Manitowoc Grove Crane AT635E Carrier Operator's Manual PDF

OPERATOR’S AND SAFETY HANDBOOK

AT635E CARRIER S/N_________________________

PUBLISHED: OCTOBER 1993

LIST OF EFFECTIVE PAGES Original . . . . . . . January 1992 Change 1 . . . . . November 1992 Change 2 . . . . . October 1993

ii

Page Numbers

Change In Effect

Title Page thru xiii Title Page thru ii Title Page thru ii viii xii xi thru xii 1−1 thru 1−9 2−1 thru 2−16 3−1 thru 3−15 3−6 3−8 3−11 3−12 thru 3−15 3−15 4−1 thru 4−26 5−1 thru 5−20 5−15

Original 1 2 1 1 2 Original Original Original 2 2 2 1 2 Original Original 1

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 EQUIPMENT, EXCEPT THE MANUFACTURER’S WARRANTY AGAINST DEFECTS, MATERIAL AND WORKMANSHIP SET OUT BELOW: NEW EQUIPMENT WARRANTY “The Manufacturer warrants each new product made by the Manufacturer to be free from defects in material and workmanship, its obligation and liability under this warranty being limited to replacing free of charge at its factory, any part proving defective under normal use and service within six (6) months from the date of initial sale, lease or rental, providing the equipment is on record with the Manufacturer as being installed by the distributor. If the machine is not on record as being installed by the distributor, the Manufacturer will consider the date of shipment from the factory as the date of initial sale, lease or rental. This warranty is in lieu of all other warranties, express or implied and the obligation and liability of the Manufacturer under this warranty shall not include any transportation or other charges or the cost of installation or any liability for direct, indirect or consequential damages or delay resulting from the defect. Any operation beyond rated capacity or the improper use or application of the product or the substitution upon it of parts not approved by the Manufacturer shall void this warranty.

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

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

v

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

DO NOT OVERLOAD Weight of load should always be known 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 LIST OF SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−2

SECTION II SAFETY PRECAUTIONS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1 TRAVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−11 COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−14 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−16

SECTION III DESCRIPTION GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAJOR COMPONENTS AND SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outrigger System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAB CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachometer/Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

3−1 3−1 3−1 3−2 3−2 3−2 3−2 3−2 3−2 3−2 3−2 3−3 3−3 3−3 3−3 3−3 3−3 3−3 3−4 3−4 3−4

Page Cold Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Foot Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Alternator Warning Indicator (Red) . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Engine Distress Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Travel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Dual Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Low Air Pressure Indicator (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Hand Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Handbrake Warning Indicator (Red) . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Foot Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5 Transmission Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . 3−5 Exhaust Brake Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Gearshift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Torque Convertor Lock Up Indicator (Green) . . . . . . . . . . . . . . . . 3−6 Torque Convertor Automatic Lock−Up Switch . . . . . . . . . . . . . . . 3−6 Gearshift Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Emergency Gearshift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Hydraulic Pump Disconnect Control . . . . . . . . . . . . . . . . . . . . . . . . 3−6 Hydraulic Pump Engaged Indicator (Red) . . . . . . . . . . . . . . . . . . . 3−7 Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Differential Lock Indicator (Amber) . . . . . . . . . . . . . . . . . . . . . . . . . 3−7 Chassis Superstructure Change Over Switch . . . . . . . . . . . . . . . 3−7 Power to Superstructure Indicator Lamp (Amber) . . . . . . . . . . . 3−8 Rear Steering Tiller Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Rear Steering Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Rear Steering Indicator Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Two/Four Wheel Drive Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Four Wheel Drive Indicator Light (Amber) . . . . . . . . . . . . . . . . . . . 3−8 Steering Disconnected Indicator Light . . . . . . . . . . . . . . . . . . . . . . 3−9 Axle Lock and Unlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Axle Suspension Lock Warning Light (Red) . . . . . . . . . . . . . . . . . 3−9 Axle Suspension Lock Warning Light (Red) . . . . . . . . . . . . . . . . . 3−9 Steering Pump Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9 Four−Way Flasher Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Steering Column Tilt Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Steering Column Telescope Control . . . . . . . . . . . . . . . . . . . . . . . 3−10 Headlights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 xi

Page Headlight High Beam Indicator (Blue) . . . . . . . . . . . . . . . . . . . . . . 3−10 High Beam Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Fan Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10 Heat Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Defrost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Rear Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Rotary Beacon Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Windscreen Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Battery Isolator Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11 Test Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12

SECTION IV OPERATING PROCEDURES PRE−STARTING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Seat Belt Webbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signal and Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foot and Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idling the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Racing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANE TRAVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACTIVE RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii

4−1 4−1 4−2 4−2 4−2 4−2 4−2 4−2 4−2 4−2 4−3 4−3 4−3 4−3 4−3 4−3 4−4 4−4 4−5 4−6 4−6 4−7 4−7 4−7 4−7 4−7 4−7

Page TRAVELLING−GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−8 Operation Of Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−10 Travelling Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−18 Travelling Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−19 Four−wheel Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−19 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−19 Stowing And Parking After The Working Day . . . . . . . . . . . . . . . . . . . . 4−21 Tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−22 Insertion of Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−22 Change of Driver During the Working Day . . . . . . . . . . . . . . . . . . . . 4−22 End of the Working Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−23 Setting the Speed Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−23

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

LIST OF FIGURES Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−7 Cab Controls and Indicators (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . 3−13 Cab Controls and Indicators (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . 3−14 Cab Controls and Indicators (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . 3−15 Tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−25 Tachograph Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−26 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−17 Lubrication Diagram (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18 Lubrication Diagram (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−19 Lubrication Diagram (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−20

xiii

SECTION I GENERAL INTRODUCTION This Handbook provides information for the operators of the Model AT635E 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.

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

LIST OF SPECIFICATIONS GENERAL Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT635E Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . See Load Chart in cab Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4.

Gross Weight . . . . . . . See lifting and transportation decal on cab door Maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 kph (45 mph) Maximum Turning Radius . . . . . . . . . . . . . . . 12m (39.37 ft) Wall to Wall Maximum Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65% Cooling Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 litres (7.4 galls) CAPACITIES (Litres/U.S. Gallons) Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200.6 litres (53 gallons) Engine Lubrication System . . . . . . . . . . . . . . . . . 22.4 litres (5.8 gallons) Hydraulic Tank (Reservoir Capacity) . . . . . . . . 400 litres (106 gallons) Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 litres (3 gallons) Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 litres (1.14 gallons) Axle Planetary Ends . . . . . . . . . . . . . . . . . . . . . . . 1.5 litres (0.4 gallons) Transmission and Torque Convertor . . . . . . . . . . . 22.7 litres (6 gallons) Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 litres (3.3 gallons) FIRE EXTINGUISHER Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BC Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.75 lbs (1.25 kg) TRANSMISSION Speeds . . . . . . . . . . . . . . . . . . . . . Low range . . . . . . . . . . . High Range 1st . . . . . . . . . . . . . . . . . . . . . . . . . 11.41 . . . . . . . . . . . . . . . . . . . . . 4.62 2nd . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 . . . . . . . . . . . . . . . . . . . . . . 2.40 3rd . . . . . . . . . . . . . . . . . . . . . . . . . 3.42 . . . . . . . . . . . . . . . . . . . . . . 1.38 4th . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 . . . . . . . . . . . . . . . . . . . . . . . 0.85 WHEELS AND TYRES Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 kgm (435 lb ft) For roading and lifting pressures, see the Tyre Inflation decal in the cab for various tire sizes and lifting pressures.

