER indicator.

Tighten ALL fittings.

CAUTION FULL THROTTLE STALL SPEEDS FOR AN EXCESSIVE LENGTH OF TIME WILL OVER−HEAT THE CONVERTOR AND CAUSE SERIOUS DAMAGE. 26.

Transmission Oil Filter

Every 500 hours change oil filter element − See Service Manual for instructions.

27.

Rear Axle Differential.

Lube Type − EPGL−5 Lube Interval − 1600km (1000 miles) Lube Amount − 14 Litres Application − Check filler/level plug..

28.

Rear Axle Hubs.

Lube Type − EPGL−5 Lube Interval − 1600km(1000 miles) Lube Amount − 1.5 Litres (0.4 gallons) Application − Locate level mark and level plug in horizontal position, remove plug and add oil up to the lip of the aperture. Refit the level plug.

5−13

29.

Front Axle Differential.

Lube Type − EPGL−5 Lube Interval − 1600km(1000 miles) Lube Amount − 14 Litres Application − Check filler/level plug.

30.

Front Axle Hubs.

Lube Type − EPGL−5 Lube Interval − 1600km(1000 miles) Lube Amount − 1.5 Litres (0.4 gallons) Application − Locate level mark and level plug in horizontal position, remove plug and add oil up to the lip of the aperture. Refit the level plug.

31.

King Pin Trunnions

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

Application − 4 grease nipples per axle.

32.

Front Spring Pins (Spring Suspension Only)

Lube Type − EP−MPG .

Lube Interval −.

Lube Amount − Until grease extrudes.

Application − 2 grease nipples, 1 per spring.

33.

Rear Spring Pins (Spring Suspension Only)

Lube Type −EP− MPG .

Lube Interval −1600km(1000 miles).

Lube Amount − Until grease extrudes.

Application − 2 grease nipples, 1 per spring.

34.

Steering Ram Ball Joints

Lube Type − EP−MPG .

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

Application − 8 grease nipples, 4 per axle.

35.

Propshafts

Lube Type − EP−MPG .

Lube Interval − 1600km(1000 miles) 5−14

Lube Amount − Until grease extrudes.

Application − 6 grease nipples, 3 per shaft. *36. Axle Universal Joints.

Lube Type − EP−MPG .

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

Application − 8 grease nipples, 2 per joint. *Latest axles are fitted with life−time greased universal joints without grease nipples.

37.

Suspension Cylinders

Lube Type − EP−MPG Lube Interval − Monthly or 200 hours or 8000 km (5000 miles).

Lube Amount − Until grease extrudes.

Application − 2 grease nipples per cylinder.

38.

Hydraulic Oil Tank

Lube Type − GROVEXTRA HYDO Lube Interval − Daily Lube Amount − 470 Litres (123 gallons) Application − Filler cap, add oil to level of sight gauge.

39.

Engine Fuel Tank

Lube Type − Diesel Lube Interval − Daily Lube Amount − 280 litres (74 gallons) Application − Filler Cap 40.

Steering Bevel Box

Lube Type − GROVEXTRA HYDO Lube Interval − 1600km (1000 miles) Application − Remove the plug and add oil up to the lip of the aperture. Refit the level plug.

41.

Hydraulic Oil Filters

Lube Type − GROVEXTRA HYDO − Fed from the hydraulic tank Lube Interval − 1 − On commission of a new crane daily.

2 − 50 hours, Replace element after 50 hours.

5−15

Lube Amount − Supplied from the hydraulic tank.

Application − Element should be changed at 500 hours.

42.

Hydraulic Oil Filter

Lube Type − GROVEXTRA HYDO − Fed to the hydraulic tank Lube Interval − 1 − On commission of a new crane daily 2 − 50 hours, Replace element after 50 hours Lube Amount − Supplied from the hydraulic tank Application − Element should be changed at 500 hours 43.

