Manitowoc Grove TMS500E Series Carrier Operator’s Manual PDF

OPERATOR’S AND SAFETY HANDBOOK TMS500E SERIES CARRIER

S/N_______________________

PUBLISHED: FEBRUARY, 2001 UPDATED: JULY, 2001 UPDATED: JULY, 2002 UPDATED: AUGUST, 2003 UPDATED: JANUARY, 2004

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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 yourself 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.

Grove Worldwide and our Dealer Network want to ensure your satisfaction with our products and customer support.

Your local dealer is the best equipped and most knowledgeable to assist you for parts, service and warranty issues. They have the facilities, parts, factory trained personnel, and the information to assist you in a timely manner. We request that you first contact them for assistance. If you feel you need factory assistance, please ask the dealer’s service management to coordinate the contact on your behalf.

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.

The definitions of DANGER, CAUTION, and NOTE as used in this manual apply as follows.

DANGER A DANGER NOTE IS USED TO EMPHASIZE THAT IF AN OPERATION, PROCEDURE, OR PRACTICE IS NOT FOLLOWED EXACTLY, DEATH OR INJURY TO PERSONNEL MAY RESULT. 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.

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TABLE OF CONTENTS Page Section 1 - INTRODUCTION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Section 2 - SAFETY PRECAUTIONS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 OPERATOR’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 OPERATOR’S QUALIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ELECTROCUTION HAZARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Set Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Electrocution Hazard Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Special Operating Conditions and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 CRUSHING HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 WORK PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Section 3 - CAB CONTROLS AND INDICATORS ENGINE CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cluster Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Stop Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Engine Diagnostic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 TRAVEL CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Dual Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Low Air Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Park Brake On Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cross-Axle Differential Locked Indicator (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cross-Axle Differential Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Inter-Axle Differential Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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TABLE OF CONTENTS (CONTINUED) Page Inter-Axle Differential Locked Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Transmission Shift Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Check Transmission Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Suspension Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Suspension Deflated Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 CRANING CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Hydraulic Pump Engaged Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Hydraulic Pump Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ACCESSORY CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 High Beam Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Heater Air Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Air Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Heater Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Defrost Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Windshield Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Headlights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Beacon Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Headlights Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Hazard Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Left Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Right Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Steering Column Tilt/telescope Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Cab Circulating Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 12 vdc Accessory Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Air Horn (Not Shown) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Circuit Breaker and Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 ADDITIONAL OPTIONAL CARRIER CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Outrigger Control Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Outrigger Selector Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Outrigger Extension/Retraction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Center Front Stabilizer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Section 4 OPERATING PROCEDURES BREAKING-IN A NEW CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 PRE-STARTING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Seats and Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Seat Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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TABLE OF CONTENTS (CONTINUED) Page Cleaning Seat Belt Webbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Signal and Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Service and Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Warm Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Cold Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Idling the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Racing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 CRANE TRAVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Active Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Traveling - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Traveling With Boom Extension Erected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Transmission Push-Button Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Transmission Mode Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Cranes Without Remote Drive/Steer Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Cranes With Remote Drive/Steer Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Downshift/Reverse Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Transmission Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Rear Tandem Inter-Axle/Cross-Axle Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Service and Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 CRANE SHUTDOWN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Section 5 - LUBRICATION GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 LUBRICATION POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Engine Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Drive Line Slip and U-Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 90 Degree Miter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Front Axle Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Front Axle Tie Rod Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Front Axle King Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Front Axle Brake Slack Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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TABLE OF CONTENTS (CONTINUED) Page Front Axle Brake Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Spring Eye Bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Front Rear Axle Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Rear Rear Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Rear Axle Brake Slack Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Rear Axle Brake Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Outrigger Beams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Jack Cylinder Barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Coolant Strainer Coolant Strainer (Superstructure Cab Heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Jack Cylinder Support Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Front and Rear Wheel Pilots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Superstructure Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Turntable Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Turntable Gear And Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Turntable Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Upper Lift Cylinder Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Lower Lift Cylinder Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Main Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Auxiliary Hoist (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Boom Pivot Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Extend Cable Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Retract Cable Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Telescope Cylinder Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Side Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Boom Section Upper Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Boom Section Lower Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Upper Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lower Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Boom Extension Sheave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Boom Extension Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Boom Extension Mast Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Auxiliary Boom Nose Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Hook Block Swivel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Hook Block Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Headache Ball Swivel Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 WIRE ROPE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

LIST OF FIGURES Title Page Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Cab Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Transmission Shift Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Additional Carrier Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Outrigger Float Stowage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Carrier Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Superstructure Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Boom, Boom Extension, and Boom Accessories Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

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SECTION 1 INTRODUCTION This handbook provides information for the operator of the TMS500E Series Grove Crane.

The mobile crane carrier incorporates an all welded steel frame. The 6x4x2 carrier utilizes two drive axles and a single steer axles. Axle steering is provided by a power steering pump and power steering gearbox. The engine is mounted in the front of the carrier and provides power through a six speed forward and single speed reverse automatic transmission.

Hydraulic, single stage double box telescopic beams with inverted stabilizer (jack) cylinder outriggers are integral with the carrier frame. The outriggers are utilized in three positions; fully extended, intermediate (50%) extended, and fully retracted. The carrier is also equipped with a center front stabilizer that has a permanently stowed pad.

The superstructure is capable of 360 degree rotation in either direction. All crane functions are controlled from the fully enclosed cab. The crane is equipped with a four section boom with an optional swingaway. Lifting is provided by a main and optional auxiliary hoist.

NOTE Throughout this manual, reference is made to left, right, front, and rear when describing locations. 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.

1-1

Counterweight Auxiliary Hoist

Main Hoist

Boom

Outrigger Stabilizer

Telescoping Swingaway

Hydraulic Reservoir

Sling Box

Hook Block Stowage

Headache Ball Stowage

Outrigger Stabilizer

Hydraulic Oil Cooler

Auxiliary Boom Nose

Boom Nose Sheaves

Counterweight

Boom

Boom Rest

Lift Cylinder

Superstructure Cab

Main Hoist Boom Pivot

Auxiliary Hoist

Carrier Cab Front Bumper Counterweight Auxiliary Boom Nose

Center Front Stabilizer

Front Axle

Fuel Tank

Outrigger Stabilizer

Outrigger Float

Rear Tandem Axles

Basic Nomenclature

1-2

Outrigger Beam

Outrigger Beam

Outrigger Stabilizer

Outrigger Floats

SECTION 2 SAFETY PRECAUTIONS GENERAL NOTE Illustrations have been included in this section to emphasize certain proper and improper points; READ AND FOLLOW PRINTED INSTRUCTIONS.

It is impossible to compile a list of safety precautions covering all situations. However, there are basic principles that MUST be followed during your daily routine.

Safety is YOUR PRIMARY 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 and should not be relied upon in place of good operating practices.

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 could cause an accident that results in death or serious injury to personnel or damage to equipment. You are responsible for the safety of yourself and those around you.

IMMEDIATELY report all accidents, malfunctions, and equipment damages to your local Grove distributor. Following any accident or damage to equipment the local Grove distributor must be immediately advised of the incident and consulted on necessary inspections and repairs. Should the distributor not be immediately available, contact should be made directly with Grove Worldwide Customer Support. The crane must not be returned to service until it is thoroughly inspected for any evidence of damage. All damaged parts must be repaired or replaced as authorized by your local Grove Worldwide distributor and/or Grove Worldwide.

OPERATOR’S INFORMATION You must READ and UNDERSTAND the Operator’s and Safety Handbook and the Load Chart before operating the crane. You must also VIEW and UNDERSTAND the safety video titled “The Real Key to Crane Safety” supplied with your new Grove product. The handbook and Load Chart must be readily available to the operator at all times and must remain in the cab while the crane is in use.

Ensure that all personnel working around the crane are thoroughly familiar with safe operating practices. You must be thoroughly familiar with the location and content of all placards and decals on the crane. Decals provide important instructions and warnings and must be read prior to any operational or maintenance function.

You must be familiar with the regulations and standards governing cranes and their operation. Work practice requirements may vary slightly between government regulations, industry standards, and employer policies so a thorough knowledge of all such relevant work rules is necessary.

DO NOT REMOVE the Load Chart, this Operator’s and Safety Handbook, or any decal from this crane.

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.

2-1

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.

ELECTROCUTION HAZARD

OPERATOR’S QUALIFICATIONS

An untrained operator subjects himself and others to death or serious injury.

YOU MUST NOT OPERATE THIS MACHINE UNLESS:

Keep all personnel away from this machine if it is being operated near electrical power lines or equipment.

•

You have been trained in the safe operation of this machine.

Before operating this crane in the vicinity of electrical power lines or equipment, notify the power utility company. Obtain positive and absolute assurance that the power has been turned off.

•

You read, understand, and follow the safety and operating recommendations contained in the manufacturer’s manuals, your employer’s work rules, and applicable government regulations.

This machine is NOT INSULATED. Always consider all parts of the load and the crane, including the wire rope, hoist cable, pendant cables, and tag lines, as conductors.

•

You are sure the machine is operating properly and has been inspected and maintained in accordance with the manufacturer’s manuals.

•

You are sure that all safety signs, guards, and other safety features are in place and in proper condition.

Do not attempt to operate the crane unless you are trained and thoroughly familiar with all operational functions.

Controls and design may vary from crane to crane, therefore, it is important that you have specific training on the particular crane you will be operating.

Training is ESSENTIAL for proper crane operation.

Never jeopardize your own well-being or that of others by attempting to operate a crane on which you have not been trained.

You must be mentally and physically fit to operate a crane. Never attempt to operate a crane while under the influence of medication, narcotics, or alcohol. Any type of drug could impair physical, visual and mental reactions, and capabilities.

2-2

To avoid death or serious injury, keep all parts of this machine, the rigging, and materials being lifted at least 6 m (20 ft) away from all electrical power lines and equipment.

Most overhead power lines ARE NOT insulated. Treat all overhead power lines as being energized unless you have reliable information to the contrary from the utility company or owner.

The rules in this handbook must be followed at all times, even if the electrical power lines or equipment have been de-energized.

Crane operation is dangerous when close to an energized electrical power source. Exercise extreme caution and prudent judgement. Operate slowly and cautiously when in the vicinity of power lines.

