Tms800e Om Ctrl132-03

GROVE
OPERATOR’S MANUAL
This manual has been prepared for and is considered part of -
TMS800E
2
This Manual is divided into the following sections:
SECTION 1 INTRODUCTION
SECTION 2 SAFETY INFORMATION
SECTION 3 OPERATING CONTROLS AND PROCEDURES
SECTION 4 SET-UP AND INSTALLATION
SECTION 5 LUBRICATION
SECTION 6 MAINTENANCE CHECKLIST
3
NOTICE
The crane serial number is the only method your distributor or the factory
has of providing you with correct parts and service information.
The crane serial number is identified on the builder’s decal attached to the
operator’s cab. Always furnish crane serial number when ordering parts
or communicating service problems with your distributor or the factory.
To prevent death or serious injury:

• Avoid unsafe operation and maintenance.
• This crane must be operated and maintained by trained and 5
experienced personnel. Manitowoc is not responsible for qualifying
these personnel.
• Do not operate or work on this crane without first reading and
understanding Operator’s Manual and Rating Plate supplied with
crane.
• Store Operator’s Manual in holder provided on crane.
• If Operator’s Manual or Capacity Charts are missing from cab,
contact your distributor for new ones.
6
© 2008 Manitowoc Crane Group
Published 12-23-2008, Control # 132-03
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
CALIFORNIA
PROPOSITION 65 WARNING
Battery posts, terminals, and related accessories contain
chemical lead and lead compounds, chemicals known to
the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.
TMS800E TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information

Diesel Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Battery Posts, Terminals, and Related Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 T
Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
O
Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 C
Load Moment Indicating (LMI) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Two-Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Special Operating Conditions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Crushing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Job Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Hand Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Transporting The Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Boom Extension/Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
SECTION 3 . . . . . . . . . . . . . . . . . . . Operating Controls and Procedures

Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Travel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Craning Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Additional Carrier Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Superstructure Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Craning Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
GROVE TOC-1
TABLE OF CONTENTS TMS800E
Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Breaking In A New Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Pre-Starting Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
General Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Using Your Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Crane Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Crane Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Manual Transmission and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Rear Tandem Inter-Axle/Cross-Axle Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Service/Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Crane Shutdown Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set-up And Installation

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installing Cable On The Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Installing Wedge and Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removable Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Mounting The Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Stowing The Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Installing the Bi-Fold Manual Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Checking the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Boom Extension Erecting and Stowing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Preparing the Crane for Boom Extension Erection Procedure . . . . . . . . . . . . . . . 4-11
Erecting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Raising and Lowering the Hydraulic Boom Extension . . . . . . . . . . . . . . . . . . . . . . 4-20
Transportation on a Separate Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Lifting Limit Switch on the Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Folding Out/In the Deflection Sheaves on the 33 ft (10.1 m) Section . . . . . . . . . . 4-22
Positioning/Remove the Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Setting the Folding Swingaway Extension Offset . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Removing the Bi-Fold Manual Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Installing/Removing 16 ft (4.9 m) Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Installing the 16 ft (4.9 m) Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Removing the 16 ft (4.9 m) Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Boom Extension (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Identification and Slinging Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Assembly Of Boom Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Electrical Connection at the Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Unfolding/Folding the Deflection Sheave on the 16 ft (4.9 m) Section . . . . . . . . . 4-28
Positioning/Removing the Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Traveling with Manually Offsettable Boom Extension and/or Inserts Erected . . . . 4-30
Auxiliary Single-Sheave Boom Nose (Additional Equipment) . . . . . . . . . . . . . . . . . . . 4-30
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Installing/Removing Auxiliary Single-Sheave Boom Nose. . . . . . . . . . . . . . . . . . . 4-30
Removing the Auxiliary Single-Sheave Boom Nose . . . . . . . . . . . . . . . . . . . . . . . 4-31
Rigging The Auxiliary Single-Sheave Boom Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
TOC-2
TMS800E TABLE OF CONTENTS
Rigging in Transport Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Rigging in Working Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Attaching and Removing Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose . . . . . . . . 4-33
Lifting Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Raising And Setting Down The Main Boom With Rigged Lattice Extension . . . . . . . . . 4-34
Telescoping With Rigged Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Operating With The Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Procedure if the Permissible Wind Speed is Exceeded . . . . . . . . . . . . . . . . . . . . . 4-34
Monthly Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
T
Hydraulic Oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Arctic Conditions Below -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 O
Arctic Conditions Down To -40°C (-40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ALL Weather Package & Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Standard Lubricants Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
C
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Superstructure Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . 5-10
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Checklist

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
GROVE TOC-3
TABLE OF CONTENTS TMS800E
THIS PAGE BLANK
TOC-4
SECTION 1
INTRODUCTION 1
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
GROVE 1-i
INTRODUCTION TMS800E OPERATOR’S MANUAL
THIS PAGE BLANK
1-ii
TMS800E OPERATOR’S MANUAL INTRODUCTION
SECTION 1
INTRODUCTION 1
GENERAL The superstructure is capable of 360° rotation in either
direction. All crane functions, with the exception of
This Handbook provides important information for the counterweight removal, are controlled from the fully-
operator of the TMS800E Series Grove Crane. enclosed cab mounted on the superstructure. The crane is
Before placing the crane in service, take time to thoroughly equipped with a four-section boom. Additional reach is
familiarize yourself with the contents of this manual. After all obtained by utilizing an optional bi-fold boom extension.
sections have been read and understood, retain the manual Lifting is provided by a main hoist and an optional auxiliary
for future reference in a readily accessible location. hoist. For basic crane component locations, (see Figure 1-1).
The Grov e c rane ha s b een des ign ed for maximum

performance with minimum maintenance. With proper care, 2
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.
1
Grove and our Dealer Network want to ensure your 1
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 3
procedures are supplied in a separate manual with each
crane, and should be referred to for detailed information.
NOTE: Throughout this handbook, 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.
6561-3
5 5
The mobile crane carrier incorporates an all welded steel 4
frame. The 8x4x4 carrier utilizes two drive axles and two Rear View
steer axles. Steering is provided by a power steering pump, FIGURE 1-1
gearbox and control valve. The engine is mounted in the
front of the carrier and provides power through a 10 speed Item Description
forward and 2 speed reverse UltraShift™ transmission.
1 Rear View Mirror
Hydraulic, two stage double box telescopic beams with
inverted stabilizer (jack) cylinder outriggers are integral with 2 Crane Cab
the carrier frame. The outriggers are utilized in three 3 Counterweight
position; fully extended, intermediate (50%) extended, and
4 Outrigger Float
fully retracted. The carrier is also equipped with a center
front stabilizer that has a permanently stowed pad. 5 Outrigger Jack Cylinder
GROVE Published 12-23-2008, Control # 132-03 1-1

6 8
7 9 11
12
6561-2
19 14 9
9
14 12
7 16 13
17 11
10
18
6561-1
28
19 26 24 9
20 9 25
27
Left Side View
FIGURE 1-1 continued
1-2 Published 12-23-2008, Control # 132-03

TMS800E OPERATOR’S MANUAL INTRODUCTION
1
12
13 7
11
6 15 16
17
10
18
22 9 25 28
22 21
9 20 19
23 6561-4
Right Side View

Item Description Item Description

6 Folding Boom Extension 18 Auxiliary Boom Nose
7 Boom 19 Carrier Cab
8 Stinger 20 Center Front Stabilizer
9 Outrigger Stabilizer Cylinder 21 Front Axles
10 Removable Counterweights 22 Outrigger Beam
11 Auxiliary Hoist 23 Outrigger
12 Main Hoist 24 Hydraulic Oil Cooler
13 Boom Pivot 25 Rear Axles
14 Superstructure Cab 26 Fuel Tank
15 Lift Cylinder 27 Outrigger Float
16 Boom Rest 28 Carrier Outrigger Controls
17 Boom Nose Sheaves

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SECTION 2
SAFETY INFORMATION
TABLE OF CONTENTS
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2
Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Two-Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Special Operating Conditions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Job Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Hand Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
GROVE 2-i
SAFETY INFORMATION TMS800E OPERATOR’S MANUAL
THIS PAGE BLANK
2-ii
TMS800E OPERATOR’S MANUAL SAFETY INFORMATION
SECTION 2
SAFETY INFORMATION
DIESEL ENGINE EXHAUST Signal Words
CALIFORNIA DANGER
PROPOSITION 65 WARNING Identifies immediate hazards that will result in death or
Diesel engine exhaust and some of its constituents are serious injury if the message is ignored.
defects, and other reproductive harm. 2
BATTERY POSTS, TERMINALS, AND WARNING
Identifies potential hazards that could result in death or
RELATED ACCESSORIES
serious injury if the message is ignored.
CALIFORNIA CAUTION
PROPOSITION 65 WARNING Identifies potential hazards that could result in minor or
The battery posts, terminals, and related accessories moderate injury if the message is ignored.
contains chemical lead and lead compounds, chemicals
defects or other reproductive harm. Wash hands after CAUTION
handling. Without the safety alert symbol, identifies potential
hazards that could result in property damage if the
SAFETY MESSAGES message is ignored.
General NOTE: Highlights operation or maintenance procedures.

The importance of safe operation and maintenance cannot
be over emphasized. Carelessness or neglect on the part of GENERAL
operators, job supervisors and planners, rigging personnel, NOTE: Illustrations have been included in this section to
and job site workers can result in their death or injury and emphasize certain proper and improper points;
costly damage to the crane and property. READ AND FOLLOW PRINTED INSTRUCTIONS.
To alert personnel to hazardous operating practices and It is impossible to compile a list of safety precautions
maintenance procedures, safety messages are used covering all situations. However, there are basic principles
throughout the manual. Each safety message contains a that MUST be followed during your daily routine. Safety is
safety alert symbol and a signal word to identify the hazard’s YOUR PRIMARY RESPONSIBILITY, since any piece of
degree of seriousness. equipment is only as safe AS THE PERSON AT THE
CONTROLS.
Safety Alert Symbol
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
This safety alert symbol means ATTENTION!
arise. It is intended to present basic safety precautions that
Become alert — your safety is involved! Obey all safety
should be followed in daily operation.
messages that follow this symbol to avoid possible death
or injury. 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 Allow No One other than the operator to be on the crane
operation. Operational aids or warning devices can be while the crane is functioning or moving, unless they are
mechanical, electrical, electronic, or a combination thereof. seated in a two-man cab.
They are subject to failure or misuse and should not be relied
upon in place of good operating practices. OPERATIONAL AIDS
You, the operator, are the only one who can be relied upon to Grove remains committed to providing reliable products that
assure the safety of yourself and those around you. Be a enable users and operators to safely lift and position loads.
PROFESSIONAL and follow the RULES of SAFETY. Grove has been an industry leader in the incorporation of
REMEMBER, failure to follow just one safety precaution operational aids into the design of its cranes. Federal law
could cause an accident that results in death or serious injury requires that cranes be properly maintained and kept in good
to personnel or damage to equipment. You are responsible working condition. The manuals that Grove provides that are
for the safety of yourself and those around you. specific for each crane and the manufacturer’s manuals for
the operational aids shall be followed. If an operational aid
IMMEDIATELY report all accidents, malfunctions, and should fail to work properly, the crane user or owner must
equipment damages to your local Grove distributor. assure that repair or recalibration is accomplished as soon
Following any accident or damage to equipment, the local as is reasonably possible. If immediate repair or recalibration
Grove distributor must be immediately advised of the of an operational aid is not possible and there are
incident and consulted on necessary inspections and exceptional circumstances which justify continued short-term
repairs. Should the distributor not be immediately available, use of the crane when operational aids are inoperative or
contact should be made directly with Manitowoc malfunctioning, the following requirements shall apply for
CraneCARE. The crane must not be returned to service until continued use or shutdown of the crane:
it is thoroughly inspected for any evidence of damage. All
damaged parts must be repaired or replaced as authorized 1. Steps shall be taken to schedule repairs and
by your local Grove distributor and/or Manitowoc recalibration immediately. The operational aids shall be
CraneCARE. put back into service as soon as replacement parts, if
required, are available and the repairs and recalibration
can be carried out. Every reasonable effort must be
OPERATOR’S INFORMATION
made to expedite repairs and recalibration.
You must READ and UNDERSTAND the Operator’s and
2. When a load indicator, rated capacity indicator, or
Safety Handbook and the Load Chart before operating the
rated capacity limiter is inoperative or malfunctioning,
crane. You must also VIEW and UNDERSTAND the safety
the designated person responsible for supervising the
video titled “The Real Key to Crane Safety” supplied with
lifting operations shall establish procedures for
your new Grove product. The handbook and Load Chart
determining load weights and shall ascertain that the
must be readily available to the operator at all times and
weight of the load does not exceed the crane ratings at
must remain in the cab while the crane is in use.
the radius where the load is to be handled.
Ensure that all personnel working around the crane are
thoroughly familiar with safe operating practices. You must 3. When a boom angle or radius indicator is inoperative
be thoroughly familiar with the location and content of all or malfunctioning, the radius or boom angle shall be
placards and decals on the crane. Decals provide important determined by measurement.
instructions and warnings and must be read prior to any
4. When an anti-block device, two-blocking damage
operational or maintenance function.
prevention or two-block warning device is inoperative
You must be familiar with the regulations and standards or malfunctioning, the designated person responsible for
governing cranes and their operation. Work practice supervising the lifting operations shall establish
requirements may vary slightly between government procedures, such as assigning an additional signal
regulations, industry standards, and employer policies so a person to furnish equivalent protection. This does not
thorough knowledge of all such relevant work rules is apply when lifting personnel in load-line supported
necessary. personnel platforms. Personnel shall not be lifted when
anti-two block devices are not functioning properly.
DO NOT REMOVE the Load Chart, this Operator’s and
Safety Handbook, or any decal from this crane. 5. When a boom length indicator is inoperative or
Inspect the crane every day (before the start of each shift). malfunctioning, the designated person responsible for
Ensure that routine maintenance and lubrication are being supervising the lifting operations shall establish the
dutifully performed. Don’t operate a damaged or poorly boom lengths at which the lift will be made by actual
maintained crane. You risk lives when operating faulty measurements or marking on the boom.
machinery - including your own.

6. When a level indicator is inoperative or malfunctioning, • You read, understand, and follow the safety and
other means shall be used to level the crane. operating recommendations contained in the
manufacturer’s manuals, your employer’s work rules,
OPERATOR’S QUALIFICATIONS and applicable government regulations.
• 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
2
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
An untrained operator subjects himself and others to death trained.
or serious injury.
You must be mentally and physically fit to operate a crane.
YOU MUST NOT OPERATE THIS MACHINE UNLESS: Never attempt to operate a crane while under the influence
• You have been trained in the safe operation of this of medication, narcotics, or alcohol. Any type of drug could
machine. i m pa i r p h y s i c a l , v i s u a l a n d m e n ta l r e a c t i o n s , a n d
capabilities.

CRANE STABILITY/STRUCTURAL vertical stripe or fully extended position before beginning

STRENGTH operation.
Be sure the outriggers are properly extended and set, and
To avoid death or serious injury, ensure that the crane is on a
the crane is level for operation on outriggers.
firm surface with load and crane’s configuration within
capacity as shown on the crane’s Load Chart and notes. All four outrigger beams must be equally extended to the mid
position vertical stripe or fully extended position before
Do not lift loads unless the outriggers are properly extended
beginning operation.
and the crane leveled. On models equipped with outriggers
that can be pinned at the mid-extend position, the outriggers All four outrigger beam lock pins must be engaged before
must also be pinned when operating from the mid-extend operating from the mid-extend position.
position.
The operator must select the proper Load Chart and Load
This crane should have a functional load moment indicator Moment Indicating (LMI) System program for the outrigger
and control lock-out system. Test daily for proper operation. position selected.
Never interfere with the proper functioning of operational
aids or warning devices.
Before swinging the superstructure over the side when the
outriggers are retracted, check the load chart for backwards
stability.
Long cantilever booms can create a tipping condition when
in an extended and lowered position. Retract the boom
proportionally with reference to the capacity of the applicable
Load Chart.
Check crane stability before lifting loads. Ensure the
outriggers (or tires if lifting on rubber) are firmly positioned on
solid surfaces. Ensure the crane is level, brakes are set, and
the load is properly rigged and attached to the hook. Check
the Load Chart against the weight of the load. Lift the load
slightly off the ground and recheck the stability before
proceeding with the lift. Determine the weight of the load
before you attempt the lift.
Ensure all pins and floats are properly installed and outrigger
beams are properly extended before lifting on outriggers.
Unless lifting within On Rubber capacities, outrigger beams KEEP THE BOOM SHORT. Swinging loads with a long line
must be properly extended and jack cylinders extended and can create an unstable condition and possible structural
set to provide maximum leveling of the crane. On models failure of the boom.
equipped with outriggers that can be pinned at the mid-
extend position, the outriggers must also be pinned when Load Charts
operating from the mid-extend position. Tires must be clear
of the ground before lifting on outriggers. Remove all weight Load Charts represent the absolute maximum allowable
from tires before lifting on outriggers. loads, which are based on either tipping or structural
limitations of the crane under specific conditions. Knowing
Use adequate cribbing under outrigger floats to distribute the precise load radius, boom length, and boom angle
weight over a greater area. Check frequently for settling. should be a part of your routine planning and operation.
Carefully follow the procedures in this handbook when Actual loads, including necessary allowances, should be
extending or retracting the outriggers. Death or serious injury kept below the capacity shown on the applicable Load Chart.
could result from improper crane setup on outriggers. You must use the appropriate Load Chart when determining
Be sure the outriggers plus the center front stabilizer are the capability of the crane in the configuration required to
properly extended and set, and the crane is level for perform the lift.
operation on outriggers. The center front stabilizer outrigger Maximum lifting capacity is available at the shortest radius,
is a vital factor in the stability of the crane. minimum boom length, and highest boom angle.
All four outrigger beams plus the center front stabilizer Do not remove the Load Charts from the crane.
outrigger must be equally extended to the mid position