Door Hinge

Lube Type − EP−MPG Lube Interval − 250 hours Lube Amount − Until grease extrudes Application − 1 grease fitting per hinge 44.

Vapour Corrosion Inhibitor

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

5−16

WIRE ROPE LUBRICATION Wire rope is lubricated during manufacturing so the strands, and individual wires in strands, may move and adjust as the rope moves and bends. A wire rope cannot be lubricated sufficiently during manufacture to last its entire life. Therefore, new lubricant must be added periodically throughout the life of a rope to replace factory lubricant which is used or lost.

The surface of some ropes may become covered with dirt, rock dust, or other material during their operation. This covering can prevent field applied lubricants from properly penetrating into the rope. Therefore, these ropes should be cleaned before being lubricated.

The lubricant applied should be light bodied enough to penetrate to the core of the rope. Lubricant may be applied effectively by various methods. It may be dripped on, sprayed on, or put on by brushing, but in any case it should be applied at a place where the rope is being bent, such as a sheave. It should be applied at the top of the bend, at the point the strands are spread by bending and are more easily penetrated. The service life of rope will be directly proportional to the effectiveness of the method used and amount of lubricant reaching the working parts of the rope.

A proper lubricant must reduce friction, protect against corrosion, adhere to every wire and be pliable and not crack or separate when cold and yet not drip when warm.

Special lubricant can be applied at the factory to meet usual conditions.

3851

Wire Rope Lubrication

5−17

5

4

3

9

9

7,8,17

15 24

26 44

13 2 1

14 12

2 40

43

1

32

18,19

16

11

10

22

35

33

35

35

27

6

29

20

35 37 35 25 35

23

21

37

Lubrication Diagram − Spring Suspension (Sheet 1 of 5) 5−18

23

36 31 30 36 34

41

36 31 30 36 34

39

16

38

15

42

34

36

28 31

36

34

36

28

36

31

Lubrication Diagram − Spring Suspension (Sheet 2 of 5) 5−19

5

4

3

9

9

7,8,17

15 24

26 44

13 2 1

14 12

18,19

35

35

2 40

43

1

16

11

10

37

35

27

37

22

29

20

35

35 25 35

23

21

6

Lubrication Diagram − Hydragas Suspension (Sheet 3 of 5) 5−20

23

36 31 30 36 34

41

36 31 30 36 34

39

16

38

15

42

34

36

28 31

36

34

36

28

36

31

Lubrication Diagram − Hydragas Suspension (Sheet 4 of 5) 5−21

48

47

49

48 45

46

48

Lubrication Diagram (Sheet 5 of 5) 5−22

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

LOAD MOMENT INDICATING SYSTEM Using various sensing devices, the Load Moment Indicator monitors various crane functions and provides the operator with a continuous reading of the crane’s capacity. The readings continuously change as the carne moves through the motions needed to make the lift.

The LMI provides the operator with information regarding the length and angle of the boom, tip height, working radius, rated load and the total calculated weight being lifted in the crane. It also incorporates the anti two block system which provides warning to the operator of an impending two block condition.

If non permitted conditions are approached, the DS 350 GW Load Moment Indicator will warn the operator by sounding an audible alarm, lighting a warning light and cutting−off the unwanted crane movements.

The LMI is an operational aid which warns a crane operator of approaching overload conditions and also warns of overhoist conditions which could cause damage to equipment and personnel.

The device is not, and shall not, be a substitute for good operator judgement, experience and use of accepted safe crane operating procedures.

The responsibility for the safe operation of the crane shall remain with the crane operator who shall ensure that all warnings and instructions supplied are fully understood and observed.

Prior to operating the crane, the operator must carefully and thoroughly read and understand the information in the Load Moment Indicator handbook supplied with the handbook, to ensure that he knows the operation and limitations of the indicator and crane.

The Load Moment Indicator will give the correct readings only if it is correctly programmed by the Operator.