BRAKES Type . . . . . . . . . . . . . . . . . . . . . . . . Front . . . . . . . . . Duplex Wedge − Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear . . . . . . . . . Simplex Wedge Air 1−2

AXLES Ratio Front & Rear . . . . . . . . . . . . Hub . . . . . . . . . . . . . . . . . . . . . . 4.94:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diff . . . . . . . . . . . . . . . . . . . . . . 1.83:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall . . . . . . . . . . . . . . . . . . . 9.00:1 HYDRAULIC PUMP TRIPLE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Output . . . . . . . . . . . . . . . 1−52 gpm (197 lpm), 1−37.7 gpm(143 lpm), 1−25 gpm (95 lpm) @ 2500 rpm SWING MOTOR Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbit Displacement . . . . . . . . . . . . . . . . . . 14.9 cu. in (244.16 cu.cm) per rev SWING GEARBOX Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Epicyclic Gear Reduction Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15:1 Maximum r.p.m. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 r.p.m.

BOOM Four section fully powered . . . . 8.51m to 27.44m (27.92 ft to 90.02 ft) Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . −3.5° to +78 Optional Extensions . . . . . . . . . . . . 7.6m (25ft) Fixed length Swingaway, or 7.6m (25ft) Fixed length Offsettable Swingaway or 7.6 − 13.1m (25 to 43ft) telescoping swingaway HOISTS (MAIN) − Serial Numbers 50500 and 50501 only Grove Model HO−15F−20G Drum Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 inch (30.5 cm) Drum Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 inch (51 cm) Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14mm Cable Capacity . . . . . . . Useable . . . . . . . . . . . . . . . . . 365 feet (111 m) Stowable . . . . . . . . . . . . . . . 460 feet (140 m) Permissilble Line Pull . . . . . . . . . . . . . . Refer to Line Pull and Reeving Information Chart in the cab HOISTS (MAIN) − Serial Numbers 50502 Onwards Grove Model HO−15G−20G Drum Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 inch (30.5 cm) Drum Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 inch (51 cm) Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14mm Cable Capacity . . . . . . . Useable . . . . . . . . . . . . . . . . . 365 feet (111 m) Stowable . . . . . . . . . . . . . . . 460 feet (140 m) 1−3

Permissilble Line Pull . . . . . . . . . . . . . . Refer to Line Pull and Reeving Information Chart in the cab HOISTS (AUXILIARY) Grove Model HOF−15−20G Drum Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 inch (30.5 cm) Drum Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 inch (51 cm) Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14mm Cable Capacity . . . . . . . Useable . . . . . . . . . . . . . . . . . 365 feet (111 m) Stowable . . . . . . . . . . . . . . . 460 feet (140 m) Permissilble Line Pull . . . . . . . . . . . . . . Refer to Line Pull and Reeving Information Chart in the cab COUNTERWEIGHT Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed and bolted on Weight . . . . . . . . . . . . . . . . . . . . . . (See Axle Weight Distribution Chart) OUTRIGGERS Type . . . . . . . . . . . . Double Box Housing with Beam and Vertical Jacks Extended Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0m (19.68ft) Retracted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5m (8ft 2in) AIR HYDRAULIC SWIVEL Air Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Oil Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRICAL SYSTEM Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single wire Ground.

System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 negative earth Starting Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4.8kw) 24.

Alternator . . . . . . . . . . . . . . . . . . . . Rating . . . . . . . . . . . . 28v x 45amps.

STEERING PUMPS Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.6 Litres Per Min (21.3 gpm) Regulated Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.3 lpm (8.0 gpm)

1−4

CAB HEATER(S) Carrier Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Superstructure Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Combustion Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel ENGINE SPECIFICATION MAKE & MODEL

CUMMINS 6CT 8.3L

TYPE

6 CYLINDER, 4 CYCLE Turbo Charged Direct Injection

BORE

114mm (4.5 in)

STROKE

135mm (5.3in)

DISPLACEMENT

8.3 litres

GOVERNED RPM

2400

RATING

211 HP (157 kw) @ 2400 rpm

TORQUE

757 Nm (561 lbs ft) @ 1500 rpm

COMBUSTION SYSTEM

Direct Injection

LUBRICATION

22.4 litres (23.7 U.S. Qts)

COOLING CAPACITY

28 litres (7.4 U.S.)

WEIGHT WET

599−636 kg(1320−1402 lbs)

1−5

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

Partially extended outriggers are used as lifting points.

The following procedure must be adhered to:− 1.

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

2.

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

3.

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

4.

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

5.

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

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

1−6

Slinging Points 1−7

AXLE WEIGHT DISTRIBUTION CHART WEIGHT (TONNES)

FRONT AXLE (TONNES)

REAR AXLE (TONNES)

Basic Machine

24.031

12.063

11.968

Basic Machine with increased counterweight

24.454

12.250

12.204

0.400

0.400

0.000

0.377

−0.141

0.518

0.265

0.265

0.000

0.220

0.220

0.000

0.197

−0.073

0.270

0.100

−0.025

0.125

0.410

0.512

−0.102

0.247

0.325

−0.078

0.090

−0.061

0.151

0.066

0.154

−0.088

0.066

0.146

−0.080

0.050

0.078

−0.028

ITEM DESCRIPTION

OPTIONAL EQUIPMENT 30T Hookblock & Stowage(Over Front RH Wheel) 30T Hookblock & Stowage (Over Rear Outrigger Hsg) 15T Hookblock & Stowage (Over Front RH Wheel) 9T Hookblock & Stowage (Over Front RH Wheel) 9T Hookblock & Stowage (Over Rear Outrigger Housing) Headache Ball & Mounting (Behind Rear RH Wheel) Sub: Telescopic Extension in place of fixed non−offsettable Sub: Fixed Offsettable Extension in place of fixed non−offsettable extension.

Aux Hoist (In Place of 0.65T Tailweight) Aux Boom Nose Assembly (Operating Position) Aux Boom Nose Assembly (Stowed Position) Stowage Basket (For Misc.

Equipment)

1−8

Dimension Chart 1−9

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

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

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

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

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

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

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

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

2-1

Know and abide by the basic safety rules.

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

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

2-2

Be prepared for the work day.

2-3

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

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

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

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

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

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

2-4

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

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

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

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

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

Proper lubrication is a requirement in any heavy equipment operation. Follow the factory recommendations regarding the lubrication time intervals and types 2-5

of lubricants used. Adjust time intervals accordingly, when working under severe conditions.

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

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

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

Do not attempt repairs you do not understand!

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

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

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

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

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

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

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

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

2-6

Don’t smoke while performing battery maintenance.

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

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

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

Follow standard safety precautions when refueling. FUEL IT SAFELY.

2-7

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

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

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

Keep your fingers away from potentially hazardous areas.

Keep brakes properly adjusted. Keep brake linings free of oil and grease. Do not over lubricate the bearings or brake anchor pins. Refer to the Service Manual.

2-8

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

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

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

Never get off or on a moving crane.

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

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

Inspect the tires for nicks and cuts, imbedded stones, and abnormal wear. Make certain dual wheels are properly matched for diameter and tread wear. Check for stones and other objects wedged between tires on dual wheels. Ensure all wheel nuts are properly torqued.