If the load, wire rope, crane boom, or any portion of the crane contacts or comes too close to an electrical power source, everyone in, on, and around the crane can be seriously injured or killed.

The safest way to avoid electrocution is to stay away from electrical power lines and electrical power sources.

You, the operator, are responsible for alerting all personnel of dangers associated with electrical power lines and equipment. The crane is not insulated. Do not allow unnecessary personnel in the vicinity of the crane while operating. Permit no one to lean against or touch the crane. Permit no one, including riggers and load handlers, to hold the load, load lines, tag lines, or rigging gear.

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

It is not always necessary to contact a power line or power source to become electrocuted. Electricity, depending on magnitude, can arc or jump to any part of the load, load line, or crane boom if it comes too close to an electrical power source. Low voltages can also be dangerous.

Thoroughly read, understand, and abide by all applicable federal, state, and local regulations.

Federal law prohibits the use of cranes closer than 3 m (10 ft) to power sources up to 50,000 volts and greater distances for higher voltages [29CFR1910.180 and 29CFR1926.550]. Grove Worldwide recommends keeping cranes twice the minimum distance [e.g., 6 m (20 ft)] as specified by US Department of Labor - Occupational Safety and Health Administration (OSHA) standards.

SET UP AND OPERATION

During crane use, assume that every line is energized (“hot” or “live”) and take the necessary precautions.

Set up the crane in a position such that the load, boom, or any part of the crane and its attachments cannot be moved to within 6 m (20 ft) of electrical power lines or equipment. This includes the crane boom (fully extended to maximum height, radius, and length) and all attachments (jibs, boom extensions, rigging, loads, etc.). Overhead lines tend to blow in the wind so allow for lines’ movement when determining safe operating distance.

A suitable barricade should be erected to physically restrain the crane and all attachments (including the load) from entering into an unsafe distance from electrical power lines or equipment.

Plan ahead and always plan a safe route before traveling under power lines. Rider poles should be erected on each side of a crossing to assure sufficient clearance is maintained.

Appoint a reliable and qualified signal person, equipped with a loud signal whistle or horn and voice communication equipment, to warn the operator when any part of the crane or load moves near a power source. This person should have no other duties while the crane is working.

Tag lines should always be made of non-conductive materials. Any tag line that is wet or dirty can conduct electricity.

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

ELECTROCUTION HAZARD DEVICES

The use of insulated links, insulated boom cages/guards, proximity warning devices, or mechanical limit stops does not assure that electrical contact will not occur.

Even if codes or regulations require the use of such devices, failure to follow the rules listed here may result in serious injury or death. You should be aware that such devices have limitations and you should follow the rules and precautions outlined in this handbook at all times even if the crane is equipped with these devices.

Insulating links installed into the load line afford limited protection from electrocution hazards. Links are limited in their lifting abilities, insulating properties, and other properties that affect their performance. Moisture, dust, dirt, oils, and other contaminants can cause a link to conduct electricity. Due to their capacity ratings, some links are not effective for large cranes and/or high voltages/ currents.

The only protection that may be afforded by an insulated link is below the link (electrically downstream), provided the link has been kept clean, free of contamination, has

2-3

not been scratched or damaged, and is periodically tested (just before use) for its dielectric integrity.

Boom cages and boom guards afford limited protection from electrocution hazards. They are designed to cover only the boom nose and a small portion of the boom. Performance of boom cages and boom guards is limited by their physical size, insulating characteristics, and operating environment (e.g. dust, dirt, moisture, etc.). The insulating characteristics of these devices can be compromised if not kept clean, free of contamination, and undamaged.

Proximity sensing and warning devices are available in different types. Some use boom nose (localized) sensors and others use full boom length sensors. No warning may be given for components, cables, loads, and other attachments located outside of the sensing area. Much reliance is placed upon you, the operator, in selecting and properly setting the sensitivity of these devices.

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

Some variables you must know and understand are:

1.

Stay in the crane cab. DON’T PANIC.

2.

Immediately warn personnel in the vicinity to stay away.

3.

Attempt to move the crane away from the contacted power source using the crane’s controls which are likely to remain functional.

4.

Stay in the crane until the power company has been contacted and the power source has been de-energized. NO ONE must attempt to come close to the crane or load until the power has been turned off.

Only as a last resort should an operator attempt to leave the crane upon contacting a power source. If it is absolutely necessary to leave the operator station, JUMP COMPLETELY CLEAR OF THE CRANE. DO NOT STEP OFF. Hop away with both feet together. DO NOT walk or run.

Following any contact with an energized electrical source, the local, authorized Grove Worldwide distributor must be immediately advised of the incident and consulted on necessary inspections and repairs. Thoroughly inspect the wire rope and all points of contact on the crane. Should the distributor not be immediately available, contact Grove Worldwide Customer Support. The crane must not be returned to service until it is thoroughly inspected for any evidence of damage and all damaged parts are repaired or replaced as authorized by Grove Worldwide or your local Grove Worldwide distributor.

•

Proximity devices are supposed to detect the existence of electricity - not its quantity or magnitude.

•

Some proximity devices will detect only alternating current (AC) and not direct current (DC).

•

Some proximity devices detect radio frequency (RF) energy and others do not.

•

Most proximity devices simply provide a signal (audible, visual, or both) for the operator and this signal must not be ignored.

Never operate the crane during an electrical thunderstorm.

•

Sometimes the sensing portion of the proximity devices becomes confused by complex or differing arrays of power lines and power sources.

Working in the vicinity of radio frequency transmission towers and other transmission sources may cause a crane to become “electrically charged.”

DO NOT depend on grounding. Grounding of a crane affords little or no protection from electrical hazards. The effectiveness of grounding is limited by the size of the (wire) conductor used, the condition of the ground, the magnitude of the voltage and current present, and numerous other factors.

When operating cranes equipped with electromagnets you must take additional precautions. Permit no one to touch the magnet or load. Alert personnel by sounding a warning signal when moving a load. Do not allow the cover of the electromagnet power supply to be open during operation or at any time the electrical system is activated. Shut down the crane completely and open the magnet controls switch prior to connecting or disconnecting magnet leads. Use only a non-conductive device when positioning a load. Lower the magnet to the stowing area and shut off power before leaving the operator’s cab.

ELECTRICAL CONTACT

If the crane should come in contact with an energized power source, you must:

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SPECIAL OPERATING CONDITIONS AND EQUIPMENT

CRUSHING HAZARDS

Death or serious injury could result from being crushed by moving machinery.

Clear all personnel from the counterweight and superstructure area before removing the counterweight or rotating the superstructure.

Barricade the entire area where the crane is working and keep all unnecessary personnel out of the work area.

Never allow anyone to stand or work on or near the superstructure while the crane is in operation.

Always barricade the tail-swing of the rotating superstructure.

Before actuating swing or any other crane function, sound the horn and verify that all personnel are clear of rotating and moving parts.

Watch the path of the boom and load when swinging.

Avoid lowering or swinging the boom and load into ground personnel, equipment, or other objects.

Always be aware of your working environment during operation of the crane. Avoid contacting any part of the crane with external objects.

You must always be aware of everything around the crane while lifting or traveling. If you are unable to clearly see in the direction of motion, you must post a look out or signal person before moving the crane or making a lift.

Sound the horn to warn personnel.

injury could result from improper crane set up on outriggers.

Be sure the outriggers are properly extended, set and the crane is level for operation on outriggers.

All four outrigger beams must be equally extended to the appropriate vertical stripe before beginning operation.

All four outrigger beam lock pins must be engaged before operating from the mid-extend position.

The operator must select the proper Load Chart and LMI System program for the outrigger position selected.

Only the crane operator shall occupy the crane when traveling or in operation.

TRAVELING •

Before travel, fully retract and lower the boom into the boom rest and engage the turntable pin swing lock.

•

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

•

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

•

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

•

When traveling, the boom should be completely retracted or set to whatever extension is necessary for balance load on axles, lowered, and positioned in the boom rest or if equipped, a trailing boom dolly.

•

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

Clear all personnel from the outrigger area before extending or retracting the outriggers.

Carefully follow the procedures in this handbook when extending or retracting the outriggers. Death or serious

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•

When moving in tight quarters, post a signal person to help guard against collisions or bumping structures.

Follow all applicable safety precautions in this handbook when performing crane maintenance as well as crane operations.

•

Never back up without the aid of a signal person to verify the area behind the crane is clear of all personnel and obstructions.

Before crane use:

•

Check load limits of bridges on the travel route and ensure they are greater than the crane’s weight.

•

Keep lights on, use traffic warning flags and signs, and use front and rear flag vehicles when necessary. Check state and local restrictions and regulations.

•

Always drive the crane carefully, obeying speed limits and highway regulations.

•

Stay alert at the wheel.

•

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

Use the following steps when shutting down the crane: •

Engage the parking brake.

•

Fully retract and lower the boom.

•

Engage the pin swing lock or 360 degree swing lock.

•

Place controls in neutral position.

•

Shut down the engine and remove the ignition key.

•

Chock the wheels.

•

Lock the operator’s cab and install vandal guards, if used.

•

Conduct a visual inspection for cracked welds, damaged components, loose pin/bolt, and wire connections. Any item or component that is found to be loose or damaged (broken, chipped, cracked, worn-through, etc.) must be repaired or replaced.

•

Check for proper functioning of all controls and operator aids (e.g. LMI).

•

Check all braking (e.g. wheel, hoist, and swing brakes) and holding devices before operation.

Keep the crane clean at all times, free of mud, dirt, and grease. Dirty equipment introduces hazards, wears-out faster, and makes proper maintenance difficult. Cleaning solutions used should be appropriate for the job and nonflammable/toxic.

ROUTINE MAINTENANCE and INSPECTION of this crane must be performed by a qualified person(s) according to the recommendations in the Grove Worldwide Crane Maintenance and Inspection Manual. Any questions regarding procedures and specifications should be directed to the your local, authorized Grove Worldwide Distributor.