Work Site If you should encounter a tipping condition, immediately

lower the load with the hoist line and retract or elevate the
Prior to any operation, you must inspect the ENTIRE work boom to decrease the load radius. Never lower or extend the
site, (including ground conditions) where the crane will travel boom, this will aggravate the condition.
and operate. Be sure that the surfaces will support a load
greater than the crane’s weight and maximum capacity. Be sure the load is properly rigged and attached. Always
determine the weight of the load before you attempt to lift it
Barricade the area where the crane is working and keep all and remember that all rigging (slings, etc.) and lifting devices
unnecessary personnel out of that area. (hook block, jib, etc.) must be considered part of the load.
Use caution when operating in the vicinity of overhanging Measure the load radius before making a lift and stay within
banks and edges. approved lifting areas based on the range diagrams and
Be aware of all conditions that could adversely affect the working area diagrams on the crane’s load chart.
stability of the crane.
Wind can have a significant affect on loads that may be lifted
Verify the crane’s capacity by checking the Load Chart
against the weight of the load. Then, lift the load slightly at
2
by a crane. Wind forces act differently on a crane depending first to ensure stability before proceeding with the lift.
upon the direction from which the wind is blowing (e.g., wind Always keep the load as near to the crane and as close to
on the rear of the boom can result in decreased forward the ground as possible.
stability, wind on the underside of the boom can result in
decreased backward stability, wind on the side of the boom The crane can tip over or fail structurally if:
can result in structural damages, etc.). To assist you in • The load and crane’s configuration is not within the
determining prevailing wind conditions, refer to the Wind capacity as shown on the applicable load rating chart
Velocity Chart (Table 2-1). and notes.
Lifting Operations • The ground is soft and/or the surface conditions are
poor.
If the boom extension, jib, or auxiliary boom nose is to be
used, ensure the electrical cable and the weight for the anti- • Outriggers are not properly extended and set. On
two-block switch are properly installed and the LMI is models equipped with outriggers that can be pinned at
programmed for the crane configuration. Refer to the LMI the mid-extend position, the outriggers must also be
handbook supplied with the crane. pinned when operating from the mid-extend position.
Before lifting, position the crane on a firm surface, properly • Cribbing under the outrigger pads is inadequate.
extend and set the outriggers, and level the crane. • The crane is improperly operated.
If the boom extension or auxiliary boom nose is to be used, Wind forces can exert extreme dynamic loads. Grove
you must ensure that the cable for the LMI system is properly recommends that a lift not be made if the wind can cause
connected at the junction box located on the boom nose. a loss of control in handling the load. Grove recommends
Depending on the nature of the supporting surface, if the wind speed (velocity) is between 32 km/h (20 mph) to
adequate cribbing may be required to obtain a larger bearing 48 km/h (30 mph), that the load capacities shall be reduced
surface. to account for the size and shape of the load and the wind
direction in relation to the machine for all boom, boom
DO NOT OVERLOAD THE CRANE by exceeding the extension, and jib lengths. Further, operation of the crane in
capacities shown on the appropriate Load Chart. Death or wind velocities over 48 km/h (30 mph) is not recommended.
serious injury could result from the crane tipping over or To assist you in determining prevailing wind conditions, refer
failing structurally from overload. to the Wind Velocity Chart (Table 2-1).
Do not rely on the crane’s tipping to determine your lifting
capacity.
Table 2-1
Wind Velocity Chart
Wind Force
Wind Velocity Visible Indicator
Beauford km/h (mph) Effects of wind as observed on land
Designation
Scale
Zero (0) Calm <2 (<1) No wind: smoke rises vertically
1 Light Air 2-5 (1-3) Wind direction seen by smoke but not by wind vanes

Wind Force
Wind Velocity Visible Indicator
Beauford km/h (mph) Effects of wind as observed on land
Designation
Scale
2 Light Breeze 6-11 (4-7) Wind felt on face: leaves rustle: wind vane moves slightly
3 Gentle Breeze 13-19 (8-12) Leaves/small twigs in constant motion: wind extends flag
Moderate
4 21-29 (13-18) Raises dust & loose paper: moves small branches
Breeze
Reduce crane load ratings and operating parameters at 32 km/h (20 mph)
Small trees in leaf begin to sway: on ponds, crested wavelets
5 Fresh Breeze 31-39 (19-24)
form
Large branches in motion: telegraph wires whistle: umbrellas
6 Strong Breeze 40-50 (25-31)
used with difficulty
Cease all craning operations at 48 km/h (30 mph); lower & retract boom
7 Moderate Gale 52-61 (32-38) Whole trees in motion: walking against wind is inconvenient
The crane cab is equipped with a sight level bubble that Counterweight
should be used to determine whether the crane is level. The
load line can also be used to estimate the levelness of the On cranes equipped with removable counterweights, ensure
crane by checking to be sure it is in-line with the center of the the appropriate counterweight sections are properly installed
boom at all points on the swing circle. for the lift being considered.
Use tag lines whenever possible to help control the To reduce the crushing hazard and to prevent death or
movement of the load. seriou s injury, always clear all personne l from the
counterweight and superstructure area before moving the
When lifting loads, the crane will lean toward the boom and counterweight or rotating the superstructure.
the load will swing out, increasing the load radius. Ensure the
load capacity chart is not exceeded when this occurs. Do not add material to the counterweight to increase
capacity.
Be sure the hoist line is vertical before lifting. Do not subject
the crane to side loading. A side load can tip the crane or Federal law prohibits modification or additions which affect
cause it to fail structurally. the capacity or safe operation of the equipment without the
manufacturer’s written approval. [29CFR 1926.550]
Do not strike any obstruction with the boom. If the boom
should accidentally contact an object, stop immediately. MULTIPLE CRANE LIFTS
Inspect the boom. Remove the crane from service if the
boom is damaged. Multiple crane lifts are not recommended.
Never push or pull with the crane boom. Any lift that requires more that one crane must be precisely
Avoid sudden starts and stops when moving the load. The planned and coordinated by a qualified engineer.
inertia and an increased load radius could tip the crane over If it is necessary to perform a multi-crane lift, the operator
or cause it to fail structurally. shall be responsible for assuring that the following minimum
Load Chart capacities are based on freely suspended loads. safety precautions are taken.
Do not pull posts, pilings, or submerged articles. Be sure the 1. Secure the services of a qualified engineer to direct the
load is not frozen or otherwise attached to the ground before operation.
lifting.
2. Use one qualified signal person.
Use only one hoist at a time when lifting loads.
3. Coordinate lifting plans with the operator, engineer, and
Always use enough parts-of-line to accommodate the load to signal person prior to beginning the lift.
be lifted. Lifting with too few parts-of-line can result in failure
of the wire rope. 4. Communication between all parties must be maintained
throughout the entire operation. If possible, provide
Never operate the crane with less than two wraps of wire approved radio equipment for voice communication
rope on the hoist drum. between all parties engaged in the lift.

5. Use cranes and rigging of equal capabilities and use the dropping the lifting device to the ground and possibly injuring
same boom length. personnel working below.
6. Use outriggers on cranes so equipped. Caution must be used when lowering or extending the boom.
Let out load line(s) simultaneously to prevent two-blocking
7. Be certain cranes are of adequate lifting capacity.
the boom tip(s) and the hook block, etc. The closer the load
8. Calculate the amount of weight to be lifted by each crane is carried to the boom nose the more important it becomes to
and attach slings at the correct points for proper weight simultaneously let out wire rope as the boom is lowered.
distribution. Keep load handling devices a minimum of 107 cm (42 in)
below the boom nose at all times.
9. Ensure the load lines are directly over the attach points
to avoid side loading and transfer of loading from one Two-blocking can be prevented. Operator awareness of the
crane to the other. hazards of two-blocking is the most important factor in
preventing this condition. An anti two-block system is
10. DO NOT TRAVEL. Lift only from a stationary position.
intended to assist the operator in preventing dangerous two- 2
block conditions. It is not a replacement for operator
LOAD MOMENT INDICATING (LMI) awareness and competence.
SYSTEMS
To avoid death or serious injury, keep load handling devices
Electronic equipment on this crane is intended as an aid to away from boom/jib tip when extending or lowering the boom
the operator. and when hoisting up.
Under NO CONDITION should it be relied upon to replace This crane should have a functional ANTI-TWO-BLOCK and
the use of capacity charts and operating instructions. Sole CONTROL LOCK-OUT system. Test daily for proper
reliance upon these electronic aids in place of good operation.
operating practices can cause an accident.
Do not pass loads or boom over ground personnel.
Know the weight of all loads and always check the capacity
Barricade the area where the crane is working and keep all
of the crane as shown on the Load Chart before making any
unnecessary personnel out of that area. DO NOT allow
lifts.
personnel to be under the load or boom.
NEVER exceed the rated capacity shown on the Load Chart.
Never pass loads, load handling devices, or the crane boom
Always check the Load Chart to ensure the load to be lifted
over people on the ground.
at the desired radius is within the rated capacity of the crane.
Never operate the crane with less than two wraps of wire
rope on the hoist drum.
For detailed information concerning the operation and
maintenance of the load moment indicating system installed
on the crane see the manufacturer’s manual supplied with
the crane. ELECTROCUTION HAZARD
Two-Blocking
Two-blocking occurs when the load block (hook block,
headache ball, rigging, etc.) comes into physical contact with
the boom (boom nose, sheaves, jib, etc.). Two-blocking can
cause hoist lines (wire rope) rigging, reeving, and other
components to become highly stressed and overloaded in
which case the wire rope may fail allowing the load, block,
etc. to free fall.
Two-blocking is more likely to occur when both the main and
auxiliary hoist lines are reeved over the main boom nose and
boom extension/jib nose respectively. An operator,
concentrating on the specific line being used, may telescope To avoid death or serious injury, keep all parts of this
or lower the boom allowing the other hoist line attachment to machine, the rigging, and materials being lifted at least 6 m
contact the boom or boom extension/jib nose, thus causing (20 ft) away from all electrical power lines and equipment.
damage to the sheaves, or causing the wire rope to fail,
Keep all personnel away from this machine if it is being
operated near electrical power lines or equipment.

Before operating this crane in the vicinity of electrical power Set-Up and Operation
lines or equipment, notify the power utility company. Obtain
positive and absolute assurance that the power has been During crane use, assume that every line is energized (“hot”
turned off. or “live”) and take the necessary precautions.
This machine is NOT INSULATED. Always consider all parts Set up the crane in a position such that the load, boom, or
of the load and the crane, including the wire rope, hoist any part of the crane and its attachments cannot be moved to
cable, pendant cables, and tag lines, as conductors. within 6 m (20 ft) of electrical power lines or equipment. This
includes the crane boom (fully extended to maximum height,
Most overhead power lines ARE NOT insulated. Treat all radius, and length) and all attachments (jibs, boom
overhead power lines as being energized unless you have extensions, rigging, loads, etc.). Overhead lines tend to blow
reliable information to the contrary from the utility company in the wind so allow for lines’ movement when determining
or owner. safe operating distance.
The rules in this handbook must be followed at all times, A suitable barricade should be erected to physically restrain
even if the electrical power lines or equipment have been de- the crane and all attachments (including the load) from
energized. entering into an unsafe distance from electrical power lines
Crane operation is dangerous when close to an energized or equipment.
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. Plan ahead and always plan a safe route before traveling
under power lines. Rider poles should be erected on each
Even if the crane operator is not affected by an electrical
side of a crossing to assure sufficient clearance is
contact, others in the area may become seriously injured or
maintained.
killed.
Appoint a reliable and qualified signal person, equipped with
It is not always necessary to contact a power line or power
a loud signal whistle or horn and voice communication
source to become electrocuted. Electricity, depending on
equipment, to warn the operator when any part of the crane
magnitude, can arc or jump to any part of the load, load line,
or load moves near a power source. This person should
or crane boom if it comes too close to an electrical power
have no other duties while the crane is working.
source. Low voltages can also be dangerous.
Tag lines should always be made of non-conductive
Thoroughly read, understand, and abide by all applicable
materials. Any tag line that is wet or dirty can conduct
federal, state, and local regulations.
electricity.
Federal law prohibits the use of cranes closer than 3 m (10 ft)
DO NOT store materials under power lines or close to
to power sources up to 50,000 volts and greater distances for
electrical power sources.
higher voltages [29CFR1910.180 and 29CFR1926.550].
Manitowoc/Grove recommends keeping cranes twice the
minimum distance [e.g., 6 m (20 ft)] as specified by US
Electrocution Hazard Devices
Department of Labor - Occupational Safety and Health The use of insulated links, insulated boom cages/guards,
Administration (OSHA) standards. 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 of the voltage and current present, and numerous other
limitations and you should follow the rules and precautions factors.
outlined in this handbook at all times even if the crane is
equipped with these devices. Electrical Contact
Insulating links installed into the load line afford limited If the crane should come in contact with an energized power
protection from electrocution hazards. Links are limited in source, you must:
their lifting abilities, insulating properties, and other
1. Stay in the crane cab. DON’T PANIC.
properties that affect their performance. Moisture, dust, dirt,
oils, and other contaminants can cause a link to conduct 2. Immediately warn personnel in the vicinity to stay away.
electricity. Due to their capacity ratings, some links are not
3. Attempt to move the crane away from the contacted
effective for large cranes and/or high voltages/currents.
power source using the crane’s controls which are likely
The only protection that may be afforded by an insulated link
is below the link (electrically downstream), provided the link
4.
to remain functional.
Stay in the crane until the power company has been
2
has been kept clean, free of contamination, has not been
contacted and the power source has been de-energized.
scratched or damaged, and is periodically tested (just before
NO ONE must attempt to come close to the crane or
use) for its dielectric integrity.
load until the power has been turned off.
Boom cages and boom guards afford limited protection from
Only as a last resort should an operator attempt to leave the
electrocution hazards. They are designed to cover only the
crane upon contacting a power source. If it is absolutely
boom nose and a small portion of the boom. Performance of
necessary to leave the operator station, JUMP
boom cages and boom guards is limited by their physical
COMPLETELY CLEAR OF THE CRANE. DO NOT STEP
size, insulating characteristics, and operating environment
OFF. Hop away with both feet together. DO NOT walk or run.
(e.g. dust, dirt, moisture, etc.). The insulating characteristics
of these devices can be compromised if not kept clean, free Following any contact with an energized electrical source,
of contamination, and undamaged. the local, authorized, Manitowoc/Grove distributor must be
immediately advised of the incident and consulted on
Proximity sensing and warning devices are available in
necessary inspections and repairs. Thoroughly inspect the
different types. Some use boom nose (localized) sensors
wire rope and all points of contact on the crane. Should the
and others use full boom length sensors. No warning may be
distributor not be immediately available, contact Manitowoc
given for components, cables, loads, and other attachments
CraneCARE. The crane must not be returned to service until
located outside of the sensing area. Much reliance is placed
it is thoroughly inspected for any evidence of damage and all
upon you, the operator, in selecting and properly setting the
damaged parts are repaired or replaced as authorized by
sensitivity of these devices.
Manitowoc/Grove CraneCARE or your local Manitowoc/
Never rely solely on a device to protect you and your fellow Grove distributor.
workers from danger.
Special Operating Conditions and
Some variables you must know and understand are:
Equipment
• Proximity devices are supposed to detect the existence
of electricity and not its quantity or magnitude. Never operate the crane during an electrical thunderstorm.
• Some proximity devices will detect only alternating Working in the vicinity of radio frequency transmission
current (AC) and not direct current (DC). towers and other transmission sources may cause a crane to
become “electrically charged.”
• Some proximity devices detect radio frequency (RF)
energy and others do not. When operating cranes equipped with electromagnets you
must take additional precautions. Permit no one to touch the
• Most proximity devices simply provide a signal (audible, magnet or load. Alert personnel by sounding a warning
visual, or both) for the operator and this signal must not signal when moving a load. Do not allow the cover of the
be ignored. electromagnet power supply to be open during operation or
• Sometimes the sensing portion of the proximity devices at any time the electrical system is activated. Shut down the
becomes confused by complex or differing arrays of crane completely and open the magnet controls switch prior
power lines and power sources. to connecting or disconnecting magnet leads. Use only a
non-conductive device when positioning a load. Lower the
DO NOT depend on grounding. Grounding of a crane affords magnet to the stowing area and shut off power before
little or no p rotec tion f rom elect ric al h aza rds. The leaving the operator’s cab.
effectiveness of grounding is limited by the size of the (wire)
conductor used, the condition of the ground, the magnitude

CRUSHING HAZARDS
All four outrigger beam lock pins must be engaged before

operating from the mid-extend position.
Death or serious injury could result from being crushed by
moving machinery. The operator must select the proper Load Chart and LMI
program for the outrigger position selected.
Clear all personnel from the counterweight and
superstructure area before removing the counterweight or Only the crane operator shall occupy the crane when
rotating the superstructure. traveling or in operation.
Barricade the entire area where the crane is working and

PERSONNEL HANDLING
keep all unnecessary personnel out of the work area.
The American Society of Mechanical Engineers issued a
Never allow anyone to stand or work on or near the
new American National Standard entitled, Personnel Lifting
superstructure while the crane is in operation.
Systems, ASME B30.23-1998. This standard provides,
Always barricade the tail-swing of the rotating "lifting and lowering of personnel using ASME B30 Standard
superstructure. hoisting equipment shall be undertaken only in
circumstances when it is not possible to accomplish the task
Before actuating swing or any other crane function, sound
by less hazardous means. Unless all of the applicable
the horn and verify that all personnel are clear of rotating and
requirements of this volume are met, the lifting or lowering of
moving parts.
personnel using ASME B30 Standard equipment is
Watch the path of the boom and load when swinging. Avoid prohibited." This new standard is consistent with the U.S.
lowering or swinging the boom and load into ground Department of Labor, Occupational Safety and Health
personnel, equipment, or other objects. Administration (OSHA) regulations for Construction that
state, in 29CFRI926.550(g)(2): "General requirements. The
Always be aware of your working environment during
use of a crane or derrick to hoist employees on a personnel
operation of the crane. Avoid contacting any part of the crane
platform is prohibited, except when the erection, use, and
with external objects.
dismantling of conventional means of reaching the worksite,
You must always be aware of everything around the crane such as a personnel hoist, ladder, stairway, aerial lift,
while lifting or traveling. If you are unable to clearly see in the elevating work platform or scaffold, would be more
direction of motion, you must post a look out or signal person hazardous or is not possible because of structural design or
before moving the crane or making a lift. Sound the horn to worksite conditions." Additional requirements for crane
warn personnel. o pe r a ti o ns ar e s ta te d i n A S M E B 3 0. 5 , M o b il e A nd
Locomotive Cranes, and in OSHA regulations
Clear all personnel from the outrigger area before extending 29CFRI910.180 for General Industry and 29CFRI926.550
or retracting the outriggers. for Construction.
Carefully follow the procedures in this handbook when Use of a Grove crane to handle personnel is acceptable
extending or retracting the outriggers. Death or serious injury provided:
could result from improper crane set up on outriggers. • The requirements of the applicable national, state and
Be sure the outriggers are properly extended, set and the local regulations and safety codes are met.
crane is level for operation on outriggers. • A determination has been made that use of a crane to
All four outrigger beams must be equally extended to the mid handle personnel is the least hazardous means to
position vertical stripe or fully extended position before perform the work.
beginning operation.