2-9

Check the tire pressure daily. When inflating or adding air to the tires, use a tire cage and clip-on inflator. Use an extension hose which will permit standing behind the tire tread when inflating.

2-10

In freezing weather, park the crane in an area where it cannot become frozen to the ground. The drive line can be damaged when attempting to free a frozen crane.

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.

TRAVEL OPERATION.

Check load limit of bridges. Before traveling across bridges, ensure they will carry a load greater than the crane’s weight.

Watch clearances when traveling. Do not take a chance of running into overhead or side obstructions.

2-11

When moving in tight quarters, post a look-out to help guard against collisions or bumping structures.

Never back up without the aid of a signalman to verify the area behind the crane is clear of obstructions and/or personnel.

When traveling, the boom should be completely retracted, lowered, and stowed in its travel position.

Do not attempt to move the crane until brake system air pressure is at operating level.

Secure the hook block and other items before moving the crane.

When traveling, keep the lights on, use traffic warning flags and signs, and use front and rear flag vehicles. Check state and local restrictions and regulations.

2-12

Drive carefully and avoid speeding.

Before traveling a crane, check suitability of proposed route with regard to crane height, width, and length.

Secure the turntable before moving crane, use the swing lock.

2-13

Stay alert at the wheel.

When parking on a grade, apply the parking brake and chock the wheels.

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

Check operating procedures for cold weather starting.

2-14

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

Clean the crane of all ice and snow.

Allow ample time for hydraulic oil to warm up.

In freezing weather, park the crane in an area where it cannot become frozen to the ground.

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

Always handle propane tanks according to the supplier’s instructions.

Never store flammable materials on the crane.

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

2-15

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.

2-16

SECTION III DESCRIPTION GENERAL The mobile crane carrier incorporates an all welded steel frame. The 4 x 4 carrier utilizes two drive steer axles. During normal travel operations, the front axle only is used for steering. This is accomplished by using the steering wheel in the carrier cab. During craning operations, steering is performed from the superstructure cab. The steering wheel in the superstructure cab is used to control the rear axle and a control switch is used to control the front axle. The engine is mounted in the front of the carrier and provides power through an eight speed, forward and reverse, electrically shifted transmission.

MAJOR COMPONENTS AND SYSTEMS CAB ASSEMBLY The carrier cab contains all of the controls and indicators necessary for setting up the suspension and for travelling and parking functions. The cab is all−steel, acoustically treated, fully enclosed with safety glass windows throughout. Access to the cab is provided by a door which contains a safety glass window. The latch handle on the door must be actuated to open the door. A lock is provided in the latch handle to provide locking of cab door. A grab handrail is provided to aid the operator in getting in and out of the cab.

The side window of the cab is a two section window assembly. The front section is stationary and the rear section slides. A self locking latch on the sliding window maintains the window in a closed and locked position. A suspension seat is installed in the cab and is adjustable both vertically and horizontally. The seat is also equipped with a seat belt.

A 10 BC rated 2.75 pound (1.25 kg) dry type fire extinguisher is mounted in the cab behind the operator’s seat.

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

For increased operator comfort and ease of operation, the steering column can be adjusted to tilt in different positions and in addition will telescope in and out.

3−1

ENGINE The engine is used to provide crane mobility, charge the air system via the compressor and supply electrical power via the alternator to charge the batteries and provide power for carrier and control circuits, accessories and lighting. Both crane cabs contain controls for operating the engine. For engine specification refer to Section 1 − GENERAL. FUEL TANK A single 200 litres (53 U.S. gallons) capacity fuel tank is mounted on the right side of the carrier frame. The filler cap is located on the top of the tank.

DRIVE TRAIN The drive train consists of the transmission, drive shafts and the associated linkages. The transmission is electrically shifted and has 8 forward and 8 reverse speeds.

AXLES The axles are all drive steer axles. The axles have cross differential locks for travelling in adverse site conditions.

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

BRAKES The brakes are drum and shoe type and are air operated. Both axles are equipped with spring applied brakes to hold the carrier stationary when parking and to provide auxiliary braking in case of emergency.

AIR SYSTEM The air system provides the air supply to operate the service brakes and the parking brakes. The engine driven compressor supplies the air to charge the air reservoirs. An air dryer removes moisture from the air before it reaches the reservoirs.

OUTRIGGER SYSTEM The outriggers are integral with the carrier frame and are controlled from the superstructure cab or from optional remote controls. The outriggers are full hy3−2

draulic, double box type. They are positioned to provide a rigid four point platform (outriggers fully extended and set) capable of supporting the machine and it’s maximum load capacity. Integral check valves and floats are standard equipment. A sight level bubble indicator is located in the superstructure cab and at the remote control station to ensure crane levelling. (Refer to Section IV Operator’s Handbook Superstructure for operating procedures).

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

CAB CONTROLS AND INDICATORS NOTE The following paragraphs describe the controls and indicators located in the carrier cab. The numbers in parentheses (1) represent the index number from the figure title Carrier Cab Controls and indicators.

ENGINE CONTROLS AND INDICATORS 1.

Ignition Switch

This key operated switch with four positions acc (4), off (0) run (1) and start (2).

The switch is spring returned from start to run. With the switch in the off position all ignition power in the carrier is off. Positioning the switch in the run position energises all ignition components.

2.

Voltmeter

With the ignition switch in the ON position and before starting the engine, the voltmeter indicates the condition of the batteries. With the engine running the voltmeter indicates alternator voltage. The voltmeter indicates voltage on a scale from 20 to 32 volts.

3.

Fuel Quantity Gauge

Indicates the quantity of fuel in the fuel tank.

4.

Tachograph

This instrument records the road speed, and distance travelling together with other operating data. Refer to section IV in this manual for further details.

3−3

5.

Engine Oil Pressure Gauge

Indicates the engine oil pressure. Minimum with hot engine idling at 500 revs/ min should be 0.5 kg/cm2 (7 psi). Refer to Engine handbook for further details.

6.

Engine Water Temperature Gauge

Indicates the engine water temperature on a scale calibrated from 60 to 140 degrees C. The engine must not be operated with the pointer above 98 degrees C. 7.

Tachometer/Hourmeter

This meter is calibrated in rpm x 100 with a gauge of zero to 30. The tach receives its signal in an a.c. waveform from the alternator. The hourmeter (Hours) portion of the gauge is located at the bottom and registers hours of engine operation.

8.

Cold Start Switch

The switch is a two position, spring returned to off switch and is used to inject shots of starting aid into the intake manifold of a cold engine during starting. The ignition switch must be in the start position for cold start operation.

9.

Foot Throttle Pedal

The foot throttle pedal is connected to an air valve that pneumatically controls the engine speed through an air throttle cylinder on the engine.

10.

Alternator Warning Indicator (Red)

The warning light illuminates when the ignition switch (1) is turned to the ON position. The warning should go out when the engine starts. If the warning illuminates when the engine is running there is a fault in the charging system. Unless the fault is corrected the battery will run down.

11.

Engine Distress Light (Red)

The Engine distress light illuminates when engine temperature is too high or engine oil pressure too low. When the light illuminates a buzzer also sounds. Stop the Engine immediately the light shows.

TRAVEL CONTROLS AND INDICATORS 12.

Air Pressure Gauge

The gauge is a direct reading pressure gauge with a red indicator needle, and registers air pressure in the park brake system. The outer dial graduation marks 3−4

are white for psi readings from 10 to 150 psi and the inner dial graduation marks are gold for kPa readings from 100 to 1000 kPa. The gauge is connected to the air system through tubing.