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

ANCHOR WEDGE

Installing Cable Anchor Wedge

4.

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

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

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 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 previous instructions.

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

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

1

3 2

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

7−6

ERECTING AND STOWING THE SWINGAWAY BOOM EXTENSION. WARNING BEFORE ERECTING OR STOWING THE SWINGAWAY, READ AND ADHERE TO THE WARNING DECALS INSTALLED ON THE SWINGAWAY AND/OR STOWAGE BRACKETS. WARNING DO NOT ATTEMPT TO CHANGE THE OUTRIGGER CENTRES FROM FULL EXTENSION TO PARTIAL EXTENSION, OR THE REVERSE, WITH THE SWINGAWAY IN ANY OTHER POSITION THAN STOWED ALONGSIDE THE MAIN BOOM. Erecting 1.

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

2.

Elevate the boom and swing to 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.

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

4.

Remove the boom nose sheaves safety clips (2) and pins (1).

WARNING DO NOT REMOVE THE ATTACH PIN (3) SECURING THE SWINGAWAY TO THE FRONT STOWAGE BRACKETS (5) AT THIS TIME.

5.

Remove the safety clip (7) and latch pin (6) securing the latch plate (8) on the rear stowage (9) and swing the latch plate down to release the swingaway.

Stow the latch pin (8) and safety clip (7) on the rear stowage bracket (9).

7−7

6.

With the front stowage bracket (5) acting as a pivot pull outward on the swingaway tip to position the swingaway anchor fittings (10) into the attach fittings (11) on the right side of the boom nose.

7.

Remove the safety clips (14) from the attach pins (13) stowed in the base of the swingaway and insert the attach pins (13) through the attach and anchor fittings on the right side of the boom nose. Install the safety clips (14) in the attach pins (13).

8.

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

WARNING THE BOOM MUST BE RAISED TO HORIZONTAL TO PREVENT THE SWINGAWAY FROM SWINGING AROUND AFTER REMOVING THE ATTACH PINS FROM THE FRONT STOWAGE BRACKET. 9.

Elevate the boom to horizontal.

10. Remove padlock (12) and safety clip (30), turn and remove pin (3) to release the swingaway from front stowage bracket (5). For safe keeping replace the pin (3) safety clips (30) and padlock (12) in the front stowage bracket after releasing the swingaway.

WARNING WHEN ERECTING, THE SWINGAWAY ENSURE ALL PERSONNEL AND EQUIPMENT ARE KEPT CLEAR OF SWING PATH. 11. Using the rope attached to the tip of the swingaway pull the swingaway off the front stowage bracket (5). After the swingaway clears the front stowage bracket, slightly raise and/or lower the boom to help control the swingaway. Using the rope, swing the swingaway into place ahead of the boom nose engaging the anchor fittings (10) with the attach fittings (11) on the left side of the boom. It maybe necessary to retract the right rear outrigger jack slightly at this state until step 12 has been completed.

NOTE Step 13 applies only if there is difficulty in aligning the upper swingaway extension attach point to the boom nose.

7−8

WARNING DO NOT MODIFY THE ATTACH POINTS TO PERMIT THE INSTALLATION OF THE ATTACH PINS. 12. Install the attach pins (13) and safety clips (14) into the lower anchor (10) and attach fittings (11) on the left side of the boom.

NOTE On current models a boom extension alignment device is fitted.

NOTE If the boom extension alignment device does not properly align the anchor and attach fittings to allow installation of the attach pin and retainer clip, refer to the service manual and adjust the boom extension alignment device.

13. On cranes without an alignment device place blocking under the swingaway nose and relieve the weight of the swingaway by a slight lowering of the boom. Install the attach pin (13) and safety clip (14) into the upper anchor (10) and attach fittings (11). Remove the rope from the swingaway.

NOTE Refer to SETTING THE OFFSET in this Section to obtain a 17 or 32 degree offset with the swingaway.