SERVICE AND REPAIRS

Service and repairs to the crane must only be performed by a qualified person. All service and repairs must be performed in accordance with manufacturer’s recommendations, this handbook, and the Service Manual for this machine. All replacement parts must be approved by Grove Worldwide.

MAINTENANCE The crane must be inspected prior to use on each work shift. The owner, user, and operator must ensure that routine maintenance and lubrication are being dutifully performed. NEVER operate a damaged or poorly maintained crane.

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

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.

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Any modification, alteration, or change to a crane which affects its original design and is not authorized and approved by Grove Worldwide is STRICTLY PROHIBITED. Such action invalidates all warranties and makes the owner/user liable for any resultant accidents.

Before performing any maintenance, service or repairs on the crane: •

The boom should be fully retracted and lowered and the load placed on the ground.

•

Stop the engine and disconnect the battery.

•

Control should be properly tagged. Never oper-

ate the crane if it is TAGGED-OUT, nor attempt to do so until it is restored to proper operating condition and all tags have been removed by the person(s) who installed them.

Recognize and avoid pinch-points while performing maintenance. Stay clear of sheave wheels, holes, and lattice work in crane booms.

After maintenance or repairs: •

Replace all guards and covers that have been removed.

•

Remove all tags, connect the battery, and perform a function check of all operating controls.

•

Load tests must be performed when a structural or lifting member is involved in a repair.

Ensure pneumatic tires are inflated to the proper pressure (refer to the Tire Inflation Chart in Load Chart Binder).

When inflating tires, use a tire gauge, clip-on inflator, and extension hose which will permit standing clear of the tire while inflating.

BATTERIES Battery electrolyte must not be allowed to contact the skin or eyes. If this occurs, flush the contacted area with water and consult a doctor immediately.

When checking and maintaining batteries exercise the following procedures and precautions: •

Disconnect the batteries.

•

Wear safety glasses when servicing batteries.

LUBRICATION

•

The crane must be lubricated according to the factory recommendations for lubrication points, time intervals, and types. Lubricate at more frequent intervals when working under severe conditions.

Do not short across the battery posts to check charge. Short circuit, spark, or flame could cause battery explosion.

•

Maintain battery electrolyte at the proper level.

Check the electrolyte with a flashlight.

•

If applicable to your crane, check battery test indicator on maintenance-free batteries.

•

Do not break a live circuit at the battery terminal.

Disconnect the ground battery cable first when removing a battery and connect it last when installing a battery.

•

Check battery condition only with proper test equipment. Batteries shall not be charged except in an open, well-ventilated area that is free of flame, smoking, sparks, and fire.

Exercise care when servicing the hydraulic system of the crane, as pressurized hydraulic oil can cause serious injury. The following precautions must be taken when servicing the hydraulic system: 1.

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

2. Be certain all lines, components, and fittings are tight before resuming operation.

3.

4.

When checking for suspected leaks, use a piece of wood or cardboard and wear appropriate personal protective equipment.

Never exceed the manufacturer’s recommended relief valve settings.

TIRES

Inspect the tires for nicks, cuts, embedded material, and abnormal wear.

Ensure all lug nuts are properly torqued.

ENGINE Be careful when checking the engine coolant level. The fluid may be hot and under pressure. Shut down the engine and allow the radiator time to cool before removing the radiator cap.

Shut down the engine and disconnect the battery before performing maintenance. If unable to do so for the task required, keep hands clear of the engine fan and other moving parts while performing maintenance.

Be careful of hot surfaces and hot fluids when performing maintenance on or around the engine.

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WORK PRACTICES CRANE ACCESS

You must take every precaution to ensure you do not slip and/or fall off the crane. Falling from any elevation could result in serious injury or death.

Never exit or enter the crane cab or deck by any other means than the access system(s) provided (i.e., steps and grab handles).

If necessary, use a ladder or aerial work platform to access the boom nose.

Do not step on surfaces on the crane that are not approved or suitable for walking and working. All walking and working surfaces on the crane should be clean, dry, slipresistant, and have adequate supporting capacity. Do not walk on a surface if slip-resistant material is missing or excessively worn.

Do not use the top of the boom as a walkway.

Do not step on the outrigger beams or outrigger pads (floats) to enter or exit the crane.

Wear shoes with a highly slip-resistant sole material.

Clean any mud or debris from shoes before entering the crane cab or climbing onto the crane superstructure.

Excessive dirt and debris on the hand-holds, access steps, or walking/working surfaces could cause a slipping accident. A shoe that is not clean might slip off a control pedal during operation.

Do not make modifications or additions to the crane’s access system that have not been evaluated and approved

by Grove Worldwide.

JOB PREPARATION

You must inspect the crane prior to your work shift checking for cracked welds, damaged components, and evidence of improper maintenance (consult Grove Worldwide Maintenance and Inspection Manual).

You must ensure that the crane is properly equipped including access steps, covers, doors, guards, and controls.

You must ensure that the outriggers are properly extended and set before performing any lifting operations. On models equipped with outriggers that can be pinned at the mid-extend position, the outriggers must also be pinned when operating from the mid-extend position.

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Wear appropriate clothing and personal protective equipment whether or not required by local or job regulations.

Be prepared for the work day.

Before entering the cab, you must be THOROUGHLY familiar with the planned route of travel and area of operation, including surface conditions and the presence of overhead obstructions and power lines.

Always keep the crane clean, free of dirt, debris, and grease.

Fuel the crane ONLY with the engine turned off. Do not smoke while fueling the crane. Do not store flammable materials on the crane or in the operator’s cab.

Follow standard safety precautions when refueling.

FUEL IT SAFELY. Be familiar with the location and use of the nearest fire extinguisher.

Cold weather requires special starting procedures, use of built-in starting aids, if provided, and ample time for hydraulic oil to warm-up. Keep the crane free of ice and snow.

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

Check operating procedures for cold weather starting.

Don’t touch frozen metal surfaces with bare skin.

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. The drive line can be damaged when attempting to free a frozen crane.

If applicable to your crane, frequently check all air tanks for water in freezing weather If applicable to your crane, 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. Do not use aerosol starting fluids. The use of aerosol spray or other types of starting fluids containing ether/volatiles can cause explosions or fire.

SECTION 3 CAB CONTROLS AND INDICATORS The carrier cab contains all controls and indicators necessary for road travel.

engine oil pressure on a scale calibrated from zero (0) to 80 psi. It receives a signal from an oil pressure sending unit on the engine.

NOTE

Water Temperature Gauge The following paragraphs describe all the available (standard and optional; some machines may not be equipped with the optional controls shown) controls and indicators located in the cab. The numbers in ( ) represent the index number from the figure titled Cab Controls and Indicators.

NOTE All rocker switches, except the engine diagnostics switches, contain one or two LED lighted slots in the switch for illumination. In addition, all but the engine diagnostics switches contain a LED lighted square to indicate when the switch/function is activated.

ENGINE CONTROLS AND INDICATORS

The engine coolant temperature (TEMP) gauge is located on the lower left of the gauge cluster. The gauge indicates the engine coolant temperature on a scale calibrated from 100 to 240° F. The gauge receives a signal from a temperature sending unit in the engine cooling system.

Fuel Quantity Gauge

The fuel quantity (FUEL) gauge is located on the upper left of the gauge cluster. The gauge indicates the quantity of fuel in the tank and has a scale calibrated from empty (E) to full (F). The fuel quantity gauge receives a signal from a sending unit in the fuel tank.

ENGINE STOP INDICATOR

The ENGINE STOP indicator (20) is located at the top of the front console. It illuminates red when energized by a signal from the engine ECM. In addition, a warning buzzer will also sound.

GAUGE CLUSTER ENGINE WARNING INDICATOR

The gauge cluster (5) is located in the center of the front console assembly and contains a voltmeter, oil pressure gauge, water temperature gauge, and a fuel quantity gauge.

The ENGINE WARNING indicator (21) is located at the top of the front console. It illuminates amber when energized by a signal from the engine ECM.

Voltmeter

TACHOMETER

The voltmeter (VOLTS) is located on the lower right of the gauge cluster. With the ignition switch in the RUN (1) position and before starting the engine, the voltmeter indicates the condition of the batteries. With the engine running, the voltmeter indicates output voltage of the alternator. The voltmeter scale is from 10 to 16 volts.

Engine Oil Pressure Gauge

The engine oil pressure (OIL) gauge is located on the upper right of the gauge cluster. The gauge indicates the

The tachometer (2) is located on the left side of the front console. The tachometer is calibrated in RPM x 100 with a range of zero (0) to 35 and receives a signal from the sender unit on the engine.

ENGINE BRAKE SWITCH.

The ENGINE BRAKE switch (19) is located on the left side of the front console. The two position (ON/OFF) switch energizes the engine brake. When the switch is in the ON position, the amber LED in the switch will be illuminated.