13.

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.

14.

Low Air Pressure Indicator (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 indicator, the pressure switches also energize a warning buzzer.

15.

Warning Buzzer

This sounds to indicate low Engine oil pressure or high water temperature. Stop the crane as soon as possible, investigate and rectify the fault.

16.

Hand Brake Control

Operation of control releases air in the spring brake chambers, allowing the machine to be held in parking position. This control should NOT be used for stopping the machine except in an emergency as a severe sudden stop will occur.

17.

Handbrake Warning Indicator (Red)

This indicator illuminates when the handbrake is applied and ignition switch is turned ON. 18.

Foot Brake Pedal

This pedal operates a dual air valve, it progressively applies and releases the road wheel brakes via two separate air brake lines. This braking effort applied to the road wheels is proportional to the amount of pedal depression.

19.

Transmission Oil Temperature Gauge

Indicates transmission oil temperature on a scale from 60 to 160 degrees C. Normal operating temperature will be up to 110 degrees C. (230 degrees F).

Maximum temperature is 120 degrees (248 degrees F). If excessive, temperature is indicated by the transmission oil temperature gauge, stop the crane and shift to neutral. Accelerate the engine to 1200 − 1500 rpm and allow the temperature to return to normal (two or three minutes) before re−selecting gears.

3−5

20.

Exhaust Brake Control (Optional)

Apply to slow the crane on curves or downgrades. Maximum brake effect occurs in the lowest gear range. The throttle pedal must be released when this brake is used.

It cannot hold a crane stationary.

21.

Gearshift Lever

Used to select range of gears in power−shift transmission. Move lever progressively as required. For shift procedures see instructions under Operation of Transmission in Section IV of this manual.

WARNING THE LEVER IN BOTH CABS MUST BE IN NEUTRAL POSITION BEFORE THE ENGINE CAN BE STARTED. 22.

Torque Convertor Lock Up Indicator (Green)

This illuminates when the gearbox lock up is engaged, and extinguishes when disengaged.

23.

Torque Convertor Automatic Lock−Up Switch

This switch should be engaged for highway travel for Torque Convertor lock−up and disengaged for site conditions.

24.

Gearshift Override Switch

This switch is for override of the gearshift (21). In the event of failure of the automatic control this switch enables the crane to be moved by operating switch (25) after locking this switch in the down position using integral locking device. The use of this switch is considered strictly as an emergency.

25.

Emergency Gearshift Switch

This switch is used to select forward or reverse in an emergency when the gearshift lever (21) is overridden.

26.

Spare Aperture

27.

Hydraulic Pump Disconnect Control CAUTION SWITCH THE ENGINE OFF BEFORE OPERATING THE HYDRAULIC PUMP DISCONNECT CONTROL.

3−6

The hydraulic pump disconnect control is located on the right console beside the gear selector lever. The control is a push−pull cable control that is connected directly to the pump disconnect on the transmission. When the control is pulled out to the disengage position, the pump is disengaged from the torque convertor and hydraulic flow ceases. When the control is pushed in to the engage position, the torque convertor drive is engaged with the pump and hydraulic flow is produced.

28.

Hydraulic Pump Engaged Indicator (Blue)

The indicator is a blue light that will illuminate when the hydraulic pump is engaged.

29.

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 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. The locks should preferably be engaged when the crane is STATIONARY but may be engaged when moving if:− 1. the crane is moving slowly and 2. the wheels are NOT SPINNING at the same time of engagement.

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

DO NOT TRAVEL WITH THE LOCK ENGAGED ON A SURFACE THAT PROVIDES GOOD WHEEL ADHESION. 30.

Differential Lock Indicator (Amber)

When the differential lock is engaged the indicator lamp illuminates.

31.

Chassis Superstructure Change Over Switch

This switch is turned as required to change over control of the electrical system to the alternative driving cab as follows: 3−7

Switch turned to LEFT

−(1)

super cab isolated chassis cab operative

Switch turned to RIGHT

−(2)

super cab operative chassis cab isolated WARNING

ALWAYS TURN OFF ENGINE AND IGNITION SWITCH BEFORE CHANGING OVER CHASSIS/SUPERSTRUCTURE SWITCH. 32.

Power to Superstructure Indicator Lamp (Amber)

This lamp illuminates when the power to Superstructure Switch is put in the ‘ON’ position.

33.

Rear Steering Tiller Switch

This switch provides independent control of the steering functions of the rear axle.

34.

Rear Steering Switch

Select to engage or disengage the rear axle steering lock. This switch will only operate when the four wheel drive switch (36) is selected.

35.

Rear Steering Indicator Light (Red)

Illuminates to indicate the rear wheels have not been locked in the straight ahead position from the Super cab.

36.

Two/Four Wheel Drive Switch

This switch is used for changing from 4 x 2 wheel drive. Use this switch only when crane is stationary. HIGH/LOW range changes are automatic. When 4 x 2 wheel drive is selected HIGH range is engaged and when 4 x 4 wheel drive is selected LOW range is engaged in the transfer gearbox. Warning light (37) will illuminate with a 4 x 4 wheel drive.

DO NOT SELECT 4 X 4 WHEEL DRIVE FOR NORMAL ROAD TRAVEL OPERATION 37.

Four Wheel Drive Indicator Light (Amber)

Illuminates when four wheel drive is selected.

3−8

38.

Steering Disconnected Indicator Light

The steering disconnected indicator light (CARRIER STEER DISCONNECTED) is located at the top of the front console. The light illuminates when the steering mode handle is not pushed in to allow steering from the carrier.

39.

Axle Lock and Unlock Switch WARNING THE AXLE LOCKS MUST BE ENGAGED BEFORE SLEWING OVER THE SIDE WHEN ON TYRES.

Use to lock the suspension only on firm level ground for free on wheel duties or when jacking the crane up on outriggers. Lights (40) and (41) will illuminate when all axles are locked. The locks must be disengaged for road travel.

40.

Axle Suspension Lock Warning Light (Red)

This light will illuminate when all axle suspension locks are engaged.

41.

Axle Suspension Lock Warning Light (Red)

This light will be illuminated if one (or more) of the axle suspension locks is not completely disengaged. To free the locks, repeat the unlocking procedure until light is extinguished.

WARNING DO NOT DRIVE ON THE ROAD WITH AXLE SUSPENSION LOCKS ENGAGED. 42.

Steering Pump Warning Light (Red)

This light will illuminate if the Engine driven steering pump fails. Should this occur stop the engine and investigate the cause and rectify.

ACCESSORY CONTROLS AND INDICATORS 43.

Horn

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

44.

Turn Signal Lever

The turn signal lever is located on the steering column forward of the steering wheel. Positioning the switch handle to the left causes the left front and left rear 3−9

turn signals to flash. Positioning the switch handle to the right causes the right front and right rear turn signals to flash.

45.

Four−Way Flasher Switch

The four−way flasher switch is located on the steering column just behind the turn signal lever. Pushing the switch in causes all four turn signal lights to flash.

The lights will continue to flash until the switch is pulled out.

46.

Steering Column Tilt Lever

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

47.

Steering Column Telescope Control

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

48.