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

14. Remove the safety clips (20) and pins (21) from the swingaway nose sheave.

15. Remove the cable roller safety clip (22) and pin (23) from the stowed position on the swingaway and raise the mast assembly (24) to an upright position.

Swing the mast assembly (24) through 90 degrees to in line position and reinstall pin (23) and clip (22).

7−9

16. Remove the cable retainer clip (33) and pin (34) from mast assembly and route hoist cable over the mast sheave and over the sheave on the swingaway tip.

17. Install retainer pins (21) and clips (20) on swingaway nose and pin (34) and clips (33) on the mast assembly.

18.

Rig the hoist cable.

WARNING THE FOUR RETAINING PINS (13) AND CLIPS (14) MUST ALL BE IN PLACE BEFORE CONTINUING OPERATIONS WITH BOOM EXTENSION.

Stowing NOTE The swingaway extension must be fully retracted and at minimum offset to be stowed. Refer to SETTING THE TELESCOPING EXTENSION LENGTH and/or SETTING THE OFFSET in this Section.

1.

Fully retract the boom and swing to over the rear with the outriggers fully extended, jacks set, and the crane level.

2.

Lower the boom to minimum elevation to allow access to the boom nose for removal of components.

3.

Remove clips (2) and pins (1) from main boom sheaves, clips (20) and pins (21) from swingaway and clip (33) and pin (34) from mast assembly.

4.

Lay the cable off to the left side of the boom and install the attach pins (21) and safety clips (20) on the swingaway nose sheave and pin (34) and clip (33) on mast assembly (24).

5.

Remove clip (22) and pin (23) and swing mast assembly (24) through 90 degrees and lay it down in stowed position. Secure with pin (23) and clip (22).

NOTE If the telescoping swingaway extension is being used, it must be completely retracted.

7−10

6.

Attach a length of rope to the swingaway tip.

7.

Remove padlock (12), safety clip (30) and pin (3) from front stowage bracket (5).

8.

Pivot latch plate (8), on the rear stowage bracket (9) down.

9 Remove the safety clips (14) and attach pins (13) from the anchor (10) and attach fittings (11) on the LEFT side of the boom nose and stow them in the holding brackets on the base of the swingaway.

WARNING WHEN STOWING THE SWINGAWAY, ENSURE ALL PERSONNEL AND EQUIPMENT ARE KEPT CLEAR OF THE SWING PATH. CAUTION DO NOT ALLOW THE SWINGAWAY TO IMPACT THE SUPPORT BRACKET WHEN SWINGING INTO POSITION. 10. Raise the boom to horizontal to help control the swingaway and using the rope attached to the tip of the swingaway, swing the swingaway to the right side of the boom.

11. Secure the rope to prevent the swingaway from swinging away from the boom.

12. Ensure the area above the boom is clear of all obstructions and elevate the boom as necessary to allow the swingaway to be positioned in the front stowage bracket (5).

13. Insert pin (3) through bracket (5) to secure the swingaway and lock with safety clip (30). Turn pin (3) to locate in retaining lugs and fit padlock (12).

14. Remove the attach pins (13) and safety clips (14) from the anchor fittings (10) and attach fittings (11) on the RIGHT side of the boom nose.

15. Disengage the swingaway anchor fittings (10) from the boom attach fittings (11) by pushing the tip of the swingaway into position in the rear stowage bracket (9). To assist positioning the swingaway into the rear stowage bracket, elevate the boom (approximately 65 degrees) as necessary.

16. Lower the boom to horizontal, and position the rear latch plate (8) to secure the swingaway in the rear stowage bracket (9) and install the latch pin (6) and safety clip (7).

7−11

Erecting and Stowing the Swingaway Boom Extension 7−12

17.

Remove the rope from the tip of the swingaway.

18. Position the cable over the main boom nose sheaves and install the attach pins (1) and safety clips (2).

19.

Rig the hoist cable.