• The crane operator shall be qualified to operate the Lifting Systems, are available by mail from the ASME,
specific type of hoisting equipment used in the 22 Law Drive, Fairfield, New Jersey, 0700-2900
personnel lift.
• US DOL/OSHA Rules and Regulations are available by
• The crane operator and occupants have been instructed mail from the Superintendent of Documents, PO Box
in the recognized hazards of personnel platform lifts. 371954, Pittsburgh, PA, 15250-7954.
• The crane is in proper working order.
TRAVEL OPERATION
• The crane is equipped with a functional anti-two block
device. • Strictly adhere to the guidelines and restrictions in the
Load Chart for pick and carry operations.
• The crane's load capacity chart is affixed inside the
crane's cab, readily accessible to the operator. The total • Before travel, fully retract and lower the boom into the
boom rest and engage the turntable pin swing lock.
weight of the loaded personnel platform and related
rigging shall not exceed 50 percent of the rated capacity • Secure the hook block and other items before moving 2
for the radius and configuration of the crane. the crane.
• The crane is uniformly level within one percent of level • Follow the instructions in this handbook when preparing
grade and located on a firm footing. Cranes with the crane highway travel.
outriggers shall have them all fully deployed following
manufacturer's specifications. • If using for a boom dolly/trailer, thoroughly read and
understand all the steps and safety precautions in the
• The crane's Operator's And Safety Handbook and other handbook for setup and travel.
operating manuals are inside the crane's cab, readily
accessible to the operator. • Watch clearances when traveling. Do not take a chance
of running into overhead or side obstructions.
• The platform meets the requirements as prescribed by
applicable standards and regulations. • When moving in tight quarters, post a signal person to
help guard against collisions or bumping structures.
• For wire rope suspended platforms, the crane is
equipped with a hook that can be closed and locked, • Never back up without the aid of a signal person to verify
eliminating the throat opening. the area behind the crane is clear of obstructions and/or
personnel.
• The platform is properly attached and secure.
• Check load limit of bridges. Before traveling across
To avoid death or serious injury: bridges, ensure they will carry a load greater than the
NEVER use this crane for bungee jumping or any form of crane’s weight.
amusement or sport. • Always drive the crane carefully, obeying speed limits
NEVER permit anyone to ride loads, hooks, slings or other and highway regulations.
rigging for any reason. • Keep lights on, use traffic warning flags and signs, and
NEVER get on or off a moving crane. use front and rear flag vehicles when necessary. Check
state and local restrictions and regulations.
NEVER allow anyone other than the operator to be on this
crane while the machine is operating or traveling. • When parking on a grade, apply the parking brake and
chock the wheels.
Manitowoc CraneCARE continues to recommend that
cranes be properly maintained, regularly inspected and ACCIDENTS
repaired as necessary. Manitowoc CraneCARE reminds
crane owners to ensure that all safety decals are in place If this crane becomes involved in a property damage and/or
and legible. Manitowoc CraneCARE continues to urge Grove personal injury accident, immediately contact your local
crane owners to upgrade their cranes with load moment Manitowoc/Grove distributor. If the distributor is unknown
indicator (LMI) and control lever lockout systems for all lifting and/or cannot be reached, contact Product Safety and
operations. Reliability at:
The following standards and regulations are available by Manitowoc Crane Group
mail at the following addresses: 1565 East Buchanan Trail
Shady Grove, PA 17256-0021
• ASME (formerly ANSI) B30 Series American National
Safety Standards For Cableways, Cranes, Derricks, Phone: 888-777-3378 (888-PSR-DEPT)
Hoists, Hooks, Jacks, And Slings; ASME B30.5, Mobile Fax: 717-593-5102
And Locomotive Cranes, and ASME B30.23, Personnel E-mail: [email protected]

Provide a complete description of the accident, including the Any modification, alteration, or change to a crane which
crane model and serial number. affects its original design and is not authorized and approved
by Manitowoc CraneCare is STRICTLY PROHIBITED. Such
MAINTENANCE action invalidates all warranties and makes the owner/user
liable for any resultant accidents.
The crane must be inspected prior to use on each work shift.
The owner, user, and operator must ensure that routine Before performing any maintenance, service or repairs on
maintenance and lubrication are being dutifully performed. the crane:
NEVER operate a damaged or poorly maintained crane. • The boom should be fully retracted and lowered and the
Keep the crane properly maintained and adjusted at all load placed on the ground.
times. Shut down the crane while making repairs or • Stop the engine and disconnect the battery.
adjustments.
• Controls should be properly tagged. Never operate the
Always perform a function check after repairs have been crane if it is TAGGED-OUT nor attempt to do so until it is
made to ensure proper operation. Load tests should be restored to proper operating condition and all tags have
performed when structural or lifting members are involved. been removed by the person(s) who installed them.
Follow all applicable safety precautions in this handbook Recognize and avoid pinch-points while performing
when performing crane maintenance as well as crane maintenance. Stay clear of sheave wheels and holes in
operations. crane booms.
Before crane use: After maintenance or repairs:
• Conduct a visual inspection for cracked welds, damaged • Replace all guards and covers that have been removed.
components, loose pin/bolt, and wire connections. Any
item or component that is found to be loose or damaged • Remove all tags, connect the battery, and perform a
(broken, chipped, cracked, worn-through, etc.) must be function check of all operating controls.
repaired or replaced. • Perform load tests when a structural or lifting member is
• Check for proper functioning of all controls and operator involved in a repair.
aids (e.g. LMI).
Lubrication
• Check all braking (e.g. wheel, hoist, and swing brakes)
and holding devices before operation. The crane must be lubricated according to the factory
recommendations for lubrication points, time intervals, and
Keep the crane clean at all times, free of mud, dirt, and types. Lubricate at more frequent intervals when working
grease. Dirty equipment introduces hazards, wears-out under severe conditions.
faster, and makes proper maintenance difficult. Cleaning
solutions used should be non-flammable, non-toxic and Exercise care when servicing the hydraulic system of the
appropriate for the job. crane, as pressurized hydraulic oil can cause serious injury.
The following precautions must be taken when servicing the
ROUTINE MAINTENANCE and INSPECTION of this crane hydraulic system:
must be performed by a qualified person(s) according to the
recommendations in the Grove Maintenance and Inspection 1. Follow the manufacturer’s recommendations when
Manual. Any questions regarding procedures and adding oil to the system. Mixing the wrong fluids could
specifications should be directed to the your local, destroy seals, causing machine failure.
authorized Grove Distributor. 2. Be certain all lines, components, and fittings are tight
before resuming operation.
Service and Repair
3. When checking for suspected leaks, use a piece of
Service and repairs to the crane must only be performed by a wood or cardboard and wear appropriate personal
qualified person. All service and repairs must be performed protective equipment.
in accordance with manufacturer’s recommendations, this
handbook, and the service manual for this machine. All 4. Never exceed the manufacturer’s recommended relief
replacement parts must be approved by Manitowoc valve settings.
CraneCARE.

TIRES When installing and inspecting wire ropes and attachments,

keep all parts of your body and clothing away from rotating
Inspect the tires for nicks, cuts, embedded material, and hoist drums and all rotating sheaves.
abnormal wear.
Never handle the wire rope with bare hands.
Ensure all lug nuts are properly torqued.
Periodic rope inspection records are required by law. Make
Ensure pneumatic tires are inflated to the proper pressure. sure these records have been reviewed and are up to date.
When inflating tires, use a tire gauge, clip-on inflator, and
When installing a new rope:
extension hose which will permit standing clear of the tire
while inflating. • Follow proper instructions for removing rope from a reel.
• Apply back tension to the storage/payoff reel of the new
Wire Rope
rope to insure tight, even spooling onto the hoist drum.
U s e O N LY t h e w i r e r o p e s p e c i f i e d b y M a n i t o w o c
CraneCARE as indicated on the crane’s load capacity chart.
• Operate the new rope - first through several cycles at 2
light load and then through several cycles at
Substitution of an alternate wire rope may require the use of
intermediate load to allow the rope to adjust to operating
a different permissible line pull and, therefore, require
conditions.
different reeving.
When using a wedge socket:
NOTE: Wire rope may be purchased by contacting the
Manitowoc CraneCARE Parts Department. • Always inspect socket, wedge, and pin for correct size
and condition.
Always make daily inspections of the wire rope, keeping in
mind that all wire rope will eventually deteriorate to a point • Do not use parts that are damaged, cracked, or
where it is no longer usable. Wire rope shall be taken out of modified.
service when any of the following conditions exist:
• Assemble the wedge socket with live end of rope aligned
1. For rotation-resistant running ropes-more than two (2) with the centerline of pin and assure proper length of tail
broken wires in a length of rope equal to six (6) times the (dead end) protrudes beyond the socket.
rope diameter, or more than four (4) broken wires in a
Never overload or shock load a wire rope. Lubricate the wire
length of rope equal to thirty (30) times the rope
rope periodically as the lubricant becomes depleted.
diameter.
2. For running ropes other than rotation resistant-six (6)
broken wires in one rope lay or three (3) broken wires in
one strand.
3. One valley break where the wire fractures between
strands in a running rope is cause for removal.
4. Abrasion of the rope resulting in wear of the individual
outside wires of 1/3 of the original wire diameter.
5. Any kinking, bird caging, crushing, corrosion, or other
damage resulting in distortion of the rope structure.
6. Rope that has been in contact with a live power line or Inspect the boom nose and hook block sheaves for wear.
has been used as a ground in an electric circuit (e. g. Damaged sheaves cause rapid deterioration of wire rope.
welding) may have wires that are fused or annealed and
must be removed from service. To attain maximum wire rope life and minimize hook block
rotation, it is recommended that even numbers of parts-of-
7. In standing ropes, more than three (3) breaks in one line be used in multiple-part reeving whenever possible.
rope lay in sections beyond the end connection or more
than two (2) broken wires at an end connection. If applicable to your crane, the use of nylon (nylatron)
sheaves, as compared with metallic sheaves, may change
8. Core deterioration is usually observed as a rapid the replacement criteria of rotation- resistant wire rope.
reduction in rope diameter and is cause for immediate
removal of the rope. NOTE: If applicable to your crane, the use of cast nylon
(nylatron) sheaves, as compared with steel
Refuse to work with worn or damaged wire rope. sheaves, will substantially increase the service life
o f w i r e r o p e . H o w e v e r, c o n v e n t i o n a l r o p e
retirement criteria based only upon visible wire

breaks may prove inadequate in predicting rope Never exit or enter the crane cab or deck by any other means
failure. The user of cast nylon sheaves is therefore than the access system(s) provided (i.e., steps and grab
cautioned that a retirement criteria should be handles).
established based upon the user’s experience and
If necessary, use a ladder or aerial work platform to access
the demands of his application.
the boom nose.
BATTERIES Do not step on surfaces on the crane that are not approved
or suitable for walking and working. All walking and working
Battery electrolyte must not be allowed to contact the skin or surfaces on the crane should be clean, dry, slip-resistant,
eyes. If this occurs, flush the contacted area with water and and have adequate supporting capacity. Do not walk on a
consult a doctor immediately. surface if slip-resistant material is missing or excessively
When checking and maintaining batteries exercise the worn.
following procedures and precautions: Do not use the top of the boom as a walkway.
• Disconnect the batteries. Do not step on the outrigger beams or outrigger pads (floats)
• Wear safety glasses when servicing batteries. to enter or exit the crane.
• Do not short across the battery posts to check charge. Wear shoes with a highly slip-resistant sole material. Clean
Short circuit, spark, or flame could cause battery any mud or debris from shoes before entering the crane cab
explosion. or climbing onto the crane superstructure. Excessive dirt and
debris on the hand-holds, access steps, or walking/working
• Maintain battery electrolyte at the proper level. Check surfaces could cause a slipping accident. A shoe that is not
the electrolyte with a flashlight. clean might slip off a control pedal during operation.
• If applicable to your crane, check battery test indicator Do not make modifications or additions to the crane’s access
on maintenance-free batteries. system that have not been evaluated and approved by
• Do not break a live circuit at the battery terminal. Manitowoc CraneCARE.
Disconnect the ground battery cable first when removing
a battery and connect it last when installing a battery. Job Preparation
• Check battery condition only with proper test equipment. You must inspect the crane prior to your work shift - checking
Batteries shall not be charged except in an open, well- for cracked welds, damaged components, and evidence of
ventilated area that is free of flame, smoking, sparks, improper maintenance (consult Maintenance-Inspection and
and fire. Service Manual).
You must ensure that the crane is properly equipped
ENGINE including access steps, covers, doors, guards, and controls.
Be careful when checking the engine coolant level. The fluid You must ensure that the outriggers are properly extended
may be hot and under pressure. Shut down the engine and and set before performing any lifting operations. On models
allow the radiator time to cool before removing the radiator equipped with outriggers that can be pinned at the mid-
cap. extend position, the outriggers must also be pinned when
Shut down the engine and disconnect the battery before
performing maintenance. If unable to do so for the task Wear appropriate clothing and personal protective
required, keep hands clear of the engine fan and other e q ui p m e n t w h e t h e r o r n o t r e q u i r e d b y l oc a l o r j o b
moving parts while performing maintenance. regulations. Be prepared for the work day.
Be careful of hot surfaces and hot fluids when performing Before entering the cab, you must be THOROUGHLY
maintenance on or around the engine. familiar with the planned route of travel and area of
operation, including surface conditions and the presence of
WORK PRACTICES overhead obstructions and power lines.
Always keep the crane clean, free of dirt, debris, and grease.
Crane Access
Fuel the crane ONLY with the engine turned off. Do not
You must take every precaution to ensure you do not slip smoke while fueling the crane. Do not store flammable
and/or fall off the crane. Falling from any elevation could materials on the crane or in the operator’s cab.
result in serious injury or death.
Follow standard safety precautions when refueling. FUEL IT
SAFELY.