3-1

50 49

A 48

35

36 47

46 53

37

45 52 44

B

43 39

54

38

51 42

41

40

Cab Controls and Indicators (Sheet 1 of 2)

3-2

1

NA

18

19

20

2

3

17

NA

21

NA

C

4

7

5

DETAIL A 22

23

24

8

14

15

16

6

25

NA

10

9

12

13 NA

NA

11

26 27

DETAIL C 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Dual Air Pressure Gauge Tachometer Left Turn Signal Indicator Speedometer Gauge Cluster Right Turn Signal Indicator Heater Air Temperature Control Heater Fan Switch Air Flow Control Defrost Fan Switch Parking Brake Control Windshield Wiper/Washer Switch Ignition Switch Inter-Axle Differential Control Odometer Cross-Axle Differential Control (Optional) Beacon Light Switch (Optional) Headlight Switch Engine Brake On/Off Switch Engine Stop Indicator Engine Warning Indicator Cross-Axle Differential Locked Indicator (Optional) Low Air Pressure Indicator High Beam Indicator Park Brake On Indicator Inter-Axle Differential Locked Indicator Check Transmission Indicator

28

28. Suspension Deflated Indicator 29. Suspension Control 29 30. Hydraulic Pump Disconnect Switch 31. Engine Diagnostics/Idle Switch 32. 12 VDC Accessory Outlet 33. Engine Diagnostics Idle On/Off Codes Switch 34 34. Hydraulic Pump Engaged Indicator 35. Brake Pedal 36. Throttle Pedal 37. Transmission Shift Panel 38. Ash Tray 39. Seat 40. Beacon Light (Optional) 41. Fire Extinguisher 33 42. Cab Dome Light 43. Steering Wheel 44. Horn Button 45. Headlight Dimmer/Turn Signal Lever 46. Sun Visor 32 47. Cab Circulating Fan 48. Windshield Defroster Air Outlet 49. Windshield Wiper 50. Cab Marker Lights 51. Circuit Breaker and Relay Panel 52. Hazard Light Switch 53. Steering Column Tilt/Telescope Lever 54. Three Point Seat Belt NA - Not Used On This Model

30

31

DETAIL B

Cab Controls and Indicators (Sheet 2 of 2)

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IGNITION SWITCH

The IGNITION SWITCH (13) is located on the right side of the front console. The switch is key operated with four positions: accessory (ACC) (3), OFF (0), RUN (1), and START (2). With ignition switches in both cabs in the (0) position, all electrical power is off except for the headlights, marker lights, gauge lights, turn and stop light, backup lights and alarm, carrier and superstructure cab dome lights, carrier and superstructure cab 12v accessory outlets, boom work lights, superstructure cab work lights, and superstructure horn. The (3) position energizes all electrical components. The (1) position is the same as (3).

The (2) position energizes the starter motor. The switch will return to (1) when the switch is released after the engine is started. Turn the switch to (0) to shut down the engine.

THROTTLE PEDAL

sure gauge with two indicating pointers, red for the primary system and green for the secondary system. The gauge has a dual scale calibrated from 100 to 1000 kPa and 0 to 150 psi. The gauge is connected to each air system separately through tubing.

LOW AIR PRESSURE INDICATOR

The low air pressure (AIR PRESSURE LOW) indicator (23) is located on the top of the front console. The indicator is a red light that illuminates when the pressure in either or both air systems is below 517 kPa (75 psi). The indicator is controlled by two pressure switches electrically connected in parallel. To determine which system pressure is low, observe the dual air pressure gauge. In addition to illuminating the LOW AIR indicator, the pressure switches also energize a warning buzzer.

SPEEDOMETER

The THROTTLE pedal (36) is the right most pedal on the cab floor. It is used to control engine RPM. The foot pedal is electronically connected to the engine and modulates engine speed proportionately to the foot pressure applied. The pedal is angled for increased operator comfort.

The speedometer (4) is located on the front console and indicates speed in both km/h (kilometers per hour) and mph (miles per hour).

ENGINE DIAGNOSTICS SWITCHES

There is an odometer (15) located at the bottom of the speedometer and shows total distance traveled.

Two ENGINE DIAGNOSTICS switches are located on the right side panel. With the left switch (33) in the IDLE ON position, depressing the right switch (31) to either + or - with the engine running will increase or decrease the engine idle speed. With the left switch (33) in the IDLE OFF/CODES position, depressing and holding the right switch (31) in either position (+/-) will cause the engine diagnostics codes to be flashed on the red ENGINE STOP indicator.

NOTE If the engine idle speed has been increased using the ENGINE DIAGNOSTICS switches, positioning the left switch to IDLE OFF/CODES or taking the transmission out of Neutral will cause the engine ECM to return to the default idle speed. Returning the transmission to Neutral will not change the engine speed to the increased value.

ODOMETER

PARKING BRAKE CONTROL NOTE The park brake must be set before the outrigger controls will operate.

The parking brake control (11) is located on the right side of the front console. The control is a push-pull type air valve used to apply and release the parking brakes on all four rear wheels PARK BRAKE ON INDICATOR

The PARK BRAKE ON indicator (25) is located at the top of the front console. The indicator is a red light that illuminates when the crane parking brakes are applied. It is energized by a pressure switch on the parking brake valve. The pressure switch also controls the outrigger enable relay that permits operation of the outriggers.

TRAVEL CONTROLS AND INDICATORS

CROSS-AXLE DIFFERENTIAL LOCKED INDICATOR (OPTIONAL)

DUAL AIR PRESSURE GAUGE

The cross-axle differential locked (CROSS AXLE LOCKED) indicator (22) is located at the top of the front console. The amber indicator illuminates to show that the cross axle differential is locked.

The dual air pressure gauge (1) is located on the left side of the front console. The gauge is a direct reading pres-

3-4

CAUTION DO NOT OPERATE THE CROSS AXLE DIFFERENTIAL LOCK OR THE INTER AXLE DIFFERENTIAL LOCK ON DRY ROADS.

CROSS-AXLE DIFFERENTIAL CONTROL (OPTIONAL)

The CROSS-AXLE DIFFERENTIAL control (16) is located on the lower left side of the front console and is used to lock the right and left wheels in a tandem set. The cross-axle differential lock increases traction on slippery roads. It is a two position LOCK/UNLOCK lever actuated air valve.

down (Ø) arrows. The arrow buttons are used to set the gear range, and display error codes. The control is electrically connected to the transmission ECU and each time a button is pushed a short beep is sounded to verify that the ECU has received instructions.

The MODE button switches between the performance and economy modes and the crane must be stopped before the transmission will shift modes. The mode indicator will illuminate when the transmission is in the performance mode. The economy mode optimizes engine fuel efficiency and the performance mode optimizes engine horsepower.

CAUTION DO NOT OPERATE CROSS-AXLE DIFFERENTIAL LOCK WHILE CRANE WHEELS ARE TURNING.

INTER-AXLE DIFFERENTIAL CONTROL

The INTER-AXLE DIFFERENTIAL control (14) is located on the lower right side of the front console. In the LOCK position, both rear axles are locked together and turning at the same speed. In the UNLOCKED position, the axles operate independently of the each other. The control is a lever actuated air valve.

CAUTION DO NOT OPERATE INTER-AXLE DIFFERENTIAL LOCK WHILE CRANE WHEELS ARE TURNING.

Transmission Shift Panel INTER-AXLE DIFFERENTIAL LOCKED INDICATOR CHECK TRANSMISSION INDICATOR

The inter-axle differential locked indicator (INTER AXLE LOCKED) (26) is located on the top of the front console. The amber indicator illuminates when the inter axle differential lock is engaged.

BRAKE PEDAL

The brake pedal (35) is located on the cab floor, to the left of the foot throttle and is used to apply the service brakes.

TRANSMISSION SHIFT PANEL

The transmission shift panel (37) is located on the right side console. The panel has six pushbuttons, three of which are marked “D” for drive, “N” for neutral and “R” for reverse. The neutral button has a raised edge so the operator can orient his hand without looking at the panel.

Two of the pushbuttons are marked with up (×) and

NOTE If the ignition key is turned off while the CHECK TRANS indicator is ON, the transmission will remain in neutral until the fault is cleared.

The CHECK TRANSMISSION indicator (27) is located on the right side console. Illumination of the red indicator is accompanied by eight seconds of short beeps. The display will be blank and the ECU may not respond to the shift selector requests. Travel may continue to reach service assistance.

SUSPENSION CONTROL

The SUSPENSION control (29) is a lever operated air valve located on the right side console. When positioned

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to INFLATE, the suspension air bags are inflated. When positioned to DEFLATE, the suspension air bags are deflated.

NOTE The suspension air bags should be inflated at all times except when on outriggers or in a pick and carry mode.

SUSPENSION DEFLATED INDICATOR

The SUSPENSION DEFLATED indicator (28) is located on the right side console above the suspension control lever. The amber indicator illuminates when the air is removed from the suspension air bags. It is controlled by two pressure switches connected in series.

CRANING CONTROLS AND INDICATORS

outside air is drawn in to be heated. In the recirculating (RECIRC) position, the air inside the cab is recirculated to gain a maximum heating effect.

HEATER FAN SWITCH

The HEATER control switch (8) is located on the right side of the front console. This rocker switch controls the speed of the heater fan (HI or LO) which in turn regulates the volume of heated air output. The middle position is OFF. When the switch is in either HI or LO, the amber LED in the switch will be illuminated.

DEFROST FAN SWITCH

The DEFROST control switch (10) is located on the right side of the front console. The rocker switch controls the defroster fan to regulate the flow of air to the windshield for defrosting. When the switch is in the ON position, the amber LED in the switch will be illuminated.

HYDRAULIC PUMP ENGAGED INDICATOR

The PUMP ENGAGED indicator (34) is located on the right side console. The amber indicator is illuminated when the hydraulic pumps are engaged.

HYDRAULIC PUMP DISCONNECT SWITCH

The hydraulic PUMP disconnect switch (30) is located on the right side console. Positioning the switch to ENGAGE energizes the PTO clutch solenoid to engage the transmission PTO that drives the main hydraulic pumps. The switch also energizes the engine limit speed relay that sends a signal to the engine ECM to limit engine speed to 2100 rpm.

ACCESSORY CONTROLS AND INDICATORS HIGH BEAM INDICATOR

The headlight HIGH BEAM indicator (24) is located at the top of the center front console. The indicator is a blue light that illuminates when the head lights are on high beam.

HEATER AIR TEMPERATURE CONTROL

WINDSHIELD WIPER/WASHER SWITCH

The WINDSHIELD switch (12) is located on the right side of the front console. The switch has four positions; off, intermittent, low, and high range. Rotating the switch to the first detent energizes the wiper motor for intermittent operation, rotating the switch to the second detent energizes the wiper motor at low speed, and rotating it to the third detent energizes the motor at high speed. Rotating the switch counterclockwise to off stops the motor and returns the wiper blade to the parked position. Push the switch to energize windshield washer system.

HEADLIGHTS SWITCH

The HEADLIGHTS switch (18) is located on the left side of the front console. The switch is a push-pull type switch with a rheostat control. Pull the switch to the first detent to illuminate the marker and gauge lights. Pull the switch to the second detent to illuminate the headlights.

Rotating the switch knob controls the brightness of the gauge lights.