Headlights Switch

The HEADLIGHTS switch is located on the left side of the instrument panel. The switch is push−pull type switch with a rheostat control. Pulling the switch to the first detent illuminates the marker lights and the gauge lights. Pulling the switch to the second detent illuminates the headlights, the marker lights, and the gauge lights. Rotating the switch knob controls the brightness of the gauge lights.

49.

Headlight High Beam Indicator (Blue)

The headlight high beam indicator is located on the right side of the front console. The indicator is a blue light that will illuminate when the headlights are on high beam.

50.

High Beam Dimmer Switch

The dimmer switch is located on the left side of the cab. The switch is depressed and released by foot pressure. It provides for selection of either high or low headlight beams.

51.

Fan Control Switch

This is a two position switch providing two speeds for fresh air ventilation to the directional vents.

3−10

52.

Heat Control Switch

The HEAT control is located on the right side of the front console. It is a pull − push cable controlling the flow of hot water to the heater. When pushed in the flow is cut off. When the cable is pulled out the flow (and heat) is at a maximum.

53.

Defrost Control

The DEFROST control is located on the right side of the front console. The control must be pulled out for the heater air flow to be routed to defrost the windshield.

54.

Rear Fog Light Switch

This switch activates the rear fog lights, an integral warning light in this switch will illuminate when the switch is ON. 55.

Rotary Beacon Switch (Optional)

Operates the Rotary Beacon on the chassis cab roof, an integral light illuminates when the switch is in the ON position.

56.

Windscreen Washer Reservoir

Fluid reservoir for the windscreen washer system.

57.

Windshield Wiper Switch

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

58.

Battery Isolator Lever

This lever is used to isolate the batteries, as required, for maintenance work. It is located adjacent the batteries in the Engine compartment.

There is one wire which by−passes the isolator switch, this is the negative feed for the electrical quartz clock in the tachograph. This reduces the need to reset the clock every time the isolator switch is operated.

3−11

58

WARNING NEVER SWITCH THE ISOLATOR TO OFF WHILST THE MACHINE IS RUNNING AS IT WILL CAUSE EXTREME DAMAGE TO THE ALTERNATOR AND ASSOCIATED CONTROL SYSTEMS. WARNING THE ISOLATOR LEVER SHOULD BE IN THE OFF POSITION WHEN ANY WELDING OPERATIONS ARE BEING CARRIED OUT ON THE MACHINE TO AVOID DAMAGE TO THE ALTERNATOR AND ASSOCIATED CONTROL SYSTEMS. NOTE “In order to avoid inadvertent battery discharge, the battery isolation switch should be opened whenever the machine is left unattended.” This is particularly important should the change−over switch be left in “Super” mode as certain solenoids would remain energised.

59.

Test Button

This switch is used to test the dash panel lighting and audible alarms.

3−12

43

47

27 44 45 50

20 46

21 25 24 18

31

33

9.

16.

18.

20.

21.

24.

25.

26.

27.

31.

33.

43.

44.

45.

46.

47.

50.

56.

9

26

16

56

Foot Throttle Pedal Hand Brake Control Foot Brake Pedal Exhaust Brake Control Gearshift Lever Gearshift Override Switch Emergency Gearshift Switch Spare Aperture Hydraulic Pump Disconnect Control Chassis Superstructure Change Over Switch Rear Steering Tiller Switch Horn Turn Signal Lever Four−Way Flasher Switch Steering Column Tilt Lever Steering Column Telescope Control High Beam Dimmer Switch Windscreen Washer Reservoir

Cab Controls and Indicators (Sheet 1 of 3) 3−13

4

57

6

48

3.

4.

5.

6.

8.

10.

11.

34.

35.

38.

39.

40.

42.

48.

57.

10

39

11

5

34

38

42

8

Fuel Quantity Gauge Tachograph Engine Oil Pressure Gauge Engine Water Temperature Gauge Cold Start Switch Alternator Warning Indicator (Red) Engine Distress Light (Red) Rear Steering Switch Rear Steering Indicator Light (Red) Steering Disconnected Indicator Light Axle Lock and Unlock Switch Axle Suspension Lock Warning Light (Red) Steering Pump Warning Light (Red) Headlights Switch Windshield Wiper Switch

Cab Controls and Indicators (Sheet 2 of 3) 3−14

3

35

40

2

41

30

23

19

36 1.

2.

7.

12.

13.

14.

15.

17.

19.

22.

23.

28.

29.

30.

32.

36.

37.

41.

49.

51.

52.

53.

54.

55.

59.

37

22

28

13 14

17

49

12 32

15

1

29

54

52

55

51

53

7 59

Ignition Switch Voltmeter Tachometer/Hourmeter Air Pressure Gauge Dual Air Pressure Gauge Low Air Pressure Indicator (Red) Warning Buzzer Handbrake Warning Indicator (Red) Transmission Oil Temperature Gauge Torque Convertor Lock Up Indicator (Green) Torque Convertor Automatic Lock−Up Switch Hydraulic Pump Engaged Indicator (Blue) Differential Lock Switch Differential Lock Indicator (Amber) Power to Superstructure Indicator Lamp (Amber) Two/Four Wheel Drive Switch Four Wheel Drive Indicator Light (Amber) Axle Suspension Lock Warning Light (Red) Headlight High Beam Indicator (Blue) Fan Control Switch Heat Control Switch Defrost Control Rear Fog Light Switch Rotary Beacon Switch Test Button

Cab Controls and Indicators (Sheet 3 of 3) 3−15

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

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

1.

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

2.

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

3.

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

4.

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

5.

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

6.

Check the engine oil and the coolant levels frequently.

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

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 check list 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.

4−1

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 and check cap for security.

WARNING THE CAP SHOULD ONLY BE REMOVED WITH THE ENGINE COLD. SERIOUS INJURY COULD OCCUR IF THE 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.

SEATS. Adjust seat and mirrors for clear vision and safe driving.

SEAT BELTS. Seat Belt Maintenance.

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

Cleaning Seat Belt Webbing.

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

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

4−2

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

FOOT AND PARKING BRAKES. Check for proper operation.

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

(Refer to Section V − Lubrication) NOTE For tyre inflation pressures refer to the tyre inflation decal on the crane.

TYRES Check for severe cuts, foreign objects imbedded in treads, and for correct inflation pressures before starting.

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

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

4−3

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. 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.

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

4−4

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

1.

Turn the ignition switch to the start position and release immediately when the engine starts.

2.

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

WARNING ENSURE ALL THREE AIR SYSTEM PRESSURES ARE IN THE NORMAL OPERATING RANGE PRIOR TO DISENGAGING THE PARK BRAKE. 4−5

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

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

Do not race the engine for a faster warm up.

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

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

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

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

4−6

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

SHUTDOWN PROCEDURE. 1.

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

2.

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

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

CRANE TRAVEL OPERATION. 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.

ACTIVE RESTRAINTS. Seat Belts.

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

4−7

For greater restraint and comfort: 1.

Be sure the belt is snugly fitted around the hips − not the waist − and not twisted. Failure to properly fit belts may result in unnecessary injury in the event of a collision.

2.

Only one person should be strapped in each seat belt.

To lengthen the belt, tip the buckle end downward, and pull the buckle until the belt ends can be joined. Insert the belt into the open end of the buckle until a snap is heard and check for latch engagement. This belt can be shortened, after connection, by pulling on the loose end until the belt is snug. Press the buckle release to remove the belt.