Be familiar with the location and use of the nearest fire LIFT ONE LOAD AT A TIME. Do not lift two or more
extinguisher. separately rigged loads at one time, even if the loads are
within the crane’s rated capacity.
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.
Working
Never operate the crane when darkness, fog, or other
visibility restrictions make operation unsafe. Never operate a
crane in thunderstorms or high winds.
Keep unauthorized personnel clear of the working area
during operation. 2
Operate the crane only from the operator’s seat. Do not
reach in a window or door to operate any controls.
Operate the crane slowly and cautiously, looking carefully in
the direction of movement.
“Stunt” driving and “horse-play” are strictly prohibited. Never
allow anyone to hitch a ride or get on or off a moving crane.
A good practice is to make a “dry run” without a load before
making the first lift. Become familiar with all factors peculiar
to the job site.
Ensure the wire rope is properly routed on the hook block
and boom nose and that all rope guards are in place.
USE ENOUGH PARTS OF LINE FOR ALL LIFTS AND
CHECK ALL LINES, SLINGS, AND CHAINS FOR Never leave the crane with a load suspended. Should it
CORRECT ATTACHMENT. To obtain maximum lifting become necessary to leave the crane, lower the load to the
capacities, the hook block must be set up with enough parts ground and stop the engine before leaving the cab.
of line. NO LESS THAN TWO WRAPS of wire rope should
remain on the hoist drum. When slings, ties, hooks, etc., are Remember - all rigging equipment must be considered as
used, make certain they are correctly positioned and part of the load. Lifting capacities vary with working areas.
secured before raising or lowering the loads. Permissible working areas are posted in the crane cab.
When swinging from one working area to another, ensure
Be sure the rigging is adequate before lifting. Use tag lines load chart capacities are not exceeded. Know your crane!
when possible to position and restrain loads. Personnel
using tag lines should be on the ground. Never swing or lower the boom into the carrier cab.
Be sure good rigging practices are being used. Refuse to Stop the hook block from swinging when unhooking a load.
use any poorly maintained or damaged equipment. Never Swinging rapidly can cause the load to swing out and
wrap the hoist cable around a load. increase the load radius. Swing the load slowly. Swing with
caution and keep the load lines vertical.
Lifting
Look before swinging your crane. Even though the original
Operate the crane at or near governed RPM during all lifting setup may have been checked, situations do change.
operations.
Keep everyone away from suspended loads. Allow no one to
Check the hoist brake by raising the load a few inches, walk under a load. Ensure that all slings, ties, and hooks are
stopping the hoist and holding the load. Be sure the hoist correctly placed and secured before raising or lowering the
brake is working correctly before continuing the lift. load.
When lowering a load always slow down the load’s descent Use tag lines (as appropriate) for positioning and restraining
before stopping the hoist. Do not attempt to change speeds loads. Check the load slings before lifting.
on multiple-speed hoists while the hoist is in motion.
Be sure everyone is clear of the crane and work area before
making any lifts.

Never swing over personnel, regardless of whether load is At all times use standardized hand signals - previously
suspended from or attached to the boom. agreed upon and completely understood by the operator and
signal person.
Be sure the load is well secured and attached to the hook
with rigging of proper size and in good condition. If communication with the signal person is lost, crane
movement must be stopped until communications are
Use only slings or other rigging devices rated for the job and
restored.
use them properly. Never wrap the hoist cable around a load.
Keep your attention focused on the crane’s operation. If for
Check all tackle, hardware, and slings before use. Refuse to
some reason you must look in another direction, stop all
use faulty equipment.
crane movement first.
Never work the crane when darkness, fog, or other visibility
When vision is obscured, use and follow the directions of a
restrictions make such operations unsafe.
single qualified signal person.
Hand Signals Obey a signal to stop from anyone.
TRANSPORTING THE CRANE

When loading or unloading the crane on a trailer or railroad
car, use a ramp capable of supporting the weight of the
crane.
Ensure the crane is adequately secured to the transporting
vehicle.
If it is necessary to take the crane on a road or highway, first
check state and local restrictions and regulations.
Check load limits of bridges on the travel route and ensure
they are greater than the combined weight of the crane and
transporting vehicle.
Always drive the crane carefully, obeying speed limits and
highway regulations. Keep lights on and use traffic warning
flags and signs and front and rear flag vehicles as applicable.
SHUT-DOWN
Never leave the crane with a load suspended. Lower the
load to the ground before shutting down the crane.
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.
A qualified signal person shall be used at all times when: • Place controls in neutral position.
• Working in the vicinity of power lines. • Shut down the engine and remove the ignition key.
• The crane operator cannot clearly see the load at all • Chock the wheels.
times.
• Lock the operator’s cab and install vandal guards, if
• Moving the crane in an area or direction in which the used.
operator cannot clearly see the path of travel.
In cold weather, never park the crane where the tires can
become frozen to the ground.

BOOM EXTENSION/JIB engine be started from the carrier cab with the pump
disconnected.
Don’t touch metal surfaces that could freeze you to them.
Clean the crane of all ice and snow.
Allow ample time for hydraulic oil to warm up.
In freezing weather, park the crane in an area where it
cannot become frozen to the ground. 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 2
according to the supplier’s instructions.
Never store flammable materials on the crane.
If cold weather starting aids are provided on your crane, use
them. The use of aerosol spray or other types of starting
fluids containing ether/volatiles can cause explosions or fire.
TEMPERATURE EFFECTS ON HYDRAULIC

CYLINDERS
To avoid death or serious injury, follow proper procedures
during erection, stowage, and use of the boom extension/jib. Hydraulic oil expands when heated and contracts when
cooled. This is a natural phenomena that happens to all
Install and secure all pins properly. liquids. The coefficient of expansion for API Group 1
Control movement of boom extension/jib at all times. hydraulic oil is approximately 0.00043 cubic inches per cubic
inch of volume for 1°F of temperature change. Thermal
Do not remove right side boom nose pins unless boom contraction will allow a cylinder to retract as the
extension is properly pinned and secured on front and/or hydraulic fluid which is trapped in the cylinder cools.
rear stowage brackets. The change in the length of a cylinder is proportional to the
Do not remove all the pins from both front and rear stowage extended length of the cylinder and to the change in
brackets unless the boom extension is pinned to the right temperature of the oil in the cylinder. For example, a cylinder
side of the boom nose. extended 25 feet in which the oil cools 60°F would retract
approximately 7 3/4 inches (see chart below). A cylinder
See the appropriate section of this handbook for the proper extended 5 feet in which the oil cools 60°F would only retract
boom extension/jib erection and stowage procedure. approximately 1 1/2 inches. The rate at which the oil cools
depends on many factors and will be more noticeable with a
Properly inspect, maintain, and adjust boom extension/jib
larger difference in oil temperature verses the ambient
and mounting.
temperature.
Sling jib sections from the main chords or the end fittings.
Thermal contraction coupled with improper lubrication or
When assembling and disassembling jib sections, use improper wear pad adjustments may, under certain
blocking to adequately support each section and to provide conditions, cause a “stick-slip” condition in the boom. This
proper alignment. “stick-slip” condition could result in the load not moving
smoothly. Proper boom lubrication and wear pad adjustment
Stay outside of jib sections and lattice work.
is important to permit the boom sections to slide freely. Slow
Watch for falling or flying pins when they are being removed. movement, of the boom may be undetected by the operator
unless a load is suspended for a long period of time.
COLD WEATHER OPERATION If a load and the boom is allowed to remain stationary for a
Cold weather operation requires additional caution on the period of time and the ambient temperature is cooler than the
part of the operator. trapped oil temperature, the trapped oil in the cylinders will
cool. The load will lower as the telescope cylinder(s) retracts
Check operating procedures for cold weather starting. allowing the boom to come in. Also, the boom angle will
During cold weather operation, it is recommended that a cold

decrease as the lift cylinder(s) retracts causing an increase chart is for dry rod cylinders. If the cylinder rod is filled with
in radius and a decrease in load height. hydraulic oil, the contraction rate is somewhat greater.
This situation will also occur in reverse. If a crane is set up in NOTE: Operators and service personnel must be aware
the mornin g wit h cool oil a nd the da ytime ambient that load movement, as a result of this phenomena,
temperature heats the oil, the cylinders will extend in similar can be easily mistaken as leaking cylinder seals or
proportions. faulty holding valves. If leaking seals or faulty
holding valves are suspected to be the problem,
Table 2-2 has been prepared to assist you in determining the
refer to Service Bulletin 98-036 dealing with testing
approximate amount of retraction/extension that may be
telescope cylinders
expected from a hydraulic cylinder as a result of change in
the temperature of the hydraulic oil inside the cylinder. The
Table 2-2: BOOM DRIFT CHART (Cylinder length change in inches)
3 3
Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74
20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96
3 3
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in /in / °F) X 12 in/ft

SECTION 3
OPERATING CONTROLS AND PROCEDURES
TABLE OF CONTENTS
Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Stop/Module Off Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Warning/Electrical System Diagnostic Indicator . . . . . . . . . . . . . . . . . . 3-1
Engine Coolant Temperature Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine Brake On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine Brake High/Low Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Travel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Dual Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Low Air Pressure/Tire Inflation On Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3
Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Park Brake Engaged Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Cross-Axle Differential Locked Indicator (Optional) . . . . . . . . . . . . . . . . . . . . . 3-3
Cross-Axle Differential Lock Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inter-Axle Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inter-Axle DIfferential Lock Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Transmission Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Trailing Boom Trailer Emergency Brake Control (Optional) . . . . . . . . . . . . . . . 3-3
Swing Brake Engaged Indicator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Suspension Inflation Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Suspension Deflated Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Craning Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Park Brake Engaged/Swing Brake Engaged Indicator . . . . . . . . . . . . . . . . . . . 3-6
Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
High Beam/Lamp Malfunction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Heater On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Heater /Air Conditioner Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Air Conditioner Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Windshield Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Headlights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Beacon Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Headlights Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
GROVE 3-i
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cab Circulating Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Tire Inflation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
12 VDC Accessory Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cab Dome Light (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Air Horn (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Fuse and Relay Panel (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Carrier Electrical Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Additional Carrier Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Outrigger Control Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Outrigger Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Outrigger Beam Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Extend/Retract Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Center Front Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Stabilizer Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Daytime Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Superstructure Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Increment/Decrement Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Stop/Module Off Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Warning/Electrical System Diagnostic Indicator . . . . . . . . . . . . . . . . 3-11
Foot Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Craning Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Telescope/Auxiliary Hoist/Swing Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Boom Lift/Main Hoist Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Swing Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Telescope Control Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Main Hoist Speed Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Auxiliary Hoist Speed Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Hoist Rotation Indicators (Main and Auxiliary Hoist) . . . . . . . . . . . . . . . . . . . 3-11
Crane Function Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Outrigger Extend/Retract Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Center Front Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Left Front Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Right Front Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Left Rear Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Right Rear Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Center Front Stabilizer Overloaded Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Bubble Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Swing Brake Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Swing Lock Control (Pin Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
360° Swing Lock Control (Positive Lock Type) (Optional) . . . . . . . . . . . . . . . 3-13
Swing Brake Engaged Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Swing Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Cab Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Jib Stowage Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-ii
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES
Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Boom Lights Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Cab Circulating Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Windshield Wiper/Washer Switch and Motor . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Skylight Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Heater On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Heater /Air Conditioner Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Air Conditioner Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Beacon Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Crane’s Electrical System Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . 3-18
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Breaking In A New Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Pre-Starting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Hydraulic Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Hook Block and Headache Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 3
Seats and Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Signal and Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Service and Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Operation Below -40°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Operation Below -40°F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Idling The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Racing The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
General Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Control Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Preload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Using Your Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Crane Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Setting The Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Stowing The Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Setting The Center Front Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Stowing The Center Front Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Swinging The Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Elevating And Lowering The Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Telescoping The Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Lowering And Raising The Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Load Moment Indicator (LMI) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
GROVE 3-iii
Control Lever Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Crane Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Active Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Traveling - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Traveling With Boom Extension And/Or Inserts Erected . . . . . . . . . . . . . . . . 3-31
Manual Transmission and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Crane Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Rear Tandem Inter-Axle/Cross-Axle Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Service/Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Crane Shutdown Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-iv
SECTION 3
OPERATING CONTROLS AND PROCEDURES
The crane is equipped with two cabs, a carrier cab and a Water Temperature Gauge
superstructure cab. The carrier cab (see Figure 3-1) contains
The engine coolant temperature (TEMP) gauge is located on
all controls and indicators necessary for crane traveling and
the lower left of the gauge cluster. The gauge indicates the
parking. The superstructure cab (see Figure 3-3) contains all
engine coolant temperature on a scale calibrated from 100 to
controls and indicators necessary to perform all craning
240° F. The gauge receives a signal from the crane’s
operations. Both cabs utilize international symbols and
electronic operating system which receives the signal from
English text to label the various controls. For detailed
the engine ECM via J1939.
information on either cab, refer to either CARRIER CAB or
SUPERSTRUCTURE CAB in this Section. Fuel Quantity Gauge
NOTE: The following paragraphs describe all the available The fuel quantity (FUEL) gauge is located on the upper left of
(standard and optional) controls and indicators the gauge cluster. The gauge indicates the quantity of fuel in
located in the cab. Some machines may not be the tank and has a scale calibrated from empty (E) to full (F).
equipped with the optional controls shown. The The fuel quantity gauge receives a signal from the crane’s
numbers in ( ) represent the index number from electronic operating system which monitors a sending unit in
(Figures 3-1 through 3-3). the fuel tank.
NOTE: All rocker switches contain one or two LED’s in the Engine Stop/Module Off Line Indicator
switch for illumination.
The engine stop/module off line indicator (23) is located on
NOTE: All indicators on the top row of the consoles will the top left side of the front console. The top portion of the
illuminate solid, all at the same time for
approximately two seconds as a diagnostic test
switch is the stop indicator. It illuminates red when energized 3
by a signal from the engine ECM that signifies a serious
when the ignition switch is positioned to on. If any engine problem that requires the vehicle and the engine to
indicator fails to illuminate, replace it immediately. be stopped as soon as safely possible. In addition, a warning
buzzer will also sound.
CARRIER CAB
The bottom portion is the module off line indicator. This
Engine Controls and Indicators indicator will come on solid and a buzzer will sound
whenever communication with one of the crane’s electronics
Gauge Cluster modules is lost. The vehicle should be stopped as soon as
safely possible. The crane must be restored to proper
The gauge cluster (5) is located in the center of the front condition before operating again.
console assembly and contains a voltmeter, oil pressure
gauge, water temperature gauge, and a fuel quantity gauge. Engine Warning/Electrical System Diagnostic
Indicator
Voltmeter
The engine warning/electrical system diagnostic indicator
The voltmeter (VOLTS) is located on the lower right of the (24) is located at the top left side of the front console. The top
gauge cluster. With the ignition switch in the run (between portion is the warning indicator. It illuminates amber when
vertical and far right) position and before starting the engine, energized by a signal from the engine ECM that signals the
the voltmeter indicates the condition of the batteries. With operator of an engine problem which must be corrected.
the engine running, the voltmeter indicates output voltage of
the alternator. The voltmeter scale is from 10 to 16 volts. The bottom portion of the switch is the electrical system
diagnostic indicator. There are three conditions for this
Engine Oil Pressure Gauge indicator as follows:
The engine oil pressure (OIL) gauge is located on the upper a. On solid with buzzer sounding - There is an
right of the gauge cluster. The gauge indicates the engine oil interruption of communication over the main canbus
pressure on a scale calibrated from zero (0) to 80 psi. It control line between the crane’s electronic control
receives a signal from the crane’s electronic operating modules. Proper crane operating condition shall be
system which receives the signal from the engine ECM via restored as quickly as possible.
J1939.
b. Flashing with buzzer sounding - An undesirable
condition with the crane’s joysticks has been
detected. Proper crane operating condition shall be
restored before performing any hydraulic function.

c. Flashing without buzzer - An undesirable operating system which sends the information to the engine
component or electrical system condition has ECM via J1939.
occurred.
Engine Idle Switch
Engine Coolant Temperature Indicator This switch (35) is a two position (+/-) momentary rocker
The engine coolant temperature indicator (25) is located at switch on the left side of the front console. It provides idle-
the top left side of the front console. It illuminates amber to control inputs that increase and decrease the engine idle.
indicate high engine coolant temperature.
Travel Controls and Indicators
Tachometer
Dual Air Pressure Gauge
The tachometer (2) is located on the right side of the front
console. The tachometer is calibrated in RPM x 100 with a The dual air pressure gauge (1) is located on the right side of
range of zero (0) to 35. It receives a signal from the crane’s the front console. The gauge is a direct reading pressure
electronic operating system which receives the signal from gauge with two indicating pointers, red for the primary
the engine ECM via J1939. system and green for the secondary system. The gauge has
a dual scale calibrated from 100 to 1000 kPa and 0 to
Engine Brake On/Off Switch 150 psi. The gauge is connected to each air system
separately through tubing.
The engine brake on/off switch is located on the left center
side of the front console. The two position (on/off) switch (22) Low Air Pressure/Tire Inflation On Indicator
energizes the engine brake. When the top of the switch is
pushed, the switch is in the on position. The low air pressure/tire inflation on indicator (27) is located
on the top left side of the front console. The indicator
Engine Brake High/Low Switch illuminates red when the pressure in either or both air
systems is below 517 kPa (75 psi). The indicator is controlled
The two position engine brake high/low switch (20) controls
by two pressure switches electrically connected in parallel.
the amount of engine braking.
To determine which system pressure is low, observe the dual
When the top of the switch is pushed, the switch is in the high air pressure gauge. In addition to illuminating the indicator, a
position. warning buzzer will sound.
Ignition Switch The bottom of the indicator illuminates amber when the
pressure switch in the tire inflation system is activated. In
The ignition switch (14) is located on the right side of the addition to illuminating the indicator, a warning buzzer will
front console. The switch is key operated with four positions: sound.
accessory (left position), off (vertical position), run (position
between vertical and right), and start (right position). Speedometer
With ignition switches in both cabs in the off position, all The speedometer (4) is located in the center of the front
electrical power is off except for the headlights, marker lights, console above the steering wheel. The speedometer
gauge lights, turn and stop light, carrier and superstructure indicates road speed in both km/h (kilometers per hour) and
cab dome lights, carrier and superstructure cab 12V mph (miles per hour).
accessory outlets, superstructure cab work lights, and
superstructure horn. Odometer
The accessory position energizes all electrical components There is an odometer (16) located at the bottom of the
except the engine ECM. The run position is the same as speedometer and shows total distance traveled.
accessory except the engine ECM is energized. The start
Parking Brake Control
position energizes the starter relay which in turn energizes
the cranking motor solenoid and cranks the engine for NOTE: The park brake must be set before the outrigger
starting. The switch will return to run when the switch is controls will operate.
released after the engine is started. Turn the switch to off to
The parking brake control (12) is located on the right side of
shut down the engine.
the front console. The control is a push-pull type air valve
Throttle Pedal used to apply and release the parking brakes on all four rear
wheels.
The THROTTLE pedal (38) is the right most pedal on the cab
floor. It is used to control engine speed. The foot pedal Park Brake Engaged Indicator
modulates engine speed proportionately to the foot pressure
The park brake engaged indicator (29) is located at the top of
applied. The pedal is angled for increased operator comfort.
the front console. The indicator illuminates red when the
The foot pedal is monitored by the crane’s electronic