BEACON LIGHT SWITCH (OPTIONAL)

The heater air temperature (HEAT) control (7) is located on the right side of the front console. The control is a push-pull cable that opens and closes the valve in the hot water supply line to the heater. Pull to open the valve for heat.

The beacon light switch (BEACON) (17) is a two position, ON-OFF rocker switch located on the left side of the front console that controls the beacon light (40) on the top of the carrier cab. When the switch is in the ON position, the amber LED in the switch will be illuminated.

AIR FLOW CONTROL

HEADLIGHTS DIMMER SWITCH

The air flow (AIR) control (9) is located on the right side of the front console. The control is a push-pull cable that directs the air flow in the cab. In the FRESH position,

The headlight dimmer switch (45) incorporated in the turn signal switch. Pull on the turn signal handle to switch between high and low beam.

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TURN SIGNAL LEVER

CAB DOME LIGHT

The turn signal lever (45) is located on the steering column. Push the lever up for a right turn and pull down for a left turn.

The cab dome light (42) is located in the right/center of the cab roof over the seat. It is controlled by a switch on the light and by a door switch that powers the light when the cab door is opened.

HAZARD LIGHT SWITCH

AIR HORN (NOT SHOWN) (OPTIONAL)

The hazard light switch (52) is located on the steering column. Pushing forward on the switch (in the direction of the arrow) causes all the turn signals and the indicator light on the column to flash.

A set of optional air horns are mounted of top of the cab and are controlled by valve manually actuated by a cable inside the cab.

LEFT TURN SIGNAL INDICATOR

CIRCUIT BREAKER AND RELAY PANEL

The left turn signal indicator (3) is located on the top left side of the front console. It is a green indicator light that flashes when the turn signal lever is pulled down.

The circuit breaker and relay panel (51) is located on the right rear side of the cab under a removable cover. It contains 24 circuit breakers and various relays that protect and control the various electrical components of the carrier.

RIGHT TURN SIGNAL INDICATOR

The right turn signal indicator (6) is located on the top right side of the front console. It is a green indicator light that flashes when the turn signal lever is pushed up.

STEERING COLUMN TILT/TELESCOPE LEVER

The steering column tilt/telescope lever (53) is located on the steering column in front of the turn signal lever. Pulling back on the lever allows the steering column to be tilted, and pushing forward on the lever allows the steering column to be telescoped in and out.

ADDITIONAL CARRIER CONTROLS AND INDICATORS NOTE The following paragraphs describe the additional controls and indicators located on the carrier to operate the outriggers.

The numbers in parentheses ( ) represent the index number from the figure titled Additional Carrier Controls and Indicators.

HORN BUTTON

OUTRIGGER CONTROL PANELS

The horn button (44) is located in the center of the steering wheel (43). Depress button to sound the horn.

The fire extinguisher (41) is an ABC dry type and is mounted in the left side of the cab behind seat.

There are two outrigger control panels located on each side of the crane carrier. Each outrigger control panel contains the control switches for extending and retracting the outrigger beams and for raising and lowering the outrigger stabilizer (jack) cylinders for that side of the crane.

Each control panel also contains a control switch for raising and lowering the center front stabilizer. The following paragraphs explain these controls.

CAB CIRCULATING FAN

Outrigger Selector Switches

The cab circulating fan (47) is mounted on the left front of the cab and is controlled by a two speed rocker switch on the base of the fan.

There are two - two position, spring centered to off outrigger selector toggle switches on each of the outrigger control panels. One of the switches is placarded FRONT EXTENSION; FRONT STABILIZER (1) and is used to control the extension cylinders and the stabilizer (jack) cylinders on the front outrigger beam. The other switch is placarded REAR EXTENSION; REAR STABILIZER (2) and is used to control the extension cylinders and the stabilizer (jack) cylinders on the rear outrigger beam.

Both switches must be used in conjunction with the outrigger EXTEND/RETRACT switch (3).

FIRE EXTINGUISHER

12VDC ACCESSORY OUTLET

The 12 vdc accessory outlet (32) is located on the right side console. It provides an outlet for the operator to plug in a 12 vdc accessory. It is protected by a 10 amp circuit breaker.

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Outrigger Extension/Retraction Switch

Center Front Stabilizer Switch

An outrigger EXTEND/RETRACT switch (3) is located on each of the outrigger control panels and has two placarded positions EXTEND and RETRACT. It must be used in conjunction with the outrigger selector switches to control the operation of the stabilizer and extension cylinders. After positioning the desired outrigger selector switch, positioning the outrigger EXTEND/RETRACT switch energizes the control solenoid to allow hydraulic fluid to flow through the control solenoid valve and the individual solenoid valve and move the selected component in the desired direction.

The CENTER FRONT STABILIZER switch (4) is located on each of the outrigger control panels and has two placarded positions ACTIVATE and OFF. It must be used in conjunction with the outrigger EXTEND/ RETRACT switch to control the operation of the center front stabilizer. The center front stabilizer will retract automatically when any of the other four stabilizers are retracted, therefore it must be reset if lifting is to be continued.

LEFT SIDE CONTROL PANEL

RIGHT SIDE CONTROL PANEL

4

3

2

1

2 1.

2.

3.

4.

Front Outrigger Selector Switch Rear Outrigger Selector Switch Outrigger Extend/Retract Switch Center Front Stabilizer Switch

Additional Carrier Controls and Indicators

3-8

1

3

4

SECTION 4 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 seat, 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.

The guidelines below will aid in getting a long service life out of the crane.

1.

Operate as much as possible in the half to threequarters throttle or load range.

2.

Avoid long periods of operation with the engine at idle or 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.

6.

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

Check the engine oil and coolant levels frequently.

These guidelines should not be considered limitations but rather as a guide for familiarization of the machine and development of good operating habits.

PRE-STARTING CHECKS

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

ENGINE COOLANT

Check the coolant level in the radiator and fill to the proper level. Do not overfill and ensure the radiator cap is secure.

DANGER DO NOT LOOSEN RADIATOR CAP ON A HOT ENGINE. STEAM OR HOT COOLANT WILL CAUSE SEVERE BURNS.

BATTERIES

For standard or low maintenance batteries, check each cell for the correct fluid level. Add only clean distilled water and do not overfill. For maintenance free batteries, check the state-of-charge indicator if applicable. On all batteries ensure the cables and clamps are tight and not corroded.

SEATS AND MIRRORS

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 are not damaged and are in proper operating condition, especially if they have been subjected to severe stress.

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 safe operation. The following checklist items are suggested to ensure the crane is prepared for starting the day’s work.

Cleaning Seat Belt Webbing

FUEL SUPPLY

SIGNAL AND RUNNING LIGHTS

Fill the fuel tank and ensure the cap is on tight.

Check all signal and running lights for proper operation.

Replace burned out lamps with those of the same number, or equivalent.

ENGINE OIL CAUTION DO NOT OVERFILL.

Wash the seat belt webbing with any mild soap or detergent. Do not use commercial solvents. Also, bleaching or re-dyeing the webbing is not recommended because of possible loss of webbing strength.

SERVICE AND PARKING BRAKES

Check for proper operation.

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TIRES

ences are noted. (Refer to the applicable engine manufacturer’s manual for detailed procedures).

Check the pressure and condition of all tires before traveling.

START-UP PROCEDURE

NOTE

Make an under-the-hood inspection for fuel, oil, and coolant leaks, worn drive belts, and trash build-up.

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

DANGER DIESEL ENGINE EXHAUST CAN BE HARMFUL TO YOUR HEALTH. ONLY OPERATE THE ENGINE IN A WELL VENTILATED AREA OR VENT EXHAUST OUTSIDE.

WHEELS

Maintain proper torque on wheel lugs and check for proper wheel mounting. The wheels should be retorqued 80 to 160 km (50 to 100 miles) after initial installation or after any time the tires and wheels are removed. Doing this will reseat the lug nuts. Recheck the lug nuts for proper torque every (800 km) 500 miles thereafter.

CAUTION NEVER CRANK ENGINE FOR MORE THAN 30 SECONDS DURING AN ATTEMPTED START. IF ENGINE DOES NOT START AFTER 30 SECONDS, ALLOW STARTER MOTOR TO COOL FOR ABOUT TWO MINUTES BEFORE ATTEMPTING ANOTHER START.

SAFETY EQUIPMENT

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

DAILY LUBRICATION

CAUTION

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

IF ENGINE DOES NOT START AFTER FOUR ATTEMPTS, CORRECT MALFUNCTION BEFORE ATTEMPTING ANOTHER START.

COLD WEATHER OPERATION The following recommendations are for operating Grove cranes in very low (i.e. freezing) temperatures.

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

Operation of cranes at full rated capacities in temperatures between 0 °C and -40 °C (+32 °F and -40 °F) or lower shall be accomplished only by competent operators who possess the skill, experience, and dexterity to ensure smooth operation. Shock loading shall be avoided. For crane operation below -40 °C (-40 °F), capacities shall be derated 3.6% for each °C below -40 °C and 2% for each °F below -40 °F of the rated load shown on the capacity charts.

ENGINE OPERATION Start-up and shutdown procedures for most diesel engines are generally the same. Therefore, the following procedures can be applied, except where specific differ-

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Use the correct grade of oil for the prevailing temperature in the crankcase to prevent hard cranking. Diesel fuel should have a pour point of 5 °C (10 °F) less than the lowest expected temperature. In case of an emergency, white kerosene can be added to the fuel to bring the pour point down to the required temperature. This will prevent clogging of filters and small passages by wax crystals.

The addition of kerosene is NOT recommended for general use.

Warm Engine

The ENGINE WARNING indicator will illuminate for five seconds (as a lamp check) when the key is first turned on. The lamp will blink at five second intervals if the ECM detects a problem. If the light comes on and continues to blink after initial start-up, there is a problem that needs to be corrected. Press the engine diagnostic switch to ON for code retrieval and check the crane service manual or engine manufacture’s service manual for code identification.

1.

Place the hydraulic PUMP disconnect switch in the DISENGAGED position.

2.