TRAVELLING − GENERAL. WARNING FOR EXTENDED TRAVEL, CHECK THE COLD TIRE PRESSURE PRIOR TO START. (REFER TO THE TIRE INFLATION DECAL ON THE CRANE.) CAUTION THE TOWING SPEED SHOULD NEVER EXCEED 10 KM/H (6 MPH). BEFORE COMMENCING TOWING THE VEHICLE, ENSURE ALL DRIVESHAFTS BETWEEN THE TRANSMISSION AND AXLES ARE DISCONNECTED, SO PREVENTING DAMAGE TO THE TRANSMISSION. Before attempting to move the crane, ensure adherence to the following conditions of the superstructure. Procedures for accomplishing the following can be found in the Superstructure Operator’s and Safety Handbook.

1.

Ensure all boom sections are fully retracted.

2.

Ensure the boom is fully lowered into the boom rest.

3.

Ensure the rear axle steering is locked

4.

Ensure the axle differentials are unlocked

5.

Engage the swing brake.

4−8

6.

Engage the positive swing lock.

7.

Ensure the swingaway extension (if so equipped) is properly stowed and secured.

8.

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

9.

Ensure the outrigger stabilizers and outrigger beams are fully retracted.

10. Ensure the stabilizer floats are properly stowed in their holding racks (optional fitting only).

11.

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

12.

Ensure axle locks are disengaged.

CAUTION DISENGAGE THE HYDRAULIC PUMP FOR EXTENDED TRAVELING, COLD WEATHER STARTING OR ENGINE CHECKS.

AT cranes are subject to the same road regulations as any truck, regarding gross weight, width, and length limitations.

CAUTION FOR EXTENDED TRAVEL, CHECK THE COLD TYRE PRESSURE PRIOR TO START. (REFER TO TYRE INFLATION CHART.). THE TYRE LOAD RATING IS BASED UPON TRAVEL NOT EXCEEDING 45 MILES (72 KM) IN ANY ONE HOUR PERIOD. AT DESTINATION, THE TYRES MUST BE ALLOWED TO COOL TO AMBIENT TEMPERATURE BEFORE CRANE LIFTING ON RUBBER. Although AT cranes are designed for rough terrain applications, the operator should be extremely cautious and aware of the terrain in which he is operating.

WARNING DO NOT DRIVE THE CRANE WITH THE BOOM OFF CENTER. 4−9

WARNING DO NOT TRAVEL WITH AN EMPTY HOOK IN A POSITION WHERE IT CAN SWING FREELY. WARNING AVOID HOLES, ROCKS, EXTREMELY SOFT SURFACES, AND ANY OTHER OBSTACLES WHICH MIGHT SUBJECT THE CRANE TO UNDUE STRESSES OR POSSIBLE OVERTURN. CAUTION DO NOT DRIVE THE CRANE WITH THE LIFT CYLINDER BOTTOMED. POSITION THE BOOM SLIGHTLY ABOVE HORIZONTAL, UNLESS STOWED ON THE BOOM REST. WARNING ON OPEN GROUND, TOW OR PULL ONLY ON THE PINTLE HOOKS OR LIFT LUGS. CAUTION SHOULD THE CRANE BECOME MIRED DOWN, USE A TOW TRUCK OR TRACTOR TO FREE THE VEHICLE. SEVERE DAMAGE TO THE TRANSMISSION OR AXLES MAY OCCUR IF THE OPERATOR ATTEMPTS TO FREE THE CRANE UNASSISTED. Use four−wheel drive only when greater traction is necessary. Refer to FOUR− WHEEL DRIVE OPERATION in this section for operating instructions.

OPERATION OF TRANSMISSION NOTE It is recommended that only two wheel drive be used in normal road travel operation.

4−10

Description of the System The dedicated shift programmes built into the gear shift controller include the following protections:− 1.

Automatic neutral selection at power up (ignition on).

2.

Neutral start interlock.

3.

Direction change protection.

4.

Downshift protection.

5.

Lock up/shift timing synchronisation.

The Electronic Shift Lever (E.G.S.) has special circuitry to allow it to check its own operation.

The three self−test modes currently available are: 1.

Input test − static (engine stopped).

2.

Output test − static (engine stopped).

3.

Speed sensor and lamp test − dynamic (engine running).

Furthermore it will also check for possible problems while driving the vehicle, and uses L.E.D.’s ‘N’ and ‘T’ to indicate them.

General Operation of L.E.D.’s ‘N’ and ‘T’ a.

Normal driving (no problems) = L.E.D. ‘T’ always off.

b.

When an error is detected = L.E.D. ‘T’ on or blinking.

c.

In the initiated self−test modes = L.E.D. ‘T’ always on.

Detailed Operation L.E.D. ‘N’

L.E.D. ‘T’

ON Trans in neutral

OFF

a.

Normal operation

b.

Input fault

ON

Blinks slowly

c.

Input test

Blinks slowly

ON

d.

Output test

Blinks fast

ON

e.

Speed sensor test

OFF

ON

4−11

The shift controller has a display panel that includes ten L.E.D. lamps. These lamps can illuminate green − orange or red providing an indication on the status of the transmission during operation.

The lamps are also used during the special diagnostic modes to verify correct operation.

Lamps 1 − 4 a.

Indicate the selected shift lever position.

b.

Indicate the gear selected by the transmission.

FORWARD : LAMP ON ‘GREEN’ REVERSE : LAMP ON ‘ORANGE’ Lamp ‘N’ This lamp will function as follows: a.

Normal operation with the shift lever in neutral = L.E.D. ‘ON’

b.

When the vehicle speed is above 2.5 km/h indicating the direction change inhibit protection is in operation. = L.E.D. ‘BLINKING’. c.

During the initiated self−test sequences the lamp will operate as follows: Input test = L.E.D. ‘BLINKING SLOWLY’ Output test = L.E.D. ‘BLINKING FAST’ Speed sensor/lamp test = L.E.D. ‘OFF’ Input malfunction = L.E.D. ‘ON’

Lamp ‘T’ This lamp is used during the initiated self−test sequences follows: Indicating normal operation = L.E.D. ‘OFF’ Input test = L.E.D. ‘ON’ Output test = L.E.D. ‘ON’ Speed sensor/lamp test = L.E.D. ‘ON’ 4−12

Input malfunction = L.E.D. ‘BLINKING SLOWLY’ NOTE During the initialisation phase after power up (ignition on) − both the ‘N’ and ‘T’ L.E.D.’s are on. Also when the E.G.S. controller is malfunctioning both L.E.D.’s will be ‘ON’ or ‘BLINKING’ simultaneously.

Lamp No. 7 This lamp is used to indicate engagement of the lock up clutch.

Lock up engaged = L.E.D. ‘ON’.

Lamp No. 8 This lamp is used to monitor the output signal from the turbine speed sensor. i.e. vehicle stationary or, possible sensor fault (vehicle moving = LED ‘ON’ Normal driving condition = L.E.D. ‘OFF’ NOTE When the E.G.S. detects no signal from the sensor − no upshifting of the gears is possible.

Functional Description The shift levers have three detented positions.

1.

Forward − moving the lever away from the display.

2.

Reverse − moving the lever towards the display.

3.

A central neutral position.

Selection of Neutral 1.

Whenever the ignition is switched on the E.G.S. will select neutral, regardless of the shift lever position.