crane parking brakes are applied. It is illuminated by a Brake Pedal

pressure switch on the parking brake valve.
The brake pedal (37) is located on the cab floor, to the left of
The bottom of the indicator illuminates red to warn the the foot throttle, and is used to apply the service brakes.
operator that the swing brake release pressure is not enough
to hold the swing brake disengaged during trailing boom Clutch Pedal
operation. In addition to illuminating the indicator, a warning The clutch pedal (59) is located on the cab floor, to the left of
buzzer will sound. the brake pedal, and is used to apply the clutch. Refer to
OPERATING PROCEDURES in this section for complete
Cross-Axle Differential Locked Indicator (Optional)
clutch and transmission operating instructions.
The cross-axle differential locked indicator (26) is located at
the left center side of the front console. The amber indicator Transmission Shift Lever
illuminates to show that the cross axle differential is locked. The transmission shift lever (40) is located on the right side
of the cab. It is used to select the transmission gears. Refer
to OPERATING PROCEDURES in this section for complete
CAUTION clutch and transmission operating instructions.
Do not operate the cross axle differential lock or the inter-
axle differential lock on dry roads. Trailing Boom Trailer Emergency Brake Control
(Optional)
Cross-Axle Differential Lock Switch (Optional) The trailing boom (trailer emergency) brake control (11) is a
The cross-axle differential lock switch (17) is located on the push-pull type air valve located on the right side of the front
left center side of the front console and is used to lock the console. The control is used to set and release the brakes on
the trailing boom trailer.
right and left wheels in a tandem set. The cross-axle
differential lock increases traction on slippery roads. It is a
Swing Brake Engaged Indicator (Optional)
3
two position lock/unlock switch. Press top of switch for the
lock position or bottom of switch for the unlock position. swing brake engaged indicator (29) is located on the top left
side of the front console. The indicator illuminates when
there is sufficient pressure to hold the swing brake
CAUTION disengaged during trailing boom operation. In addition to
Do not operate cross-axle differential lock while crane illuminating the indicator, a warning buzzer will sound.
wheels are spinning or at speeds over approximately 16 Suspension Inflation Control Switch
km/h (10 mph). Release the throttle when locking or
unlocking. The suspension inflation control switch (34) is located on the
right side console. When positioned to the right to inflate, the
Inter-Axle Differential Lock Switch suspension air bags are inflated. When positioned to the left
to deflate, the suspension air bags are deflated.
The inter-axle differential lock switch (15) is located on the
left center side of the front console. In the lock (press top of NOTE: The suspension air bags should be inflated at all
switch) position, both rear axles are locked together and times except when on outriggers or in a pick and
turning at the same speed. In the unlocked (press bottom of carry mode.
switch) position, the axles operate independently of each
Suspension Deflated Indicator
other.
The SUSPENSION DEFLATED indicator (33) is located on
Inter-Axle DIfferential Lock Indicator the right side console. The amber indicator illuminates when
The inter-axle differential lock indicator (32) is located on the the air is removed from the suspension air bags. It is
left center side of the front console. The amber indicator controlled by four pressure switches connected in series.
illuminates when the inter-axle differential lock is engaged.

53 51
53
See View A
39
50
37
49
38
59
56
40
55
47
34
46
33
See View B
45
18
48
10
41
8
43
7
42
54
52
7000
9
6560
View B
FIGURE 3-1

23 24 58 29 28 3 2 1 11
25 5 6
27 4
12
22
35
20 36 15 32 26
17
35 16
16
15
32 26
17
21
31 19 14 6833
View A 13
FIGURE 3-1 continued 3

1 Dual Air Pressure Gauge 20 Engine Brake High-Low Switch
2 Tachometer 21 Headlights Switch
3 Left Turn Signal Indicator 22 Engine Brake On/Off Switch
4 Speedometer 23 Engine Stop/Module Off Line Indicator
5 Gauge Cluster (fuel, temperature, oil, volts) 24 Engine Warning/Electrical Diagnostic Indicator
6 Right Turn Signal Indicator 25 Engine Coolant Temperature Indicator
7 Heater On/Off Switch Cross-Axle Differential Locked Indicator
26
(Optional)
8 Heater/Air Conditioner Fan Switch
27 Low Air Pressure/Tire Inflation On Indicator
9 12 Volt Accessory Outlet
28 High Beam/Lamp Malfunction Indicator
10 Air Conditioner Switch (Optional)
Park Brake Engaged/Swing Brake Engaged
Trailing Boom Trailer Emergency Brake Control 29
11 Indicator (swing brake may be optional)
(Optional)
30 Not Applicable
12 Parking Brake Control
31 Dimmer Switch
13 Windshield Wiper/Washer Switch
32 Inter-Axle Differential Lock Indicator
14 Ignition Switch
33 Suspension Deflated Indicator
15 Inter-Axle Differential Lock Switch
34 Suspension Inflation Control Switch
16 Odometer
35 Engine Idle Switch
17 Cross-Axle Differential Lock Switch (Optional)
36 Not Applicable
18 Tire Inflation Switch
19 Beacon Light Switch (Optional)

The swing brake engaged indicator (bottom of the indicator)

illuminates red to warn the operator that the swing brake
Item Description
release pressure is not enough to hold the swing brake
37 Brake Pedal disengaged during trailing boom operation. In addition,
38 Throttle Pedal illuminating the indicator, a warning buzzer will sound.
(Optional)
39 Carrier Electrical Diagnostic Connector
40 Transmission Shift Lever Accessory Controls and Indicators
41 Ash Tray High Beam/Lamp Malfunction Indicator
42 Beacon Light (Optional) The headlight high beam/lamp malfunction indicator (28) is
43 Fire Extinguisher located at the top left of the center front console. The
indicator is a blue light that illuminates when the headlights
44 Cab Dome Light (Not Shown) are on high beam or amber when there is a lamp
45 Steering Wheel malfunction.
46 Horn Button Heater On/Off Switch
Headlight Dimmer/Turn Signal Lever/Cruise The heater on/off switch (7) is located on the right side
47
Control console. Press the right side of the switch to ON for heat.
48 Seat Press the left side of the switch to turn the heater off.
49 Sun Visor Heater Control Switch
50 Cab Circulating Fan The heater control switch (52) is located on the right side
51 Windshield Defroster Air Outlet console. Push the switch to the right to (OPEN) the valve for
heat. Push the switch to the left to (CLOSE) the valve.
52 Heater Control Switch
53 Cab Marker Lights Heater /Air Conditioner Fan Switch
54 Fuse and Relay Panel (Not Shown) The heater/air conditioner fan switch (8) is located on the
right side console. The switch controls the speed which in
55 Hazard Light Switch turn regulates the volume of heated air output of the heater
56 Steering Column Tilt/Telescope Lever and air conditioner fan by positioning switch to: low (switch
positioned to left), medium (switch centered), and high
57 Not Applicable
(switch positioned to right).
58 Not Applicable
NOTE: Either air condition or heater switch must be
59 Not Applicable positioned to “on” before the fan will become
60 Jib Stowage Controller operational.
Air Conditioner Switch (Optional)
CAUTION The air conditioning switch (10) is located on the right side
Do not operate inter-axle differential lock switch while console. The switch controls the operation of the optional air
crane wheels are spinning or at speeds over conditioning system in conjunction with the fan switch. Press
approximately 16 km/h (10 mph). Release the throttle the switch to the right to turn air conditioner on. Press the
when locking or unlocking. switch to the left to turn the air conditioner off.
Windshield Wiper/Washer Switch

Craning Controls and Indicators
The windshield wiper/washer toggle switch (13) is located on
Park Brake Engaged/Swing Brake Engaged Indicator the lower right side of the front console. The switch is used
for removing moisture from the windshield.The switch has an
The park brake engaged indicator (29) is located at the top of off and high position with six intermittent positions between
the front console. The top of the indicator illuminates red high and off. Pushing the switch up from the off position
when the crane parking brakes are applied. Illumination is energizes the wiper motor. Continue to push switch up for
determined by a pressure switch on the parking brake valve. each intermittent position and the high position. Push the
The park brake must be set before the outrigger controls will switch down to off to stop the motor and return the wiper
operate. blade to the parked position.

Push the very top of the switch to activate the washer switch Left Turn Signal Indicator
to spray washer fluid on the windshield.
The left turn signal indicator (3) is located on the top left side
Headlights Switch of the front console. It is a green indicator light that flashes
when the turn signal lever or hazard switch is pulled down.
The headlights switch (21) is a three position switch located
on the bottom left side of the front console. The bottom Right Turn Signal Indicator
position is off. The center position will illuminate marker,
The right turn signal indicator (6) is located on the top right
clearance and gauge lights. The top position will turn on the
side of the front console. It is a green indicator light that
headlights in addition to the marker, clearance and gauge
flashes when the turn signal lever or hazard switch is pushed
lights.
up.
Beacon Light Switch (Optional)
Steering Column Tilt/Telescope Lever
The beacon light switch (19) is a two position, on-off switch
The steering column tilt/telescope lever (56) is located on the
located on the left side of the front console that controls the
steering column behind the turn signal lever. Pulling back on
beacon light (42) on the top of the carrier cab.
the lever allows the steering column to be tilted, and pushing
Dimmer Switch forward on the lever allows the steering column to be
telescoped in and out.
The dimmer switch (31) is located on the left bottom side of
the front console. The switch controls the brightness of the Horn Button
gauge lights.
The horn button (46) is located in the center of the steering
NOTE: The headlight switch (21) must be in the center or wheel (45). Depressing the horn button energizes the circuit
top position before gauge lights will illuminate and sounding the horn.
the dimmer switch becomes functional.
Fire Extinguisher
3
Headlights Dimmer Switch
The fire extinguisher (43) is mounted on the left inside rear of
The headlights dimmer switch (47) is incorporated in the turn the cab.
signal switch. It is located on the left side of the steering
column. The switch is activated by pulling or pushing the turn Cab Circulating Fan
signal lever toward you or away from you. The cab circulating fan (50) is mounted on the left front of the
cab and is controlled by a two speed rocker switch on the
Turn Signal Lever
base of the fan.
The turn signal lever (47) is located on the steering column.
Positioning the lever down causes the indicator light on the Tire Inflation Switch
console and the left front and left rear signals to flash. The tire inflation switch (18) is located on the left side of the
Positioning the lever up causes the indicator light on the front console. It is a two position switch that activates the tire
console and the right front and right rear signals to flash. inflation system. Push the top of the switch to activate the tire
inflation system. An amber indicator will illuminate and the
Cruise Control
warning buzzer will sound when the switch is in the on
The cruise control (47) is incorporated in the turn signal lever position.
located on the left side of the steering column. Push the
switch to ON to turn the cruise control on. Accelerate to 12 VDC Accessory Outlet
desired speed and push (SET COAST) button on end of The 12 vdc accessory outlet (9) is located on the right side
lever. console. It provides an outlet for the operator to plug in a 12
If cruise is stopped by braking and switch is still positioned to vdc accessory. This outlet should be used only for
ON, the switch can be pushed to (RESUME-ACCEL) to components requiring 8 amps or less.
resume cruise speed. Position switch to OFF to turn the
Cab Dome Light (Not Shown)
cruise control off.
The cab dome light (44) is located in the center of the cab
Hazard Light Switch roof directly over the seat. It is controlled by a switch on the
The hazard light switch (55) is located on the steering light and by a door switch that powers the light when the cab
column. Pulling on the switch (in the direction of the arrow) door is opened.
causes all the turn signals and the indicator light on the
console to flash.

Air Horn (Not Shown) side operates the outrigger beams for that side only. The
stabilizers may be operated from the left or right side of the
A set of air horns are mounted on top of the cab and are
unit.
controlled by a valve manually actuated by a cable inside the
cab. Outrigger Beam Selector Switch
Fuse and Relay Panel (Not Shown) The OUTRIGGER BEAM SELECTOR switch (2) is used to
indicate desired operation of the front or rear outrigger beam
The fuse and relay panel (54) is located on the right rear side
for the side of the unit the control panel is on.
of the cab under a removable cover. It contains 8 fuses and
various relays that protect and control the various electrical Extend/Retract Switch
components of the carrier. In addition, it contains the crane’s
Master Control Module. The EXTEND/RETRACT switch (3) will operate both the
outrigger beams or the stabilizers. After positioning the
Carrier Electrical Diagnostic Connector desired selector switch, positioning the extend/retract switch
energizes the control solenoid to allow hydraulic fluid to flow
The carrier electrical diagnostic connector (39) is located on
through the control solenoid valve and the individual
the left side of the cab beneath the front console. It is used
solenoid valve and move the selected component in the
for servicing the engine ECM, transmission ECM or the
desired direction. In addition, when the switch is positioned
crane’s electrical system.
to either position, a signal is sent to the engine ECM to
NOTE: A laptop computer with appropriate cable and increase engine speed above idle for operation of the
engine or electrical system software are required. outriggers.
Additional Carrier Controls and Indicators Center Front Stabilizer Switch
NOTE: The following paragraphs describe the additional The CENTER FRONT STABILIZER switch (4) is located in
controls and indicators located on the carrier to the center of the outrigger control panel. It must be used in
operate the outriggers. The numbers in conjunction with the extend/retract switch to control the
parentheses ( ) represent the index number from operation of the center front stabilizer. The center front
(Figure 3-2). stabilizer will retract automatically when any of the other four
stabilizers are retracted; therefore, it must be reset if lifting is
Outrigger Control Summary to be continued.
There is an OUTRIGGER CONTROL panel located on each Stabilizer Selector Switch
side of the crane carrier. Each panel contains switches for
extending and retracting the outrigger beams and for raising The STABILIZER SELECTOR switch (5) is used to indicate
and lowering the outrigger stabilizer (jack) cylinders on all which stabilizer is desired to operate.
sides of the crane. Each control panel also contains a control
Daytime Running Lights
switch for raising and lowering the center front stabilizer. The
following paragraphs explain these controls. Daytime running lights is a feature in which the headlight low
beams will come on automatically anytime the carrier ignition
Outrigger Control Panel switch is in the on position, engine is running, and the park
There is one OUTRIGGER CONTROL PANEL (1) on each brake is released regardless of the position of the headlight
side of the unit’s frame. The panel on the right side operates switch.
the outrigger beams for that side only. The panel on the left

3 4
5
2
5
6831
6563
Item Description
1 Outrigger Control Panel
2 Outrigger Beam Selector Switch
3 Extend/Retract Switch
4 Center Front Stabilizer Switch
5 Stabilizer Selector Switch
FIGURE 3-2

SUPERSTRUCTURE CAB electronic operating system which receives the signal from
the engine ECM via J1939.
NOTE: The following paragraphs describe all the available
(standard and optional) controls and indicators Fuel Quantity Gauge
located in the cab. Some machines may not be
The fuel quantity (FUEL) gauge is located on the upper left of
equipped with the optional controls shown. The
the gauge cluster. The gauge indicates the quantity of fuel in
numbers in ( ) represent the index number from
the tank and has a scale calibrated from empty (E) to full (F).
(Figure 3-3).
The fuel quantity gauge a signal from the crane’s electronic
NOTE: All rocker switches contain one or two LED’s in the operating system which monitors a sending unit in the fuel
switch for illumination. tank.
Engine Controls and Indicators Ignition Switch

The ignition switch (32) is located on the right side console.
Engine Increment/Decrement Switch
The switch is key operated with four positions: accessory
The engine increment/decrement switch (31) located on the (left position), off (vertical position), run (position between
right side console is used to set the engine operating speed. vertical and right), and start (right position). The switch is
It is a two position (+/-) momentary switch. spring returned from start to run. In the off position, all
electrical power in the superstructure is off except for the
Pushing the top of the switch quickly increases (+) engine
boom work lights, cab work lights, dome light, swing horn,
RPM to the maximum allowed operating speed. Pushing the
and accessory outlet. In the accessory position, all electrical
bottom of the switch quickly decreases (-) engine RPM to
components are energized. Placing the switch in the start
idle speed. Pushing and holding either side of the switch will
position energizes the starter motor solenoid for starting the
increase or decrease engine speed. Releasing the switch
engine. Releasing the switch will allow it to spring return to
will hold the engine at the current speed. Pressing the foot
the run position. To shut down the engine, turn the switch to
pedal will increase engine speed above the “hold” speed.
the off position.
Releasing the foot pedal causes the engine to return to the
“hold” speed. Tachometer
Gauge Cluster The tachometer (27) is located on the pedestal mounted
console and registers engine RPM. The tachometer is
The gauge cluster (29) is located on the left side of the
calibrated in rpm x 100 with a range of zero (0) to 35. It
pedestal mounted console beside the LMI panel and
receives a signal from the crane’s electronic operating
contains a voltmeter, oil pressure gauge, water temperature
system which receives the signal from the engine ECM via
gauge, and a fuel quantity gauge.
J1939.
Voltmeter
Hourmeter
The voltmeter (VOLTS) is located on the lower right of the
The hourmeter (28) is located at the bottom of the
gauge cluster. With the ignition switch in the run (between
tachometer and registers the total hours that the engine has
vertical and right) position and before starting the engine, the
run. The hourmeter receives an electrical signal from the
voltmeter indicates the condition of the batteries. With the
tachometer.
engine running, the voltmeter indicates output voltage of the
alternator. The voltmeter scale is from 10 to 16 volts. Engine Stop/Module Off Line Indicator
Engine Oil Pressure Gauge The engine stop/module off line indicator (48) is located on
the top left side of the pedestal mounted console. The top
The engine oil pressure (OIL) gauge is located on the upper
portion of the switch is the stop indicator. It illuminates red
right of the gauge cluster. The gauge indicates the engine oil
when energized by a signal from the engine ECM that
pressure on a scale calibrated from zero (0) to 80 psi. It
signifies a serious engine problem that requires the vehicle
receives a signal from the crane’s electronic operating
and the engine to be stopped as soon as safely possible. In
system which receives the signal from the engine ECM via
addition, a warning buzzer will also sound.
J1939.
The bottom portion is the module off line indicator. This
Water Temperature Gauge indicator will come on solid and a buzzer will sound
The engine coolant temperature (TEMP) gauge is located on whenever communication with one of the crane’s electronics
the lower left of the gauge cluster. The gauge indicates the modules is lost. The vehicle should be stopped as soon as
engine coolant temperature on a scale calibrated from 100 to safely possible. The crane must be restored to proper
240° F. The gauge receives a signal from the crane’s condition before operating again.