Ensure the parking brake is set and position the transmission in neutral.

NOTE The engine will not crank unless the transmission is in neutral.

3.

Turn the IGNITION switch to START (2) and release immediately when the engine starts. Do not push or hold the throttle down. The ECM will automatically provide the proper amount of fuel to start the engine.

4.

Immediately check the engine instruments for proper indication after starting. Shut down the engine if the oil pressure gauge does not reach the proper reading within 15 seconds.

heater on and off at start-up and during operation.

The engine is equipped with an electric air heater grid at the air inlet elbow to aid in cold starting and reduce white smoke at start-up. In the preheat mode with the carrier cab ignition switch in run (1), the ECM will turn the heater ON for 30 seconds as a preheat cycle, then OFF. The preheat mode will be activated when the sum of the coolant and air inlet temperatures are less than 25 °C (77 °F).

1.

Place the hydraulic PUMP disconnect switch in the DISENGAGED position.

2.

Ensure the parking brake is set and position the transmission in neutral.

DANGER

NOTE

BOTH AIR SYSTEM PRESSURES MUST BE IN THE NORMAL OPERATING RANGE PRIOR TO DISENGAGING THE PARK BRAKE. CAUTION IF OIL PRESSURE AND/OR TEMPERATURE INDICATOR(S) DO NOT DISPLAY THE PROPER READINGS, SHUT DOWN ENGINE AND CORRECT MALFUNCTION.

5.

Allow the engine to warm up for about five minutes before applying a load. Do not race the engine for a faster warm up.

The engine will not crank unless the transmission is in neutral.

3.

Turn the ignition key to run (1) and wait for 30 seconds for the preheat cycle to be completed.

4.

Turn the IGNITION switch to START (2) and release immediately when the engine starts. Do not push or hold the throttle down. The ECM will automatically provide the proper amount of fuel to start the engine.

5.

Immediately check the engine instruments for proper indication after starting. Shut down the engine if the oil pressure gauge does not reach the proper reading within 15 seconds.

Cold Engine

DANGER DANGER BOTH AIR SYSTEM PRESSURES MUST BE IN THE NORMAL OPERATING RANGE PRIOR TO DISENGAGING THE PARK BRAKE.

DO NOT SPRAY STARTING FLUID INTO THE AIR INLET. THE SPRAY WILL CONTACT THE HEATER ELEMENTS AND COULD EXPLODE CAUSING PERSONAL INJURY.

The ENGINE WARNING indicator will illuminate for five seconds (as a lamp check) when the key is first turned on. The lamp will blink at five second intervals if the ECM detects a problem. If the light comes on and continues to blink after initial start-up, there is a problem that needs to be corrected. Press the engine diagnostic switch to ON for code retrieval and check the crane service manual or engine manufacture’s service manual for code identification.

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

6.

Allow the engine to warm up for about five minutes before applying a load. Do not race the engine for a faster warm up.

IDLING THE ENGINE NOTE The engine ECM monitors the engine and, under certain conditions, cycles the air

Idling the engine unnecessarily for long periods of time wastes fuel and fouls injector nozzles. Unburned fuel causes carbon formation; oil dilution; formation of lac-

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quer or gummy deposits on the valves, pistons and rings; and rapid accumulation of sludge in the engine.

your hips as possible and pull it toward the door to a snug fit so the retractor can take up the slack.

NOTE

NOTE

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

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

RACING THE ENGINE

DO NOT race the engine during the warm-up period or operate the engine beyond governed speed (as might occur in downhill operation or downshifting). Engine bearings, pistons, and valves may be damaged if these precautions are not taken.

4.

If the shoulder belt is too snug, do the following:

SHUTDOWN PROCEDURE

1.

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

2.

Position the ignition switch to OFF.

3.

Drain the fuel filter-water separator.

a. Pull the shoulder belt out (A) at least 130 mm (5 in) so that when it is left go, it returns to your chest. b. Then pull down on the shoulder belt (B) the least amount needed to ease pressure but no more than 25 mm (1 in) and let go.

CRANE TRAVEL OPERATION ACTIVE RESTRAINTS

5.

Seat Belts

1.

DANGER

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

KEEP ANY SHOULDER BELT SLACK TO A MINIMUM, NO MORE THAN 25 MM (1 IN). BELT SLACK BEYOND THE SPECIFIED AMOUNT COULD SIGNIFICANTLY REDUCE THE AMOUNT OF PROTECTION IN AN ACCIDENT BECAUSE THE BELT IS TO LOOSE TO RESTRAIN YOU AS INTENDED.

Latch Plate

6.

Push Button

Buckle

To reduce slack in the belt, pull the belt out as you did in step 3.a.

To unfasten the belt, push in on the button in the center of the buckle. To store the belt, pull out about 180 mm (5 in) and let go. The belt should retract when the buckle is unlatched. To help prevent damage to the seat belt and interior, before closing the door be sure the belt is fully retracted and the latch plate is out of the way.

TRAVELING - GENERAL CAUTION

2.

3.

4-4

Pull the belt across your lap and push the latch plate into the buckle until it clicks.

To reduce the risk of sliding under the belt during a collision, position the belt across your lap as low on

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

CAUTION

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

CHECK COLD TIRE PRESSURE PRIOR TO EXTENDED TRAVEL. REFER TO TIRE INFLATION DECAL ON CRANE. CAUTION JOB SITE TRAVEL WITH DEFLATED SUSPENSION MUST BE LIMITED TO 8 KM/K (5 MPH). ATTEMPTING TO TRAVEL AT HIGHER SPEEDS MAY CAUSE DRIVETRAIN COMPONENT FAILURE.

Do not move the crane until the superstructure has been secured as outlined below. Procedures for accomplishing the following can be found in the Superstructure Operator’s and Safety Handbook.

1.

To ensure the axles and/or suspension are not overloaded, adhere to the following. a. Check that front axle load does not exceed 9526 kg (21,000 lb) and rear axle load does not exceed 18,598 kg (41,000 lb). b. Refer to certification label on inside of cab door for Gross Axle Weight Rating (GAWR).

Outrigger Float Stowage TRAVELING WITH BOOM EXTENSION ERECTED

Travel with boom extension erected is permissible under the following conditions.

1.

Boom extension shall be erected at minimum offset with stinger section (if applicable) pinned in fully retracted position.

Ensure the boom is fully lowered into the boom rest.

2.

Jobsite travel only on firm, level surface.

4.

Engage the swing brake.

3.

Main boom shall be fully retracted.

5.

Engage the swing lock.

4.

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

6.

Ensure the swingaway, if so equipped, is properly stowed and secured with mast is stowed position.

5.

Swing lock pin shall be engaged.

7.

Ensure the hook block and/or headache ball are stowed securely in the stowage trays provided. They may be stowed reeved or unreeved.

6.

Suspension air bags shall be inflated.

7.

Tires shall be properly inflated.

2.

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

3.

8.

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

8.

Hookblock may be reeved over main boom nose, hanging 0.9 m (3 feet) below nose sheaves.

9.

Ensure the center front stabilizer is fully retracted.

Float remains installed

9.

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

10. Ensure the stabilizer floats are properly stowed in their holding racks. If stowing the optional aluminum floats, they must be positioned in the rack with the handle positioned as shown in the figure titled Outrigger Float Stowage.

11. Ensure the cover doors on the battery box and sling box are closed.

10. When traveling with the boom over the front: a. Boom angle shall be greater than 15 degrees and less than 40 degrees. b. Any counterweight configuration may be used (Heavy, Standard, or Light).

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11. When traveling with the boom over the rear: a. Boom angle shall be greater than 0 degrees and less than 40 degrees. b. Heavy counterweight configuration must be used.

TRANSMISSION PUSH-BUTTON SHIFT SELECTOR

The transmission push-button shift selector is located on the right side console. When the engine is first started, the ECU will automatically initialize the transmission to neutral. Press “D” for forward travel and “R” for reverse travel. Press “N” to select neutral. The “N” key has a raised edge so that the operator can orient his hand without looking at the shift selector. Each time a key is pressed, a short beep will be sounded to verify that the ECU in the cab has received instruction to shift.

NOTE Seek service immediately if engine starts in any other range than neutral.

The transmission will start in the first range when “D” is selected and automatically shift up as the crane speed increases. The display on the push-button selector shows the current gear. Use the UP× or DOWNØ arrow key to increase or decrease the range of gears.

There is no limitation speed on upshifting, however; if a down shift is selected with the engine speed too high the ECU will prevent the shift from occurring. If shifts to “D” or “R” are inhibited, the digit on the display will flash.

the transmission ECU will change modes. The primary mode is the economy mode and the secondary mode is the performance mode. The mode indicator on the shift selector is illuminated when the transmission is in the performance (secondary) mode. In the economy mode, the transmission shifts to optimize the fuel efficiency of the engine. In performance mode, the transmission shifts to optimize the horsepower of the engine.

Cranes With Remote Drive/Steer Option

Transmission shifting is controlled by engine RPM, throttle position and mode of operation. There are two modes of operation and the crane must be stopped before the transmission EPU will change modes. The primary mode is the economy mode and the secondary mode is the jobsite mode. The mode indicator on the shift selector is illuminated when the transmission is in the jobsite (secondary) mode. In the economy mode, the transmission shifts to optimize the fuel efficiency of the engine. In jobsite mode, the transmission can only be operated in forward 1st gear and reverse. The transmission is shifted to the jobsite mode as soon as the MASTER power switch on the superstructure remote control box is positioned to ON. DOWNSHIFT/REVERSE INHIBITOR

Although there is no speed limit on upshifting, there is on downshifting and shifts into reverse “R” and drive ”D” from neutral ”N”. If a down shift or neutral-to-range shift is selected when the engine speed is too high, the ECU will prevent the shift from occurring until neutral is reselected and/or the shift is made at a lower speed. A continuous “beep” tone is emitted if reverse is selected during forward movement or a neutral-to-range shift is selected at too high an engine speed.