2.

If the lever is not in neutral, the ‘N’ L.E.D. will be off, and the engine cannot be started due to the protection of the neutral start interlock.

4−13

3.

With the lever in neutral and the engine running the ‘N’ L.E.D. will either be on or ‘blinking’.

If it is ‘blinking’ it means the vehicle speed is in excess of the direction change protection limit − typically 2.5 km/h.

4.

To engage gear in either direction, it is mandatory that the vehicle speed is below this limit (l.E.D. ‘N’ not blinking) and the throttle pedal is in the idle position.

5.

If the speed sensor indicates ‘standstill’ L.E.D. ‘8’ will be on ‘green’.

NOTE The selection of neutral is not restricted and is possible under all circumstances.

Selecting Forward 1.

In forward, L.E.D.’s 1−4 light up green indicating the selected shift lever position.

2.

Move the 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’.

Upshifting Forward 1.

An upshift is made by momentarily moving the lever to the right of up position, against spring pressure and then allowing it to return to the forward detented position.

Holding the lever in the up position gives sequential upshifts at 1.5 second intervals.

L.E.D.’s 1−4 will light up indicating the actual gear selected.

Downshifting Forward 1.

A downshift is made by momentarily moving the lever to the left or down position, against spring pressure, and then allowing it to return to the forward detented position.

Holding the lever in the down position gives sequential down shifts at 1.5 second intervals.

L.E.D.’s 1−4 will light up indicating the actual gear selected.

4−14

(See note on ‘downshift’ protection).

Selecting Reverse 1.

In reverse, L.E.D.’s 1−4 light up ‘orange’ indicating the selected shift lever position.

2.

Move 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.

Upshifting or Downshifting in Reverse Mode 1.

The sequence of these functions is identical to that already described for the forward mode, except the L.E.D.’s 1−4 will light up orange.

UPSHIFT

HEATSINK

SPRING RETURN

FORWARD

REVERSE

LOCK

LOCK

1

2

3

4

5

N

T

F

N

R

DOWNSHIFT SPRING RETURN

6

7

8

DISPLAY

Shift Lever Positions Quick Shift Protection 1.

If repeated and rapid movement of the shift lever is attempted to the up or down position and back to the detented position − the selected lever position alters faster than when holding the lever to get sequential shifts.

2.

The transmission gear selection however will ‘creep’ towards the selected lever position, one gear at a time with an interval of 1.5 seconds between shifts.

4−15

3.

This is indicated by L.E.D.’s 1−4 ‘blinking’ which indicates the actual transmission gear selected.

Down Shift Protection If the shift lever is down shifted while driving and the change would cause overspeed of the transmission, the shift will be inhibited − but the new lever position will be accepted.

This is indicated by the L.E.D. corresponding to the requested gear position coming on, while the L.E.D. indicating the current gear selected will ‘blink’.

Direction Change Protection 1.

A change to the shift lever direction, forward or reverse is accepted only when the following conditions prevail: a.

The throttle pedal is completely released (at idle).

b.

The vehicle speed is below 2.5 km/h.

2.

If both conditions are met, a downshift to 1st gear is made following by the engagement of the new direction clutch.

3.

If either condition is not met, the transmission is placed automatically in neutral and the ‘N’ L.E.D. will ‘blink’.

4.

In this event L.E.D. 1 will be on indicating the newly selected direction, and the intended shift to 1st gear. The L.E.D. corresponding to the actual gear the transmission is selecting will ‘blink’ red.

5.

When the vehicle has slowed down and the optimum conditions are met, the E.G.S. will implement the requested change.

Throttle Switch Sensor Terminal 14 of the E.G.S. control is connected to ground via an air operating throttle position sensor switch.

This monitors the status of the throttle pedal to initiate various functions of the E.G.S. including: Direction change protection and extended range lock up.

Lock Up Operation The lock up clutch is automatically engaged when the available tractive effort in lock up drive is higher than in convertor drive.

4−16

if the vehicle speed falls below a pre−determined level, lock up is automatically dis−engaged.

With the throttle pedal depressed (normal driving) lock up can engage in any forward gear position.

With the throttle pedal at idle, lock up can engage in any gear position (forward or reverse).

When a gear shift is requested (lever movement) the lock up clutch will be dis− engaged automatically for 0.3 seconds before the shift is implemented.

Extended Lock Up When the throttle pedal is in the idle position, a special set of lock up limits (extended lock up) is applied giving improved braking performance than the normal limit values (standard lock up).

The throttle idle position is detected by an air operated switch under the cab floor. (i.e. idle position = switch open).

Emergency E.G.S. Override and Fwd/Rev Select Switches In the event of a malfunction with the E.G.S. system which results in a loss of drive using the normal E.G.S. shift controller, two switches are provided in the carrier cab for emergency use.

1.

An E.G.S. override switch and locking bar.

2.

A forward and reverse select switch.

The intended use of this feature is strictly to move the vehicle to a safe location for permanent repairs, and not for prolonged driving.

The operation of the emergency system is as follows: 1.

Select the E.G.S. override switch. − this will interrupt all power to the carrier E.G.S. controller.

2.

Select the forward or reverse switch. − this will engage 2nd gear in either direction, provided there is no problem with the transmission solenoids.

3.

The forward and reverse switch has no effect unless the E.G.S. override switch is selected first.

Towing Before towing the vehicle ensure that the rear wheel drive is disengaged and remove the propshaft from the front axle if towing speed is to exceed 10kph or distance is to exceed 10km. The engine cannot be started by towing or pushing.

4−17

CAUTION

Failure to follow the above precautions can cause serious transmission damage.

Temperature Check the transmission gauge in the cab occasionally for normal temperature 80° −110° C (175° − 230° F). if it exceeds 120° C (248° F) due to overload shift to neutral with crane stopped and run the engine at 1200 − 1500 rpm. This should reduce the temperature in two or three minutes to normal values.

If the transmission overheats during normal operation, check the oil level.

If high temperatures persist, stop the engine and check the system.

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

Allow the engine to warm up.

CAUTION NEVER ACTUATE THE 2/4 WHEEL DRIVE AXLE SWITCH WHEN THE WHEELS ARE MOVING. CAUTION USE FOUR WHEEL DRIVE ONLY WHEN MORE TRACTION IS REQUIRED.

2.

Position the DRIVE AXLE switch to either 2WD or 4WD.

3.

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’.

4.

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

4.

Position the transmission shift lever to the second gear position, accelerate until maximum gear speed is attained.

4−18

5.

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

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).

FOUR−WHEEL DRIVE OPERATION. If more traction is required due to slipping or spinning wheels, engage the rear axle drive. Engage four−wheel drive as follows.

CAUTION BEFORE SHIFTING FROM TWO−WHEEL DRIVE TO FOUR−WHEEL DRIVE (OR FROM FOUR BACK TO TWO), CRANE TRAVEL MUST BE STOPPED. 1.

Position the DRIVE AXLE selector switch to 4WD.

2.

Select the gear speed and direction of travel as described under TRAVELING − FORWARD. 3.

Return the DRIVE AXLE selector switch to the 2WD position as soon as two−wheel traction will suffice.

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

1.

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

2.

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

4−19

3.

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

4.

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

5.

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

6.