Engine Warning/Electrical System Diagnostic Boom Lift/Main Hoist Controller

Indicator
The boom lift/main hoist controller (8) is located on the right
The engine warning/electrical system diagnostic indicator armrest. The controller, when pushed to the right (lowers the
(24) is located at the top left side of the pedestal mounted boom) or left (raises the boom), actuates the control valve to
console. The top portion is the warning indicator. It raise or lower the boom.
illuminates amber when energized by a signal from the
When used for main hoist, the controller, when pushed
engine ECM that signals the operator of an engine problem
forward (lowers the cable) or back (raises the cable),
which must be corrected.
actuates the control valve to raise or lower the main hoist
The bottom portion of the switch is the electrical system cable.
diagnostic indicator. There are three conditions for this
indicator as follows: Swing Horn Button
a. On solid with buzzer sounding - There is an The swing horn button (20) is located on the right side of the
interruption of communication over the main canbus swing controller and is used by the operator to provide a
control line between the crane’s electronic control warning that the superstructure is rotating. Press in on the
modules. Proper crane operating condition shall be button to sound the swing horn.
restored as quickly as possible.
Telescope Control Pedal
b. Flashing with buzzer sounding - An undesirable
The telescope control foot pedal (3), supplied when the
condition with the crane’s joysticks has been
crane is equipped with an auxiliary hoist, is located on the
detected. Proper crane operating condition shall be
right side of the cab floor. Pushing forward on the top of the
restored before performing any hydraulic function.
pedal will extend the boom and pushing down on the bottom
of the pedal will retract the boom.
c. Flashing without buzzer - An undesirable
component or electrical system condition has
Main Hoist Speed Selector Switch
3
occurred.
The three-position main hoist speed selector switch (10) is
Foot Throttle Pedal
located on the right armrest. Select the top of the switch for
The foot throttle pedal (4) is located on the right side of the high speed or the bottom of the switch for low speed.
cab floor. The pedal is used to control engine RPM. The Position the switch in the center position to “off” to disable
pedal modulates engine speed proportionately to the foot main hoist functions.
pressure applied.
Auxiliary Hoist Speed Selector Switch
Craning Controls and Indicators The three-position auxiliary hoist speed selector switch (16)
is located on the left armrest. Select the top of the switch for
Telescope/Auxiliary Hoist/Swing Controller
high speed and the bottom of the switch for low speed.
The telescope or auxiliary hoist/swing controller (18) is Position the switch in the center to “off” to disable auxiliary
located on the left armrest. The controller controls the hoist functions.
telescope functions when the crane is not equipped with an
auxiliary hoist. Pushing the controller forward actuates the Hoist Rotation Indicators (Main and Auxiliary Hoist)
control valve to telescope the boom out and pulling the The hoist rotation indicators (51) are located on the top of the
controller back telescopes the boom in. main and auxiliary hoist controllers. The indicator is
When equipped with an auxiliary hoist, the controller controls electronically driven by a sensor attached to the main hoist.
auxiliary hoist functions and telescope functions through a A pulsating signal is sensed by the operator’s thumb during
foot pedal (3). Pushing the controller forward actuates the hoist operation.
control valve to let out the hoist cable and pulling the Crane Function Power Switch
controller back reels the cable in.
The crane function power switch (37) is located on the right
When used for swing, the controller, when pushed to the side console. Push the bottom of the switch to disconnect
right (rotates the turntable clockwise) or left (rotates the power from the crane functions controlled by the controllers
turntable counterclockwise), actuates a control valve to on the armrests.
provide 360 degree continuous rotation in the desired
direction. Push the top of the switch to energize the pilot supply
solenoid to allow functions controlled by the controllers on
the armrests to be performed.

Positioning the switch to OFF prevents inadvertent operation To extend the left front stabilizer, push the top of the outrigger
of functions due to bumping the controllers while roading or extend/retract switch (44) and the bottom of the left front
any other operation. outrigger switch.
Outrigger Extend/Retract Switch To retract the left front stabilizer, push the bottom of the
outrigger extend/retract switch (44) and the bottom of the left
NOTE: The park brake in the carrier cab must be set front outrigger switch.
before the outrigger controls will operate.
Right Front Outrigger Switch
NOTE: Be sure the outriggers plus the center front
stabilizer are properly extended and set, and the The right front outrigger switch (19) is located on the right
crane is level for operation on outriggers. The side console. It is a three-position switch used to extend or
center front stabilizer outrigger is a vital factor in the retract the right front stabilizer and extension cylinders. It
stability of the crane. must be used in conjunction with the outrigger extend/retract
switch.
All four outrigger beams plus the center front
stabilizer outrigger must be equally extended to the To extend the right front outrigger beam, push the top of the
mid position vertical stripe or fully extended outrigger extend/retract switch (44) and the top of the right
position before beginning operation. front outrigger switch.
The outrigger extend/retract momentary switch (44) is To retract the right front outrigger beam, push the bottom of
located on the right side console. It must be used in the outrigger extend/retract switch (44) and the top of the
conjunction with the outrigger selector switches to control the right front outrigger switch.
operation of the stabilizer and extension cylinders.
To extend the right front stabilizer, push the top of the
Push the top of the switch to select the extend function or outrigger extend/retract switch (44) and the bottom of the
push the bottom of the switch to select the retract function. In right front outrigger switch.
addition, when the switch is positioned to either extend or
To retract the right front stabilizer, push the bottom of the
retract position, a signal is sent to the engine ECM to
outrigger extend/retract switch (44) and the bottom of the
increase engine speed above idle for operation of the
right front outrigger switch.
outriggers.
Left Rear Outrigger Switch
Center Front Stabilizer Switch
The left rear outrigger switch (43) is located on the right side
A center front stabilizer switch (45) is located on the right
console. It is a three-position switch used to extend or retract
side console. To extend the center front stabilizer, push the
the left rear stabilizer and extension cylinders. It must be
top of the outrigger extend/retract switch, then push the top
used in conjunction with the outrigger extend/retract switch.
of the center front stabilizer switch.
To extend the left rear outrigger beam, push the top of the
To retract the center front stabilizer, push the bottom of the
outrigger extend/retract switch (44) and the top of the left
outrigger extend/retract switch, then push the bottom of the
rear outrigger switch.
center front stabilizer switch.
To retract the left rear outrigger beam, push the bottom of the
NOTE: The center front stabilizer will retract anytime the
extend/retract switch is positioned to the retract
position.
To extend the left rear stabilizer, push the top of the outrigger
Left Front Outrigger Switch extend/retract switch (44) and the bottom of the left rear
The left front outrigger switch (11) is located on the right side outrigger switch.
console. It is a three-position switch used to extend or retract To retract the left rear stabilizer, push the bottom of the
the left front stabilizer and extension cylinders. It must be outrigger extend/retract switch (44) and the bottom of the left
used in conjunction with the outrigger extend/retract switch. rear outrigger switch.
To extend the left front outrigger beam, push the top of the
Right Rear Outrigger Switch
front outrigger switch. The right rear outrigger switch (42) is located on the right
side console. It is a three-position switch used to extend or
To retract the left front outrigger beam, push the bottom of
retract the right rear stabilizer and extension cylinders. It
the outrigger extend/retract switch (44) and the top of the left
must be used in conjunction with the outrigger extend/retract
front outrigger switch.
switch.

To extend the right rear outrigger beam, push the top of the brake according to the pressure from the swing power brake
outrigger extend/retract switch (44) and the top of the right valve.
Swing Lock Control (Pin Type)
To retract the right rear outrigger beam, push the bottom of
the outrigger extend/retract switch (44) and the top of the The pin swing lock control handle (6) is located on the right
right rear outrigger switch. side of the cab. The purpose of the pin swing lock is to lock
the superstructure in position directly over the front or over
To extend the right rear stabilizer, push the top of the the rear. When the control handle is pushed down and turned
outrigger extend/retract switch (44) and the bottom of the clockwise, the superstructure is directly over the front or rear,
right rear outrigger switch. the swing lock pin drops into a socket on the carrier frame,
To retract the right rear stabilizer, push the bottom of the locking the superstructure in place. When the control handle
outrigger extend/retract switch (44) and the bottom of the is pulled up and turned clockwise, the pin is pulled out of the
right rear outrigger switch. socket, unlocking the superstructure.
Center Front Stabilizer Overloaded Indicator 360° Swing Lock Control (Positive Lock Type)
(Optional)
The center front stabilizer overloaded indicator (26) is
located on the pedestal mounted console. The indicator is a The 360 degree swing lock control lever (25) is located on
red light that will illuminate when the pressure switch in the the right side of the operator’s seat next to the control
front stabilizer circuit senses over-pressurization indicating armrest. The purpose of the swing lock is to secure the
an overload condition. In addition to the indicator light, a superstructure in position in 2.7 degree increments in its 360
buzzer will sound. degree of rotation. The lock is engaged when the control
lever is pushed down and disengaged when the control lever
Bubble Level Indicator is pulled up.
The bubble level indicator (5) is located on a bracket on the Swing Brake Engaged Indicator
3
right side of the cab. The indicator provides the operator with
a visual indication for determining the levelness of the The swing brake engaged indicator (49) is located on the
machine. pedestal mounted console.
The indicator illuminates red to warn the operator that the
Swing Brake Selector Switch
swing brake release pressure is not enough to hold the
The swing brake selector switch (17) is located on the left swing brake disengaged.
armrest. This two-position switch (on/off) is used to control a
hydraulic valve that directs a regulated flow of pressure to Swing Speed Switch
and from the swing brake. Push the top of the switch to ON to The swing speed switch (50) is a two-position switch located
apply the swing brake and push the bottom of the switch to on the left armrest. Push the top of the switch for high swing
OFF to release the swing brake. speed or the bottom of the switch for low swing speed.
Swing Brake Pedal Cab Tilt Switch
The swing brake pedal (22) is located on the left side of the The cab tilt switch (47) is located on the right armrest. It is a
cab floor. The swing brake pedal is used to actuate the swing three position, momentary spring centered to off rocker
brake to slow or stop swing motion. Braking is proportional to switch. The switch allows the cab to be tilted either up or
pedal depression. down.
With the pedal not depressed and the swing brake control
Jib Stowage Controller
valve disengaged, hydraulic pressure is applied to the brake,
overcoming spring pressure and releasing the brake. The remote jib stowage controller (52) is stored behind the
seat in the superstructure cab. The IN and OUT switch on
Depressing the pedal actuates a swing power brake valve to
the controller is used to pivot the boom extension during
apply pressure to the brake assembly. This pressure aids the
erecting and stowing procedure. Refer to Section 4 - SET-UP
spring pressure to overcome the hydraulic pressure being
AND INSTALLATION.
applied to the brake release circuit and applies the spring

1
2 30
23
See View A
See View B
4 See View C
5 35
22 6
25
3
20 12
21
See View D
52
15
13
FIGURE 3-3

48 24 26 49 30
29
27
28 6834
3
View A
47
10
51
50
17
18
6566-1
51
20
View D
16

37 38 21
40
39
41
31
33 46
11
42
19
43 36
34
44
45
View C 6564-2
6564-1
32 View B

1 Work Lights 10 Main Hoist Speed Selector Switch
2 Windshield Wiper/Washer Left Front Outrigger Stabilizer and Extension
11
Switch
3 Telescope Control Pedal
12 Cab Dome Light
4 Foot Throttle Pedal
13 Fuse Panel
5 Bubble Level Indicator
14 Beacon Light (Not Shown)
6 Swing Lock Control (Pin Type)
15 Fire Extinguisher
7 Seat Adjustment Lever (Not Shown)
16 Auxiliary Hoist Speed Selector Switch (optional)
8 Boom Lift/Main Hoist Controller
17 Swing Brake Selector Switch
9 Not Applicable
18 Telescope /Auxiliary Hoist/Swing Controller

Accessory Controls and Indicators

Item Description
Dimmer Switch
19 Right Front Outrigger Switch
The dimmer switch (39) is located on the right side console.
20 Swing Horn Button The switch controls the brightness of the panel and gauge
21 Skylight Wiper Switch; Skylight Wiper lights.
22 Swing Brake Pedal Work Lights Switch
23 Cab Circulating Fan The work lights switch (40) is a two position on/off switch
Engine Warning/Electrical System Diagnostic located on the right side console controls the crane’s work
24 lights (1) mounted on the bottom front of the superstructure
Indicator
cab. Press the top of the switch to the on position to
25 360° Swing Lock Control (Positive Lock Type) illuminate the work lights. Press the bottom of the switch to
26 Center Front Stabilizer Overloaded Indicator turn the work lights off.
27 Tachometer Boom Lights Switch (Optional)
28 Hourmeter The boom lights switch (41) is a two position on/off switch
29 Gauge Cluster located on the right side console. The switch controls the
flood lights located on the boom base section. Press the top
30 LMI Panel
of the switch to the on position to illuminate the flood lights.
31 Engine Increment/Decrement Switch The amber indicator in the switch will illuminate. Press the
32 Ignition Switch bottom of the switch to turn the flood lights off.
33 Air Conditioner Switch (Optional) Cab Circulating Fan 3

34 Heater Control Switch The cab circulating fan (23) is located on the right side of the
cab. A swivel allows the fan to be positioned in any direction
35 Crane’s Electrical System Diagnostic Connector
and a high-off-low switch on the base controls the fan.
36 Heater/Air Conditioner Fan Switch
Cab Dome Light
37 Crane Function Power Switch
The cab dome light (12) is located on the right rear corner of
38 Windshield Wiper/Washer Switch
the cab roof and provides illumination of the cab. The light is
39 Dimmer Switch controlled by a on/off switch on the light.
40 Work Lights Switch Fire Extinguisher
41 Boom Lights Switch (Optional)
The fire extinguisher (15) is located at the left rear side of the
42 Right Rear Outrigger Switch cab. The fire extinguisher is a BC rated dry type fire
43 Left Rear Outrigger Switch extinguisher for emergency use.
44 Outrigger Extend/Retract Switch Windshield Wiper/Washer Switch and Motor

45 Center Front Stabilizer Switch The windshield wiper/washer toggle switch (38) is located on
the right side of the front console. The switch is used for
46 Heater On/Off Switch
removing moisture from the windshield.The switch has an off
47 Cab Tilt Switch (optional) and high position with six intermittent positions between high
48 Engine Stop/Module Off Line Indicator and off. Pushing the switch up from the off position energizes
the wiper motor (2). Continue to push switch up for each
49 Swing Brake Engaged Indicator intermittent position and the high position. Push the switch
50 Swing Speed Switch down to off to stop the motor and return the wiper blade to
the parked position.
51 Hoist Rotation Indicator (Main and Aux Hoist)
Push the very top of the switch to activate the washer switch
52 Jib Stowage Controller
to spray washer fluid on the windshield.
Skylight Wiper Switch

The skylight wiper switch (21) is installed on the right side
console. The wiper is used to remove moisture from the

skylight. The switch has an off and high position with six Air Conditioner Switch (Optional)
intermittent positions between high and off. Pushing the
The air conditioning switch (33) is located on the lower right
switch up from the off position energizes the wiper motor.
side console. The switch controls the operation of the
Continue to push switch up for each intermittent position and
optional air conditioning system in conjunction with the FAN
the high position. Push the switch down to off to stop the
switch. Press the top of the switch to turn air conditioner on.
motor and return the wiper blade to the parked position.
Press the bottom of the switch to turn the air conditioner off.
Heater On/Off Switch
Beacon Light
The heater (on/off) switch (46) is located on the lower right
The beacon light (14) is located on a bracket on the left rear
side console. Press the top of the switch to on for heat. Press
side of the machine beside the hoists. It is operational
the bottom of the switch to turn heater off.
anytime the ignition switch is in the ACC or RUN position.
Heater Control Switch
Crane’s Electrical System Diagnostic Connector
The heater control switch (34) is located on the lower right
This connector (35) is mounted on the side of the right side
side console. Push the top of the switch to (OPEN) the valve
console by the operator’s right leg. It is used for servicing the
for heat. Push the bottom of the switch to (CLOSE) the valve.
engine ECM, transmission ECM or crane’s electrical system.
Heater /Air Conditioner Fan Switch NOTE: A laptop computer with appropriate cable and
The heater/air conditioner fan switch (36) is located on the electrical system software are required.
lower right side console. The switch controls the speed
Fuse Panel
which in turn regulates the volume of heated air output of the
heater and air conditioner fan by positioning switch to: low The fuse panel (13) is located under the cover panel on the
(press bottom of switch), medium (switch centered), and back wall of the cab behind the seat. It contains 16 fuses and
high (press top of switch). 4 relays that protect and control various circuits of the
superstructure.