CAUTION

TRANSMISSION TEMPERATURE DO NOT COAST WITH TRANSMISSION IN NEUTRAL OR SEVER TRANSMISSION DAMAGE CAN RESULT

TRANSMISSION MODE CONTROL

The transmission will, after a short period of time, learn the operators driving technique and make minor adjustments accordingly. A machine driven by two different operators may seem to shift different at first. The shifting pattern will be adjusted to the operating driving technique as the machine is driven.

Cranes Without Remote Drive/Steer Option

Transmission shifting is controlled by engine RPM, throttle position and mode of operation. There are two modes of operation and the crane must be stopped before

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The transmission is programmed to restrict full operation until specified temperatures are reached. For temperatures of -7 °C (20 °F) and below, operation is restricted to Neutral, Reverse, and Second. Above these temperatures, all ranges are in full operation.

If the sump temperature reaches 121 °C (250 °F), operation is inhibited. Check the transmission fluid level if the transmission overheats during normal operation. If the high temperature persists, stop and have the transmission checked by service personnel.

Note Stop and idle engine from 1200 to 1500 rpm to bring transmission temperature down.

REAR TANDEM INTER-AXLE/CROSS-AXLE LOCKS

6.

CAUTION DO NOT OPERATE DIFFERENTIAL LOCKS ON DRY ROADS.

DANGER STOP IMMEDIATELY IF LOW AIR PRESSURE WARNING SOUNDS AND DETERMINE CAUSE OF AIR LOSS. STOP BY DOWNSHIFTING AND USE ENGINE AS A BRAKE. MAKE FINAL STOP USING A SINGLE BRAKE PEDAL MOVEMENT TO AVOID EXCESSIVE LOSS OF AIR AND SUDDEN ENGAGEMENT OF PARKING BRAKES.

To engage the inter-axle or cross axle differential locks for maximum pulling power when approaching slippery or poor road conditions, do the following: CAUTION DO NOT ENGAGE OR DISENGAGE DIFFERENTIAL LOCKS WHILE WHEELS ARE TURNING.

1.

Stop the crane and position the control lever to the LOCK position.

2.

Proceed over the poor road conditions cautiously.

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

When adverse conditions have passed, do the following: 1.

Stop the crane and position the control lever to the UNLOCK position.

2.

Resume driving at a safe speed.

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.

7.

Regularly check the air pressure gauge. System air pressure should never drop below 310 kPa (45 psi).

If both systems drop below 310 kPa (45 psi), the automatic spring brakes will actuate. Normal operating pressure is 724 to 862 kPa (105 to 125 psi).

SERVICE/PARKING BRAKES DANGER

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

1.

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

2.

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

DO NOT USE PARKING BRAKE FOR STOPPING CRANE EXCEPT IN CASE OF AN EMERGENCY, AS A SEVERE SUDDEN STOP WILL OCCUR. CAUTION

3.

RELEASE BRAKES BEFORE MOVING CRANE, OR DRIVE TRAIN DAMAGE WILL RESULT.

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

4.

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

5.

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

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

8.

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

4-7

ENGINE BRAKING

1.

NOTE

DANGER

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

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

1.

2.

Position the ENGINE BRAKE On/Off switch to ON.

NEVER PARK CRANE NEAR HOLES, OR ON ROCKY OR EXTREMELY SOFT SURFACES. THIS MAY CAUSE THE CRANE TO OVERTURN, RESULTING IN INJURY TO PERSONNEL.

2.

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

3.

Apply parking brakes and if necessary, chock the wheels.

4.

Position all controls to neutral or off.

5.

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

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.

7.

Close all windows.

8.

Remove the keys from the crane.

9.

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

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

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

Perform the procedures found under Recommended Crane Shutdown Procedures found in the Superstructure Operators and Safety Handbook.

DANGER CAUTION BEFORE ENGAGING ENGINE BRAKE ON SLIPPERY ROADS, BE SURE CRANE IS MAINTAINING TRACTION.

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

4-8

STEP 10 DOES NOT TAKE THE PLACE OF THE PRESTARTING 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.

SECTION 5 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 Product Support, Chambersburg, Pennsylvania.

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. 0.28 kg (1 oz) of EPMPG equals one pump on a standard 0.45 kg (1 lb) grease gun.

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 relubricate to ensure complete lubrication of the entire wear area.

The following describe the lubrication points and gives the lube type, lube interval, lube amount, and application of each. Each lubrication point is numbered, and this number corresponds to the index number shown on the Lubrication Diagram.

CAUTION THE FOLLOWING LUBE INTERVALS ARE TO BE USED AS A GUIDELINE ONLY. ACTUAL LUBE INTERVALS SHOULD BE FORMULATED BY THE OPERATOR TO CORRESPOND ACCORDINGLY TO CONDITIONS SUCH AS CONTINUOUS DUTY CYCLES AND/OR HAZARDOUS ENVIRONMENTS. CAUTION COMPONENTS UTILIZING SYNTHETIC OR SEMI-SYNTHETIC LUBRICANTS SHOULD ALWAYS BE SERVICED WITH THESE TYPE LUBRICANTS. THE SUBSTITUTION OR ADDITION OF PETROLEUM BASED LUBRICANTS IN THESE COMPONENTS COULD CAUSE THE SEALS TO LEAK.

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

5-1

4.

Lube Type - EP-MPG Lube Interval - 500 hours or 16,090 km (10,000 mi) Lube Amount - Until grease extrudes Application - 2 grease fittings

CARRIER LUBRICATION 1.

2.

Engine Crankcase.

Lube Type - EO - 15W40 Lube Interval - Check fluid level every 10 hours or daily; drain, fill and replace filter every 250 hours.

Lube Amount - Capacity - 28 liters (30 quarts) Application - Fill to full mark on dipstick.

5.

Engine Cooling System.

6.

CAUTION USE OF NON-SEMI-SYNTHETIC LUBRICANT MAY DAMAGE COMPONENTS AND/OR INVALIDATE PUBLISHED LUBRICATION INTERVALS.

Lube Amount - 0.95 liters (1.0 quart) Application - Fill to the oil level mark on the housing with the fill plug and the oil level mark horizontal.

NOTE

7.

NOTE

Lube Interval - Check fluid level every 100 hours or monthly; Drain, fill, and replace filter after first 500 hours and thereafter every 1000 hours or 18 months.

Lube Amount - Capacity - 27 liters (29 quarts) Application - Through dipstick opening to oil level mark on dipstick.

5-2

Front Axle Tie Rod Ends.

Lube Type - EP-MPG Lube Interval - 1000 hours or 12 months Lube Amount - Until grease extrudes Application - 2 grease fittings

Lube Type - HYDO

Any fluid used in the transmission must be Allison C-4 qualified.

Front Axle Hubs.

Lube Type - SSGL-5 Lube Interval - Check fluid level every 250 hours or 3 months and refill as necessary.

Transmission.

The transmission should be at operating temperature when checking level and draining.

90 Degree Miter Box. Lube Type - EP-MPG Lube Interval - 1000 hours or 12 months Lube Amount - Until grease extrudes Application - 1 grease fitting

Lube Type - AFC Lube Interval - Check coolant level every 10 hours or daily; Refer to Service Manual Section 2 Engine for additional information.

Lube Amount - Capacity - 36 liters (38 quarts) Application - Fill radiator to bottom of filler neck with mixture of 50% AFC and 50% water. Run engine through two (2) thermal cycles. Check coolant level and refill as required.

3.

Drive Line Slip and U-Joints.

8.

Front Axle King Pins.

Lube Type - EP-MPG Lube Interval - 1000 hours or 12 months Lube Amount - Until grease extrudes Application - 4 grease fittings

9.

Front Axle Brake Slack Adjusters.

Lube Type - EP-MPG Lube Interval - 1000 hours or 12 months Lube Amount - Until grease extrudes Application - 2 grease fittings

Carrier Lubrication Diagram

5-3

16

21

1.

2.

3.

4.

5.

6.

7.

8.

14,15

17

22

Engine Crankcase Engine Coolant System Transmission Drive Line Slip and U-Joints 90 Degree Miter Box Front Axle Hubs Front Axle Tie Rod Ends Front Axle King Pins

22

13

4

12

20 Far Side

16

17

4

19

18

7

8

22

9.

10.

11.

12.

13.

14.

15.

16.

Front Axle Brake Slack Adjusters Front Axle Brake Camshafts Spring Eye Bushings Front Rear Axle Differential Rear Rear Axle Differential Rear Axle Brake Slack Adjusters Rear Axle Brake Camshafts Outrigger Beams

21 22

17.

18.

19.

20.

6

9,10

11

Jack Cylinder Barrels Hydraulic Reservoir Hydraulic Filter Coolant Strainer (Superstructure Cab Heater) Jack Cylinder Tubes Front and Rear Aluminum Wheel Pilots

LUBE SYMBOL DESCRIPTION SPECIFICATION A6-829-101130 AFC 50/50 Fully formulated anti-freeze coolant A6-829-003483 EO Engine oil SAE 15W40 A6-829-003477 EP-MPG Extreme pressure multi-purpose grease A6-829-006444 HYDO Hydraulic Oil A6-829-012964 SSGL-5 Semi-Synthetic Gear Lube A6-829-102979 OGL Open Gear Lube A6-829-003689 ASC Anti-seize compound

14,15

4

4

3

1

2 17

5

10. Front Axle Brake Camshafts.

Lube Type - EP-MPG Lube Interval - 1000 hours or 12 months Lube Amount - Until grease extrudes Application - 2 grease fittings 11. Spring Eye Bushings.

Lube Type - BAS Lube Interval - 40,225 km (25,000 mi) or 2 years Application - Disassemble spring eye bushings.

Clean and lubricate bushings. Install bushings.

Refer to Service Manual Section 4 - Front Axle, Suspension, and Steering.

refill, and clean magnetic drain plug every 80,450 km (50,000 mi) or 2 years.

CAUTION IF THE MAKEUP AMOUNT IS SUBSTANTIALLY MORE THAN 0.5 PINT (0.23 LITER) CHECK FOR LEAKS. CAUTION USE OF NON-SEMI-SYNTHETIC LUBRICANT MAY DAMAGE COMPONENTS AND/OR INVALIDATE PUBLISHED LUBRICATION INTERVALS.