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

WARNING IF LOW PRESSURE OCCURS AND THE BUZZER SOUNDS DURING OPERATION,STOP IMMEDIATELY AND DETERMINE THE CAUSE OF AIR LOSS. DOWNSHIFT,USE THE ENGINE AS A BRAKE, AND MAKE THE FINAL STOP USING A SINGLE BRAKE PEDAL MOVEMENT TO AVOID EXCESSIVE LOSS OF AIR AND CONSEQUENT SUDDEN ENGAGEMENT OF THE AUTOMATIC SPRING BRAKES. 7.

Regularly check the air pressure gauge indication. System air pressure should never be allowed to fall below 45 psi (310 kPa/3.1 bar). If both systems drop below 45 psi (310 kPa/3.1 bar), the automatic spring brakes will actuate.

Normal operating pressure range is 105 to 120 psi (724 to 827kPa/7.24 to 8.27 bar).

NOTE If the pressure drops over 2 psi (14 kPa/0.14bar) per minute with the engine stopped,have the air system checked for leaks.

4−20

WARNING ENSURE THE BRAKES ARE RELEASED BEFORE ANY ATTEMPT TO DRIVE, OR DRIVE TRAIN DAMAGE WILL RESULT. THE PARKING BRAKE IS TO BE USED FOR PARKING ONLY. DO NOT USE THE PARKING BRAKE FOR STOPPING THE CRANE EXCEPT IN CASE OF AN EMERGENCY, AS A SEVERE SUDDEN STOP WILL OCCUR. 8.

Parking brakes are controlled by a readily identified lever on the console panel. To apply the parking brake, pull the control back. To release the parking brake push the control forward.

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. STOWING AND PARKING AFTER THE WORKING DAY. The proper stowing and parking of the crane after the working day is one of the simplest and easiest ways of extending the serviceable life of the crane and preventing theft, vandalism, and accidents.

1.

Perform the procedures found under Recommended Crane Shutdown Procedures in the Superstructure Operator’s and Safety Handbook.

2.

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

3.

Apply parking brakes and if necessary, chock the wheels.

4.

Shut down the engine using the proper procedures as specified by this Handbook and the engine manual.

Ensure all controls are in neutral and/or positioned to off.

6.

Perform any other specified procedures required at the end of the workday, i.e. drain water from the fuel filter − water separator, refueling, etc.

4−21

7.

Close all windows.

8.

Remove the keys from the crane.

9.

Lock up the crane. Install vandal guards, if used.

WARNING STEP 10 DOES NOT TAKE THE PLACE OF THE PRE−STARTING CHECKS WHICH MUST BE PERFORMED JUST PRIOR TO USING THE CRANE AT THE NEXT WORKING DAY.

10. Make a thorough walk around inspection to ensure that all cylinders that can be retracted are retracted. The only exceptions are those cylinders which cannot be fully retracted, i.e., steer cylinders. Also, look for anything that could hinder or prevent starting the next day’s work.

11.

Move battery isolation switch to off.

TACHOGRAPH Insertion of Chart 1.

Record the driver’s name, starting mileage, crane number, registration number, journey starting point, and date started on the tachograph chart.

2.

Ensure the time shown on the clock is correct.

NOTE Only open the tachograph when the vehicle is stationary.

3.

Turn the key counterclockwise and open the tachograph. Adjust the time shown, if it is incorrect, by rotating the clock setting wheel 4.

Lift the chart clamping lever and place the chart over the centre boss.

Press the clamping lever down to retain the chart.

5.

Close the tachograph and turn the key clockwise to lock it in place.

Change of Driver During the Working Day 1.

Open the tachograph, lift the chart clamping lever, and remove the tachograph chart.

4−22

2.

Press the clamping lever down and close the tachograph.

3.

Record the finishing mileage and distance driven.

4.

Take the chart to the next vehicle and record the vehicle number, the registration number, the time of the change to the vehicle and the starting mileage.

5.

Repeat the procedure according to Insertion of Chart in this section.

End of the Working Day 1.

Open the tachograph, lift the chart clamping lever, and remove the tachograph chart.

2.

Press the clamping lever down and close the tachograph.

3.

Record the total readings or one or two vehicles.

4.

Record the place of finish and date.

Setting the Speed Warning Light 1.

Open the tachograph.

2.

Rotate the speed warning light adjustment screw and observe the number displayed in the window adjacent to this screw. The number displayed is the speed in km/h at which the warning light illuminates. It may be adjusted over the range 31 to 75 mph (50 to 120 km/h).

4−23

Inserting the Tachograph Chart

4−24

Malfunction warning light This light switches on for the following reasons: the tachograph chart is missing the styli aren’t in contact with the chart and a recording is not being made the cover is not properly closed

The Time Group Selector can be set at: during driving periods (selector 1 only) This time group is not used in all EEC countries. during all non−driving working hours, including periods as passenger crew member. during breaks from work and daily rest periods

Speed warning light This light switches on whenever the set maximum speed is exceeded.In tacho− graphs with rpm registration,a maxi− mum engine speed is also set

Road speed (km/h, mph)

Clock operation ”tell−tale” The chevroned disc lets you know whether the clock is running.Be sure that the time is correctly set before starting a trip, as it is essential that all recordings are correct to British time even when abroad

TACHOGRAPH 4−25

Automatic tachograph recordings Road Speed (km/h) Time Groups driving periods (thicker traces) this is a working period not recognised in all EEC countries, if recordings are found on this track, they are assigned to group all other non−driving work periods, including periods as a co−driver, even if sleeping whilst the vehicle is moving rest periods

Handwritten entries (centre field only) Prior to departure Name Place of departure 19 Date NO Vehicle registration number Odometer reading

kilometres travelled (each zig−zag = 10 km peak to peak) If there is a change of driver or at the end of the work day: Place of arrival Odometer reading km Net distance driven

TACHOGRAPH CHART 4−26

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

5−10

15.

Lift Cylinder Lube Type − EP − MPG Lube Interval − 50 Hours 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 super structure. Ensure the entire bearing is lubed by rotating the super structure 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.

5−11

Hoist Main 20.

Model HO−15F− (Main) Lube Type − EPGL Lube Interval − 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.

21.

Model HO−15F (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.

5−12

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.

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.

5−13

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.

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 Lube Type − EP−MPG .

Lube Interval −.

Lube Amount − Until grease extrudes.

Application − 2 grease nipples, 1 per spring.

33.

Rear Spring Pins Lube Type −EP− MPG .

Lube Interval −1600km(1000 miles).

5−14

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) 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.

Front and Rear Springs Lube Type − EO Lube Interval − 1600km(1000 miles).

Lube Amount − Liberally in spring leafs Application − Oil Can.

38.

Hydraulic Oil Tank Lube Type − GROVEXTRA HYDO Lube Interval − Daily Lube Amount − 400 Litres (106 gallons) Application − Filler cap, add oil to level of sight gauge.

39.

Engine Fuel Tank Lube Type − Diesel Lube Interval − Daily Lube Amount − 200 litres (53 gallons) Application − Filler Cap 5−15

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.

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

2 40 43

1

32

18,19

16

10

22

35

33

26 44

13 2 1

14 12

35

11

35

27

6

29

35 37 35 25 35

20

37

Lubrication Diagram (Sheet 1 of 3) 5−18

23

21

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 (Sheet 2 of 3) 5−19

48

49

47

48 45

46

48

Lubrication Diagram (Sheet 3 of 3) 5−20