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

Setting the Offset − Refer to Swingaway Offset Positions Figure.

1.

Fully extend and set the outrigger beams and jacks, ensuring the crane is level. Fully retract and swing the boom to over the rear and position to above horizontal.

2.

Extend and lower the boom until the swingaway tip is on the ground.

3.

To set the offset from 2 degrees to 17 or 32 degrees perform the following procedures.

CAUTION DO NOT OVERLOAD THE SWINGAWAY ANCHOR FITTINGS OR THE SWINGAWAY BASE SECTION WHEN LOWERING THE BOOM. a) Slowly lower the boom until the pressure is relieved from offset links (1) and attaching pins (2).

WARNING ENSURE THE SWINGAWAY IS FULLY SUPPORTED BEFORE REMOVING THE UPPER ATTACH PINS AND RETAINER CLIPS FROM THE OFFSET. b) Remove and attach pins (2), washers and retainer clips from the offset links (1) and boom extension.

7−13

c) Slowly elevate and telescope the boom at the same time until the offset links align with the proper holes for the desired offset. d) Install the attach pins (2), washers and retainer clips through the offset links (1) and boom extension.

4.

To set the offset from 17 or 32 degrees to 2 degrees or from 32 to 17 degrees perform the following procedures.

CAUTION DO NOT OVERLOAD THE SWINGAWAY ANCHOR FITTINGS OR THE SWINGAWAY BASE SECTION WHEN LOWERING THE BOOM. a) Slowly lower the boom until the pressure is relieved from the offset links (1) and attaching pins (2). b) Remove the retainer clips, washers and attach pins (2) from the offset links (1) and boom extension base. c) Slowly lower and retract the boom at the same time until the offset links align with the proper holes for the desired offset. d) Install the retainer clips, washers and attach pins (2) into the offset links (1) and the boom extension base.

Setting the Telescoping Extension Length Extending 1.

If not already done, fully extend and set the outrigger beams and jacks, ensuring the crane is level. Fully retract and swing the boom to over the rear.

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

2.

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

7−14

3.

Loosen the Right hand side wear pads (37) and (38) on the swingaway until the telescoping section is free.

4.

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

WARNING BEFORE REMOVING THE HITCH PIN AND PIN (16) SECURING THE TELESCOPING SECTION INSIDE THE BASE SECTION ENSURE THE TELESCOPING SECTION CANNOT SLIDE COMPLETELY OUT OF THE BASE SECTION. NOTE Use the hoist cable to control the extension of the telescoping swingaway by anchoring the wedge socket to the cable anchor (39) under the nose of the swingaway.

5.

Remove the pin (16) and hitch pin securing the telescoping section to the base section.

6.

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

7.

Install the pin (16) and hitch pin.

8.

If the wear pads (37) and (38) are loosened, re−tighten as necessary to ensure the telescoping section is straight with the base section.

Retracting WARNING WHEN USING THE HOIST CABLE TO PULL THE TELESCOPING SECTION INTO THE SWINGAWAY BASE, DO NOT DAMAGE THE HOIST CABLE OR SWINGAWAY BY PULLING THE SECTION PAST ITS FULLY STOWED POSITION. 7−15

NOTE If it was necessary to loosen the wear pads (37) and (38) to extend the section, it may be necessary to loosen them to retract the section.

CAUTION IF A BINDING CONDITION OCCURS DURING RETRACTION STOP IMMEDIATELY RESOLVE THE PROBLEM BEFORE CONTINUING THE RETRACTION OF THE TELESCOPING SECTION. 1.

With the hoist cable reeved over the swingaway nose sheave, attach the wedge and socket to the anchor (39) under the nose of the swingaway.

2.

Carefully tighten the hoist cable and remove pin (16) and hitch pin.

3.

Slowly reel in the hoist cable pulling the section into the swingaway base until the pin and hitch pin (16) can be installed.

7−16

Swingaway Offset Positions

7−17