OPERATING PROCEDURES Engine Coolant

Check the coolant level in the radiator and fill to the proper
Breaking In A New Carrier level. Do not overfill and ensure the radiator cap is secure.
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 DANGER
occasional oil, air, or coolant leak may develop. Immediate
Do not loosen radiator cap on a hot engine. Steam or hot
corrective action should be taken to avoid major repairs later.
coolant will cause severe burns.
For detailed engine break-in, refer to the applicable engine
manual.
Batteries
The guidelines below will aid in getting a long service life out
of the crane. Check the state-of-charge indicator if applicable with
maintenance free batteries or check each cell for the correct
1. Operate as much as possible in the half to three- fluid level if equipped with standard or low maintenance
quarters throttle or load range. batteries. Use only clean distilled water and do not overfill.
On all types of batteries, make sure the cables and clamps
2. Avoid long periods of operation with the engine at idle or
are tight and not corroded.
continuous maximum horsepower levels.
3. Observe instruments often and shut down at the first Hydraulic Reservoir and Filter
indication of an abnormal reading. Check the hydraulic level sight gauge and filter condition
4. Operate to a power requirement that allows acceleration indicator on the hydraulic tank. Hydraulic fluid should be at
to governed speed when conditions require more power. normal operating temperature and the boom and outriggers
in a retracted position.
3
5. Check all components frequently for proper operation,
unusual noises, and excessive heating. Check breather for cleanliness and security.
6. Check the engine oil and coolant levels frequently. Wire Rope
These guidelines should not be considered limitations but Inspect the wire rope in accordance with applicable Federal
rather as a guide for familiarization of the machine and Regulations. Sheaves, guards, guides, drums, flanges, and
development of good operating habits. any other surfaces that come in contact with the rope should
be inspected for any condition that could cause possible
Pre-Starting Checks damage to the rope.
A complete walk-around visual inspection of the crane Hook Block and Headache Ball
should always be made with special attention to structural
damage, loose equipment, leaks, or other conditions that Inspect for nicks, gouges, cracks, and evidence of any other
would require immediate correction for safe operation. Refer damage. Replace a hook that has cracks or shows evidence
to Section 6 - Maintenance Checklist. The following checklist of excessive deformation of the hook opening (including
items are suggested to ensure the crane is prepared for twist). Be sure the safety latch is free and aligned.
starting the day’s work.
Seats and Mirrors
Fuel Supply Adjust seat and mirrors for clear vision and safe driving.
Fill the fuel tank and ensure the cap is on tight.
Seat Belts
Engine Oil Seat Belt Maintenance
Seat belt assemblies are maintenance-free; however, they
CAUTION should be periodically inspected to ensure that they are not
Do not overfill. damaged and are in proper operating condition, especially if
they have been subjected to severe stress.
Check the oil level in the crankcase and fill to the FULL mark Cleaning Seat Belt Webbing
on the dipstick. 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 Operation Below -40°C

possible loss of webbing strength.
For crane operation below -40°C, capacities shall be derated
Signal and Running Lights 3.67% of the capacities shown on the load chart for each
degree (1°C) below -40°C.
Check all signal and running lights for proper operation.
Replace burned out lamps with those of the same number, or Operation Below -40°F
equivalent.
For crane operation below -40°F, capacities shall be derated
Service and Parking Brakes 2.0% of the capacities shown on the load chart for each
degree (1°F) below -40°F.
Check for proper operation.
Tires
Engine Operation
Start-up and shutdown procedures for most diesel engines
Check the pressure and condition of all tires before traveling.
are generally the same. Therefore, the following procedures
NOTE: For tire inflation pressures, refer to the Tire Inflation can be applied, except where specific differences are noted.
Decal on the crane. (Refer to the applicable engine manufacturer’s manual for
detailed procedures).
Wheels
Start-Up Procedure
Maintain proper torque on wheel lugs and check for proper
wheel mounting. If equipped with steel or aluminum wheels, Make an under-the-hood inspection for fuel, oil, and coolant
the wheels should be retorqued 80 to 160 km (50 to 100 leaks, worn drive belts, and trash build-up.
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. DANGER
Safety Equipment Diesel engine exhaust can be harmful to your health. Only
operate the engine in a well ventilated area or vent
Check all lights, windshield wipers, washers, washer liquid exhaust outside.
supply, horn, instruments, signaling devices, etc.
Daily Lubrication
Ensure all components requiring daily lubrication have been CAUTION
serviced. (Refer to Section 5, Lubrication). Never crank engine for more than 30 seconds during an
attempted start. If engine does not start after 30 seconds,
Cold Weather Operation allow starter motor to cool for about two minutes before
The following recommendations are for operating attempting another start.
Manitowoc/Grove cranes in very low (i.e. freezing)
temperatures.
Use particular care to ensure that cranes being operated in CAUTION
very cold temperatures are operated and maintained in If engine does not start after four attempts, correct
accordance with the procedures as provided by Manitowoc malfunction before attempting another start.
Crane Group. Cranes should have appropriate hydraulic oil,
lubricants, and other auxiliary items required for operation in Use the correct grade of oil for the prevailing temperature in
sub-zero temperatures. Individual crane functions should be the crankcase to prevent hard cranking. Diesel fuel should
operated to ensure they are sufficiently warmed prior to have a pour point of 5°C (10°F) less than the lowest
performing a lift. expected temperature. In case of an emergency, white
Operation of cranes at full rated capacities in temperatures kerosene can be added to the fuel to bring the pour point
between 0°C and -40°C (+32°F and -40°F) or lower shall be down to the required temperature. This will prevent clogging
accomplished only by competent operators who possess the of filters and small passages by wax crystals. The addition of
skill, experience, and dexterity to ensure smooth operation. kerosene is NOT recommended for general use.
Shock loading shall be avoided. For crane operation below -
Warm Engine
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 The engine warning and engine stop indicators will illuminate
load shown on the capacity charts. and go off after about two seconds (as a check) when the key

is first turned on. If an indicator comes on and continues to The engine is equipped with an automatic cold starting
blink after initial start-up, there is a problem that needs to be system that provides a metered flow of starting fluid to the
corrected. Check the engine manufacturer’s service manual engine when the engine temperature is 13 °C (55°F) or
for further information. below. A thermostatically-controlled valve automatically
opens to allow starting fluid to the engine. It is recommended
1. Ensure the parking brake is set and position the
that no other type of cold starting aid be used with this
transmission in neutral.
engine. An engine block heater is also provided.
NOTE: The engine will not crank unless the transmission
If starting fluid runs out, replace the empty starting fluid
shift is in neutral.
container with a full container.
2. Turn the ignition switch to start (far right position) and
release immediately when the engine starts. Do not
push or hold the throttle down. The ECM will CAUTION
automatically provide the proper amount of fuel to start T h e o p t i o n a l e n g i n e c o l d s ta r t s y s t e m o p e r a t e s
the engine. automatically when the engine temperature is 13°C
3. Immediately check the engine instruments for proper (55°F) or below. If the engine does not start immediately,
indication after starting. Shut down the engine if the oil avoid overloading the air box with highly volatile fluid
pressure gauge does not reach the proper reading which could result in a minor explosion.
within 15 seconds.
1. Ensure the parking brake is set and position the
transmission in neutral.
NOTE: The engine will not crank unless the transmission
DANGER shift is in neutral.
Both air system pressures must be in the normal
operating range prior to disengaging the park brake.
2. Turn the ignition switch to start (far right position) and 3
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.
CAUTION
If oil pressure and/or temperature indicator(s) do not 3. Immediately check the engine instruments for proper
display the proper readings, shut down engine and indication after starting. Shut down the engine if the oil
correct malfunction. pressure gauge does not reach the proper reading
within 15 seconds.
4. Allow the engine to warm up for about five minutes
before applying a load. Do not race the engine for a
faster warm up.
DANGER
Cold Engine Both air system pressures must be in the normal
operating range prior to disengaging the park brake.
DANGER
Wear proper eye protection when replacing starting fluid
containers. Starting fluid can cause blindness or severe CAUTION
eye damage and breathing problems. If oil pressure and/or temperature indicator(s) do not
display the proper readings, shut down engine and
correct malfunction.
CAUTION
Always start a cold engine from the carrier cab. 4. Allow the engine to warm up for about five minutes
before applying a load. Do not race the engine for a
The engine warning and engine stop indicators will illuminate faster warm up.
and go off after about two seconds (as a check) when the key
is first turned on. If an indicator comes on and continues to Idling The Engine
blink after initial start-up, there is a problem that needs to be Idling the engine unnecessarily for long periods of time
corrected. Check the engine manufacturer’s service manual wastes fuel and fouls injector nozzles. Unburned fuel causes
for further information. carbon formation; oil dilution; formation of lacquer or gummy

deposits on the valves, pistons and rings; and rapid

accumulation of sludge in the engine.
CAUTION
NOTE: When prolonged engine idling is necessary,
maintain at least 800 rpm. Run the engine at or near the governed RPM during
operation of all crane functions.
Racing The Engine
NOTE: Carefully read and become familiar with all crane
DO NOT race the engine during the warm-up period or operating instructions before and operating the
operate the engine beyond governed speed (as might occur crane.
in downhill operation or downshifting). Engine bearings,
pistons, and valves may be damaged if these precautions Using Your Load Chart
are not taken.
NOTE: One of the most important tools of every Grove
Shutdown Procedure Manitowoc crane is the load chart found in the
crane operator's cab.
1. Allow the engine to run at fast idle speed for about five
minutes to avoid high internal heat rise and allow for NOTE: Refer to (Figure 3-4) for terms to know in
heat dissipation. determining lifting capacities.
2. Position the ignition switch to off (vertical position). The load chart contains the lifting capacities of the crane in
all allowable lifting configurations, and must be thoroughly
3. Drain the fuel filter-water separator.
understood by the operator.
General Crane Operation The load chart is divided into capabilities limited by crane
structural strength and stability which is shown by a bold line
Pump Drive across the chart. Structural strength limits are above the line
The main No. 1 hydraulic pump (a piston pump and a gear and stability limits are below the line.
pump section) is driven by an engine PTO. The two-section The left column is the load radius, which is the distance from
No. 2 hydraulic pump (two gear pump sections) is direct the axis of the crane rotation to the load center of gravity. The
engine driven. top row lists various boom lengths from fully retracted to fully
Control Lever Operation extended (with swingaway extension). The number at the
intersection of the left column and top row is the total load
The control lever operation for crane functions is limit for that load radius and boom length. The number in
proportional, i.e., the closer the lever is to neutral (center), parentheses below the total load limit is the required boom
the slower the system responds. Return the control lever to angle (in degrees) for that load. Boom lengths between
neutral to hold the load. Do not feather the hoist control to increments should always be treated as if it were the next
hold the load. longer length. For example, if the actual boom length is 15.2
m (50 ft) and the chart shows boom lengths of 14.6 - 16.4 m
NOTE: Always operate the control levers with slow, even
(48 - 54 ft), use the load capacity shown in the 16.4 m (54 ft)
pressure.
column.
Preload Check Another important section is the range diagram. The range
After the crane has been readied for service, an operational diagram shows the operating radius and tip height that can
check of all crane functions (with no load applied) should be be achieved at a given boom length and angle. If the
performed. Preload check is as follows: operator knows the radius and tip height required for a
specific lift, the angle and boom length can quickly be
• Extend and set the outriggers and level the crane. determined from the range diagram. Or if he knows the boom
• Raise, lower, and swing the boom right and left at least length and angle, he can quickly determine the tip height and
45 degrees. operating radius.
• Telescope the boom out and back in, ensuring all A lifting diagram is included for over-side, over-rear, and
sections extend and retract properly. over-front lifting areas. The lifting area diagram shows that
the locations of the outrigger stabilizer cylinders in the full
• Raise and lower the cable a few times at various boom extended position are used to mark the boundaries of the
lengths. Make sure there are no kinks and that the cable lifting areas.
is spooling on the hoist properly.
Another section contains notes for lifting capacities. Be sure
to read and understand all notes concerning lifting
capacities.

The load chart also gives weight reductions for Manitowoc/ handling devices such as chains, slings, or spreader bars
Grove load handling devices such as hookblocks, overhaul must also be added to the weight of the load.
balls, boom extension sections, etc, which must be
considered as part of the load. The weight of any other load
MA
IN
BO
OM
LE
NG AXIS OF ROTATION
TH
BOOM ANGLE
HORIZONTAL
4605
OPERATING RADIUS
3
TERMS TO KNOW FIGURE 3-4
NOTE: The information in the following paragraph is an kg (172 lbs) for a total of 128 kg (282 lbs). The lift requires
example of how to compute a lift. The numbers slings and spreader bars weighing 159 kg (350 lbs) which
used in the example may not coincide with the load makes the total weight for the load handling devices 286 kg
chart in the crane cab. (632 lbs).
Problem: A concrete beam weighing 2268 kg (5000 lbs) A check of the load chart for a 15.2 m (50 ft) radius and
needs to be lifted to a height of 9.1 m (30 ft) at a radius of 19.5 m (64 ft) of boom length shows a capacity of 3601 kg
15.2 m (50 ft) (maximum). The range diagram indicates the (7940 lbs) on outriggers over-front and 4970 lbs on
boom must be extended to 18.9 m (62 ft) in order to reach a outriggers 360 degrees. We subtract the load handling
height of 9.1 m (30 ft) at a radius of 15.2 m (50 ft). weight of 632 lbs from the load capacity of 3601 kg (7940
lbs) and 2254 kg (4970 lbs). The result is a weight capacity of
First we need to check the crane for load handling devices.
3315 kg (7308 lbs) over-the-front and 1968 kg (4338 lbs) for
In our example, the crane is equipped with a auxiliary boom
360 degrees. We are constricted in making the lift over-front
nose (rooster sheave) and a five ton overhaul ball. The
only and the boom angle will be about 29 degrees.
rooster sheave is 50 kg (110 lbs), and the overhaul ball is 78

Crane Functions outrigger jack cylinders (aka outrigger stabilizer

cylinders) using the levers on each float.
2. Depress the appropriate Outrigger Selector switch to
EXTENSION and then position the Outrigger Extension/
Retraction switch to EXTEND. The outrigger beam
DANGER should begin to extend. Refer to Engaging the Mid
Death or serious injury could result from improper crane Extend Lock Pin if the crane is to be operated at the mid-
setup on outriggers. extend position.
DANGER
All four outrigger beams must be equally extended to the
WARNING mid position vertical stripe or fully extended position
The outriggers and the center front stabilizer must be before beginning operation.
properly extended and set and the crane level before any
other operation of the crane on outriggers is attempted. NOTE: More than one outrigger may be extended at one
time. However, each Outrigger Selector switch
should be depressed individually and the outrigger
extension/retraction switch momentarily positioned
WARNING to EXTEND to ensure that each outrigger is fully
The center front stabilizer will retract when any main extended.
outrigger stabilizer is retracted. Reset center front 3. After all four outrigger beams have been extended,
stabilizer if any main outrigger stabilizer is retracted or depress the appropriate Outrigger Selector switch to
extended after initial set-up. STABILIZER and position the Outrigger Extension/
Retraction switch to EXTEND.
4. Extend each stabilizer, until the floats touch the ground.
Setting The Outriggers
NOTE: More than one stabilizer may be extended at one
NOTE: The park brake must be set and the Hydraulic time.
Boost switch must be in the LOW position before
the outriggers will operate. 5. After all floats are on the ground, extend the front
stabilizers about 8 to 10 cm (3 to 4 inches) and then
NOTE: The air suspension system must be deflated when extend the back stabilizers the same distance. Repeat
on outriggers.
until all tires are off the ground.
The outrigger control switches are located on the outrigger
control box located in a pocket at the front of the
superstructure cab. In addition, the outriggers may be DANGER
operated from optional control boxes mounted on both sides
All four outrigger beam lock pins must be engaged before
of the carrier just forward of the front outriggers. When using
the optional control boxes, the engine speed is increased
due to a signal to the engine ECM when the EXTEND/
RETRACT switch is placed in either position.
DANGER
Operator must select proper load chart and LMI program
CAUTION for the outrigger position selected.
Depress outrigger selector switch before the outrigger
extension/retraction switch. Failure to do so may cause a 6. Repeat step 5 until all wheels are clear of the ground
hydraulic lock against the individual solenoid valves, and and the crane is level as indicated by the sight level
keep them from opening. bubble located on the right side of the cab. If it is
suspected that the bubble level indicator is out of
adjustment, verify and adjust the bubble level as follows:
1. If outrigger floats are not already installed, remove them
from float stowage locations on left, right, and rear of a. Locate the crane on a firm level surface.
carrier frame. Secure the floats to the rods of the

b. Extend and set the outriggers. Level the crane, as Stowing The Outriggers
indicated by the bubble level indicator, with the
1. Position the rear Outrigger Selector switches to
outriggers.
STABILIZER and position the Outrigger Extension/
c. Place a miracle pointer, carpenter level, or similar Retraction switch to RETRACT until the rear stabilizers
type device on a machined surface such as the have retracted several inches.
turntable bearing or bearing mounting surfaces.
2. Position the front outrigger selector switches to
d. Level the crane with the outriggers as indicated on STABILIZER and position the Outrigger Extension/
the device used in step (c). Retraction switch to RETRACT until the front stabilizers
have retracted several inches.
e. Adjust the bubble level indicator with the mounting
screws to show level. 3. Repeat steps 1 and 2 until the crane is resting on all four
wheels and the stabilizer floats are several inches off the
Engaging the Mid Extend Lock Pin
ground.
Locking Pin
DANGER
Keep feet and hands clear of floats when unlocking the
floats from the stabilizers.
4. Release the locking levers and allow the floats to drop to

the ground.
3
Lug
4907-1
FIGURE 3-5
1. Turn the locking pin (Figure 3-5) 90° from its stowed
position and allow the pin to rest on top of the outrigger
beam.
NOTE: It may be necessary to jog the outrigger extension/ 4741
retraction switch slightly to ensure proper pin
engagement.
2. Slowly extend or retract the outrigger beam, allowing the
locking pin to drop into the hole in the top of the outrigger
beam, engaging the outrigger beam at the desired FIGURE 3-6
length.
5. Continue to retract the stabilizers until they are fully
retracted.