12. Front Rear Axle Differential.

Lube Type - SSGL-5 Lube Interval - Check lubricant level every 250 hours or 3 months and refill as necessary. Drain, refill, change filter, and clean magnetic drain plug every 80,450 km (50,000 mi) or 2 years.

CAUTION IF THE MAKEUP AMOUNT IS SUBSTANTIALLY MORE THAN 0.5 PINT (0.23 LITER) CHECK FOR LEAKS.

CAUTION USE OF NON-SEMI-SYNTHETIC LUBRICANT MAY DAMAGE COMPONENTS AND/OR INVALIDATE PUBLISHED LUBRICATION INTERVALS.

Lube Amount - Capacity - 14.3 liters (30.2 pints) Normal makeup - less than 0.23 liter (0.5 pint) Application - Fill to bottom of hole in the housing.

CAUTION USE OF NON-SEMI-SYNTHETIC LUBRICANT MAY DAMAGE COMPONENTS AND/OR INVALIDATE PUBLISHED LUBRICATION INTERVALS.

Lube Amount - Capacity - 14.3 liters (30.2 pints) Normal makeup - less than 0.23 liter (0.5 pint) Application - Fill to bottom of hole in the housing.

13. Rear Rear Axle Differential.

Lube Type - SSGL-5 Lube Interval - Check lubricant level every 250 hours or 3 months and refill as necessary. Drain,

5-4

NOTE Any lubricant used in the field for either top-off or refill of the axles must be an “Extended Drain Lubricant” as approved

by Arvinmeritor. These lubricants are listed in Arvinmeritor Technical bulletin TP-9539 available at www.arvinmeritor.com or by contacting Grove Customer Support.

Lube Amount - Capacity - 12.2 liters (25.8 pints) Normal makeup - less than 0.23 liter (0.5 pint) Application - Fill to bottom of hole in the housing.

14. Rear Axle Brake Slack Adjusters.

Lube Type - EP-MPG Lube Interval - 1000 hours or 12 months Lube Amount - Until grease extrudes Application - 4 grease fittings 15. Rear Axle Brake Camshafts.

Lube Type - EP-MPG Lube Interval - 1000 hours or 12 months Lube Amount - Until grease extrudes Application - 4 grease fittings 16. Outrigger Beams.

Lube Type - EP-OGL Lube Interval - 500 hours or 6 months Lube Amount - Spray lubricant on bottom of outrigger beams.

Application - By spray; 8 places; extend beams fully and coat the bottom plate.

NOTE

17. Jack Cylinder Barrels.

Lube Type - EP-OGL Lube Interval - 500 hours or 6 months Lube Amount - Fully extend jack cylinder and spray lubricant on to cylinder barrels.

Application - By spray; 5 places

Remove one valve to equalize the pressure before checking the swing gearbox oil level. This will keep the oil from pushing out.

CAUTION

18. Hydraulic Reservoir.

Lube Type - HYDO Lube Interval - Check fluid level every 10 hours or daily, using sight gauge on side of tank, with boom down and all outrigger cylinders retracted; drain and refill as necessary.

Lube Amount - 371 liters (98 gal.), to FULL mark on sight gauge.

Application - Fill through breather/fill cap on top of tank. When tank is drained, clean the magnetic pipe plug.

19. Hydraulic Filter.

Change the filter when the indicator is red.

20. Coolant Strainer (Superstructure Cab Heater).

Close the shutoff valves. Unscrew the hex plug and clean the strainer screen after first 100 hours and every 2000 hours or 12 months thereafter.

21. Jack Cylinder Support Tubes.

Lube Type - EP-OGL Lube Interval - 500 hours or 6 months Lube Amount - Spray lubricant on ID of jack cylinder support tubes before installing jack cylinders.

Application - By spray; 5 places.

22. Front and Rear Aluminum Wheel Pilots.

Lube Type - ASC Lube Interval - When wheels are removed for service.

Lube Amount - Generously coat the wheel pilot or hub pads with Anti-Seize (ASC) compound. Do not apply Anti-Seize compound to the face of the wheel of the hub.

SUPERSTRUCTURE LUBRICATION

WHEN CHECKING THE SWING GEAR BOX OIL LEVEL, PLACE THE DIP STICK INTO THE SLEEVE UNTIL THE CAP IS FLUSH WITH THE END OF THE SLEEVE. DO NOT SCREW THE CAP ONTO THE SLEEVE TO CHECK LEVEL.

Lube Interval - Check and fill every 50 hours. Drain and fill after first 250 hours and every 500 hours or 12 months thereafter.

CAUTION USE OF NON-SEMI-SYNTHETIC LUBRICANT MAY DAMAGE COMPONENTS AND/OR INVALIDATE PUBLISHED LUBRICATION INTERVALS.

Lube Amount Tulsa Gearbox - Capacity - 1.66 liters (1.75 quarts) Application - Full until oil appears in sight gauge.

SOM Gearbox - Capacity - 4.0 liters (4.25 quarts) Application - Fill to mark on dipstick.

31. Turntable Gear and Drive Pinion.

Lube Type - EP-OGL Lube Interval - 500 hours or 6 months Lube Amount - Coat all teeth Application - Spray on 32. Turntable Bearing.

Lube Type - EP-MPG Lube Interval - 500 hours or 6 months Lube Amount - Until grease extrudes the whole circumference of the bearing.

Application - 2 grease fittings at the front of the turntable. Rotate the turntable 90° and apply grease to fittings. Continue rotating 90° and grease the fittings until the whole bearing is greased.

30. Turntable Gearbox.

Lube Type - SSGL-5

5-5

33. Upper Lift Cylinder Pivot Pin.

35. Main Hoist.

Lube Type - EP-MPG Lube Interval - 500 hours or every 3 months Lube Amount - Until grease extrudes Application - 1 grease fitting 34. Lower Lift Cylinder Pivot Pin. Lube Type - EP-MPG Lube Interval - 500 hours or 3 months Lube Amount - Until grease extrudes Application - 2 grease fittings

36

Lube Type - AGMA EP-4 Lube Interval - Check and fill every 40 hours or weekly. Drain and fill annually.

Lube Amount - Capacity - 5.2 liters (5.5 quarts) Application - Fill until level with the check plug opening.

36. Auxiliary Hoist (Optional).

Lube Type - AGMA EP-4 Lube Interval - Check and fill every 40 hours or weekly. Drain and fill annually.

Lube Amount - Capacity - 5.2 liters (5.5 quarts) Application - Fill until level with the check plug opening.

35

30 30.

31.

32.

33.

34.

35.

36.

Turntable Gear Box Turntable Gear and Drive Pinion Turntable Bearing Upper Lift Cylinder Pivot Pin Lower Lift Cylinder Pivot Pin Main Hoist Auxiliary Hoist (Optional)

34

33 32

31

6305-2

Superstructure Lubrication Diagram

5-6

BOOM, BOOM EXTENSION, AND BOOM ACCESSORIES LUBRICATION 50. Boom Pivot Shaft.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 2 grease fittings, one on each side 51. Extend Cable Sheaves.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 3 grease fitting; extend boom for entry through access holes.

52. Retract Cable Sheaves.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 4 grease fittings; extend boom for entry through access holes.

53. Telescope Cylinder Wear Pads.

Lube Type - EP-MPG Lube Interval - 125 hours or 3 months.

Lube Amount - Thoroughly coat all areas the wear pads move on.

Application - By brush: 2 places; extend boom for entry through access holes.

54. Side Wear Pads.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Thoroughly coat all areas the wear pads move on.

Application - By brush: 12 places; extend boom for entry through access holes.

55. Boom Section Upper Wear Pads.

Lube Type - EP-MPG Lube Interval - 50 hours or 1 week Lube Amount - Thoroughly coat all areas the wear pad moves on.

Application - By brush: 6 places; extend boom for entry through access holes.

56. Boom Section Lower Wear Pads.

Lube Type - EP-MPG Lube Interval - 50 hours or 1 week Lube Amount - Thoroughly coat all areas the wear pad moves on.

Application - By brush; 3 places; extend boom for entry through access holes.

57. Upper Boom Nose Sheave.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 1 grease fitting per sheave 58. Lower Boom Nose Sheave.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 1 grease fitting per sheave 59. Boom Extension Sheave.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 1 grease fitting 60. Boom Extension Roller.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 1 grease fitting 61. Boom Extension Mast Sheave.

Lube Type - EP-MPG Lube Interval - 500 hours or 12 months Lube Amount - Until grease extrudes 62. Auxiliary Boom Nose Sheave.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 1 grease fitting 63. Hook Block Swivel Bearing.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 1 grease fitting 64. Hook Block Sheaves.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 1 grease fitting per sheave (3 fittings total - 30 ton) (2 fittings total - 15 ton)

5-7

Boom, Boom Extension, and Boom Accessories Lubrication Diagram

5-8

58

56

55

52

60

59

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

Boom Pivot Shaft Extend Cable Sheaves Retract Cable Sheaves Telescope Cylinder Wear Pads Side Wear Pads Boom Section Upper Wear Pads Boom Section Lower Wear Pads Upper Boom Nose Sheaves Lower Boom Nose Sheaves Boom Extension Sheaves Boom Extension Roller Boom Extension Mast Sheave Auxiliary Boom Nose Sheave Hook Block Swivel Bearing Hook Block Sheaves Headache Ball Swivel Top

53

51

61

54

56

54 51

63

64

55

58 62

6305-3

65

65. Headache Ball Swivel Top. Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Until grease extrudes Application - 1 grease fitting NOTE See Engine Section in Service Manual for instructions on exhaust brake lubrication.

WIRE ROPE LUBRICATION Wire rope is lubricated during manufacturing so that the strands, and individual wires in strands, may move 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. For more detailed information concerning the lubrication and inspection of wire rope, refer to WIRE ROPE in Chapter 1, Section 2 - GENERAL MAINTENANCE in the Service Manual NOTES

5-9

NOTES

5-10