3
4
6612 1
2
1 3
2
1 2 3 FIGURE 3-7
Stowing the Mid-Extend Lock Pin

Item Description
1 Cotter Pin Locking Pin
2 Quick Pin
3 Outrigger Float
4 Rubber Bumper
5 Frame
6. Position the desired Outrigger Selector switch to
EXTENSION and hold the Outrigger Extension/
Retraction switch to RETRACT. The appropriate
outrigger beam should begin to retract.
NOTE: More than one outrigger beam may be retracted at
one time.
4907-2
7. After all outriggers have been fully retracted, stow the
outrigger floats. (Figure 3-7) Secure the floats with quick
pins and cotter pins. FIGURE 3-8
1. Retract the outrigger extension/retraction cylinder.
NOTE: If the lock pin (Figure 3-8) is wedged in the hole in
the outrigger beam, it may be necessary to jog the
outrigger extension/retraction switch slightly while
pulling upward on the pin.
2. Lift the lock pin and turn it 90° to its stowed position.

Setting The Center Front Stabilizer
CAUTION DANGER
Never operate center front stabilizer unless boom is Do not elevate or swing boom over side unless outriggers
retracted and in boom rest, and outriggers and stabilizers are properly extended and crane is level.
are extended and set. Retract center front stabilizer
before stabilizers and outriggers.
1. Position the CENTER FRONT STABILIZER control

switch t o ACTIVATE and position the outrigger DANGER
extension/retraction switch to EXTEND.
Clear boom and tail swing path of all obstructions and
personnel.
CAUTION
Do not try to lift or level the crane with the center front
stabilizer.
DANGER
2. Continue to extend the stabilizer until the float is firmly
set on the ground. When swinging from over-the-front to over-the-side, refer
to over-the side load chart and make certain the capacity
Stowing The Center Front Stabilizer is not exceeded. Traveling with any load over-the-side is
prohibited.
3
DANGER
Center front stabilizer will retract when any main outrigger CAUTION
stabilizer is retracted. Reset center front stabilizer if any Disengage 360° swing lock, pin swing lock, and swing
main outrigger stabilizer is retracted or extended after brake before swinging.
initial set-up.
CAUTION
CAUTION Never push or pull swing controller through neutral to the
Only operate center front stabilizer when outriggers are opposite direction to stop swing motion.
extended and set, and boom is retracted and in boom
rest. To swing the boom, push the controller on the left hand
armrest to the right for right swing or to the left for left swing.
1. Position the CENTER FRONT STABILIZER control Always operate the controller with a slow, even pressure.
switch t o ACTIVATE and position the outrigger Rotation is stopped utilizing the swing brake foot pedal.
extension/retraction switch to RETRACT. When rotation is stopped, press the top of the swing brake
NOTE: Keep feet and hands clear of the float when switch to the on position to prevent further rotation.
unlocking it from the stabilizer.
Elevating And Lowering The Boom
2. Fully retract the center front stabilizer.
Swinging The Boom

DANGER
Clear area above and beneath boom of obstructions and
personnel before elevating or lowering boom.
DANGER
Death or serious injury could result from being crushed by Elevating the Boom
moving machinery. Sound swing horn and clear all
personnel from moving parts. To elevate the boom, push the controller on the right hand
armrest to the left, and hold until the boom reaches the
desired elevation.

Lowering the Boom Retracting The Boom (With Single Hoist) (Optional)
To lower the boom, push the controller on the right hand
armrest to the right and hold until the boom is lowered to the
desired position.
WARNING
When retracting the boom, the load will lower unless the
cable is taken in at the same time.
WARNING
To retract the boom, push the controller on the left hand
Long cantilever booms can create a tipping condition
armrest to the right and hold until the boom retracts to the
even when unloaded and in an extended and lowered
desired position.
position.
Telescope Control Pedal
The telescope control pedal is used on cranes equipped with
an auxiliary hoist. Push on the top of the pedal to extend the
boom and push on the bottom of the pedal to retract the
DANGER boom.
Lower boom and let out cable simultaneously to prevent
two-blocking. Lowering And Raising The Hoist Cable
CAUTION WARNING
The closer the load is to the boom nose, the more Keep the area beneath the load clear of all obstructions
important it becomes to let out cable as the boom is and personnel when lowering or raising the cable (load).
lowered.
Telescoping The Boom

NOTE: When the crane is equipped with an auxiliary hoist
the telescope function is controlled by a foot pedal. WARNING
Do not jerk controller when starting or stopping hoist.
Extending The Boom (With Single Hoist) (Optional)
Jerking causes load to bounce, which could result in
possible damage to the crane.
NOTE: When the load is stopped at the desired height, the

WARNING automatic brake will engage and hold the load as
When extending the boom, simultaneously let out the long as the controller remains in neutral.
cable to prevent two-blocking the boom nose and hook
Lowering The Cable
block.
Push the main hoist (right hand armrest) or auxiliary hoist
(left hand armrest) controller forward, away from the
operator, and hold until the hook or load is lowered to the
desired height.
DANGER
Check the load chart for maximum load at given radius, Raising the Cable
boom angle, and length before extending boom with a
load. Pull the main hoist (right hand armrest) or auxiliary hoist (left
hand armrest) controller, toward the operator, and hold until
Push the controller on the left hand armrest to the left, and the hook or load is raised to the desired height.
hold until the boom reaches the desired length.

Hoist Speed Range Selection
CAUTION
When defining virtual walls (s). always allow a safe
DANGER working distance to any obstacles. Never work outside a
safe working area as defined by common practice,
Do not change the hoist speed range with the hoist
standards, and manuals.
rotating.
To change the speed range of the hoist(s), press the top

(high speed) or bottom (low speed) of the main hoist speed
switch located on the right hand armrest or auxiliary hoist
speed switch located on the left hand armrest. WARNING
There are no cut-outs associated with the swing angle set
Operational Aids limitation or the work are definition features.
An Anti-two Block Device is also incorporated into the

system to prevent the hook block or headache ball from
DANGER coming into contact with the boom nose or boom extension.
Electronic equipment on this crane is intended as an aid This condition will also cause a lockout of hoist up, boom
to the operator. Under no condition should it be relied down, and telescope out, and also provide a visual and an
upon to replace the use of capacity charts and operating audible alarm.
instructions. Sole reliance upon these electronic aids in Refer to the LMI Operator’s Handbook for more detailed
place of good operating practices can cause an accident. information on the function of the LMI system. 3
Load Moment Indicator (LMI) System Control Lever Lockout System
The Load Moment Indicator (LMI) is an electro-mechanical The control lever lockout system consists of hydraulic
sensing system designed to alert the crane operator of solenoid valves located in the directional control valves. The
impending capacity when the system has been properly valves are activated in such a manner as to prevent
preset by the operator. The control panel is mounted in the worsening the condition, i.e. boom down, telescope out, or
front console of the operator’s cab. When an overload hoist up. The control lever lockout system is used with the
condition is sensed, the system provides the operator with a anti-two-block system or the load moment indicator (LMI)
visual and audible warning, and locks out the control levers system. The LMI sends a signal to the canbus system which
to prevent lowering the boom, extending the boom, or raising turns off the solenoids on the directional valves.
the main or auxiliary hoist cables.
Crane Travel Operation
Three additional features are included within the LMI system:
• Swing Angle Set Limitation Active Restraints
• Work Area Definition Seat Belts

• Anti-two Block Device
Swing Angle Set Limitation allows left and right swing Latch Plate
angle to be preset. When the preset angle is reached, the
system will provide an audible warning.
Work Area Definition allows the crane operator to describe
the crane’s working area by setting up “virtual walls”. They
are referred to as virtual walls because they exist in the
system and are not real walls. The virtual walls represent
obstacles (i.e. buildings, towers, poles, etc.) in the crane’s
working range. They are set by defining points along the
outer limits of the working area with the tip of the boom. Once
the working area has been defined, the system will provide a
visual and an audible warning if the boom approaches a
Buckle
virtual wall.
Push Button FIGURE 3-9

1. Before fastening a seat belt, always adjust the driver’s Traveling - General
seat to the position in which you will drive.
2. Pull the belt across your lap and push the latch plate into CAUTION
the buckle until it clicks (Figure 3-9). Check cold tire pressure prior to extended travel. Refer to
tire inflation decal on crane.
3. To reduce the risk of sliding under the belt during a
collision, position the belt across your lap as low on your
hips as possible and pull it toward the door to a snug fit
so the retractor can take up the slack.
CAUTION
NOTE: The lap/shoulder belt is designed to lock only Job site travel with deflated suspension must be limited to
during a sudden stop or impact. At other times is 8 km/h (5 MPH). Attempting to travel at higher speeds
should move freely. may cause drive train component failure.
4. If the shoulder belt is too snug, do the following:
a. Pull the shoulder belt out (A) at least 130 mm (5 in)
so that when it is left go, it returns to your chest CAUTION
(Figure 3-10). If traveling with 24,000 pounds (10,900 kg) of
b. Then pull down on the shoulder belt (B) the least counterweight installed, maximum travel speed is 2.5
amount needed to ease pressure but no more than mph. Suspension air bags should be inflated.
25 mm (1 inch) and let go.
Do not move the crane until the superstructure has been
secured as outlined below.
1. To ensure the axles and/or suspension are not
overloaded, adhere to the following.
a. For highway travel with 18,000 pounds (8170 kg of
c o u n t e r w e i g h t , i n s ta l l 8 0 0 0 l b ( 3 6 3 0 k g ) o f
counterweight on the carrier. Check that front axle
load does not exceed 49,200 lb (22,300 kg) and rear
axle load does not exceed 60,000 lb (27,200 kg).
FIGURE 3-10 b. For highway travel with 14,000 lb (6350 kg) or

12,000 lb (5440 kg) of counterweight, install 4000 lb
5. To reduce slack in the belt, pull the belt out as you did in (1810 kg) of counterweight on the carrier. Check
step 4.a. that front axle load does not exceed 49,200 lb
(22,300 kg) and rear axle load does not exceed
60,000 lb (27,200 kg).
c. GVW should never exceed 109,200 lb (49,530 kg).
DANGER Also refer to certification label on inside of cab door
Keep any shoulder belt slack to a minimum, no more than for Gross Axle Weight Ratio (GAWR).
25 mm (1 inch). Belt slack beyond the specified amount
could significantly reduce the amount of protection in an NOTE: For 24,000 pounds (10,900 kg) counterweight job
accident because the belt is too loose to restrain you as site travel without extension and/or inserts erected,
intended. the boom must be extended to a length of 50 feet
(15 m).
6. To unfasten the belt, push in on the button in the center 2. Ensure all boom sections are fully retracted or set to
of the buckle. To store the belt, pull out about 180 mm whatever extension is necessary for balance load on the
(7.1 in) and let go. The belt should retract when the axles.
buckle is unlatched. To help prevent damage to the seat
belt and interior, before closing the door be sure the belt 3. Ensure the boom is fully lowered into the boom rest.
is fully retracted and the latch plate is out of the way. 4. Engage the swing brake.
5. Engage the swing lock.
6. Ensure the swingaway, if so equipped, is properly
stowed and secured or removed from crane.

7. Remove the hookblock and/or headache ball from the b. With the boom over the rear, the counterweight
hoist cable(s) and stow securely before traveling or used must be from 5440 kg (12,000 lb) to 8170 kg
ensure headache ball is properly secured to the tie down (18,000 lb).
provided for that purpose.
7. Swing lock and pin shall be engaged.
8. Ensure the outrigger stabilizers and outrigger beams are
8. Hookblock must be removed from main boom nose.
fully retracted and the floats are removed.
9. Headache ball may be reeved over boom extension,
9. Ensure the center front stabilizer is fully retracted. Floats
hanging 0.9 m (3 feet) below sheave.
remain installed.
10. Suspension air bags shall be inflated.
10. Ensure the stabilizer floats are properly stowed in their
holding racks. 11. The tires shall be properly inflated.
11. Ensure the cover doors on the outrigger control panels, 10 m (33 ft)/17 m (56 ft) Extension Plus One or Two 6 m
battery box, and sling box are closed. (20 ft) Insert(s
12. Close and/or install all superstructure cab windows and Travel is permissible under the following conditions.
door.
1. The 10 m (33 ft) or 17 m (56 ft) boom extension shall be
13. If traveling with 24,000 pounds (10,900 kg) of erected at minimum offset. If traveling with just the 10 m
counterweight installed, maximum travel speed is 2.5 (33 ft) extension, the stinger section must be stowed on
mph. Suspension air bags should be inflated. the boom base section, not on the extension base
section.
Traveling With Boom Extension And/Or Inserts
Erected 2. Jobsite travel only on firm, level surface.
10 m (33 ft)/17 m (56 ft) Extension 3. Main boom shall be fully retracted. 3
Travel is permissible under the following conditions. 4. Main boom angle: 3 degrees minimum, 30 degrees
maximum.
1. The 10 m (33 ft) or 17 m (56 ft) boom extension shall be
erected at minimum offset. If traveling with just the 10 m 5. Maximum travel speed: 4 km/h (2.5 mph).
(33 ft) extension, the stinger section must be stowed on 6. With the boom over the front, the counterweight used
the boom base section, not on the extension base can be from 0 kg to 8170 kg (18,000 lb) or 10,900 kg
section. (24,000 pounds). Travel with the boom over the rear is
2. Jobsite travel only on firm, level surface. not permitted with insert(s) erected.
3. Main boom shall be fully retracted. 7. Swing lock and pin shall be engaged.
4. Main boom angle: 3 degrees minimum, 30 degrees 8. Auxiliary hoist or IPO counterweight must be installed.
maximum. 9. Hookblock must be removed from main boom nose.
5. Maximum travel speed: 4 km/h (2.5 mph). 10. Headache ball may be reeved over boom extension,
6. Counterweight: hanging 0.9 m (3 feet) below sheave.
a. With the boom over the front, the counterweight 11. Suspension air bags shall be inflated.
used can be from 0 kg to 8170 kg (18,000 lb) or 12. The tires shall be properly inflated.
10,900 kg (24,000 pounds).

Manual Transmission and Clutch upshift. Double clutching operation is accomplished as

follows.
Clutch Operation
1. Depress the clutch (do not engage clutch brake) and
shift into neutral.
Free Travel
1.5 inch
2. Release clutch pedal and accelerate the engine (when
Pedal Travel making downshift) or allow engine to slow down (when
upshifting) until engine speed approximately
corresponds to road speed of the gear ratio selected.
3. Depress the clutch pedal (do not engage clutch brake)
and shift into gear.
4. Release the clutch pedal. Always use the double
clutching technique.
4664 NOTE: Never allow your foot to ride the clutch pedal when
Depress Pedal
the clutch is engaged. This causes premature
Last One Inch To Engage
Clutch Brake
release bearing failure and short clutch facing life.
FIGURE 3-11
Shifting Gears
Clutch pedal adjustment provides for approximately 3.8 cm Next to concern for safety, good shifting habits are probably
(1.5 in) for free travel movement of the pedal after the first the most important capability a driver can have. Knowing
free travel of 1.3 cm (0.5 in) is passed before engaging the how and when to shift can return savings in trip time and
release bearing fully. It is important that this free travel be operating expense.
maintained to avoid possible excessive wear on the bearing
and/or clutch slippage. Approximately the last one inch of In the early stage of moving the crane, keep the engine
downward clutch pedal travel engages the clutch brake speed down to the actual power requirement but anticipate
which overcomes the tendency of the clutch to rotate at high the next shift demand and do not cause the engine to labor
speed when the clutch is disengaged. A slight but definite with the next shift. Start the crane in the lowest gear
resistance to clutch pedal downward movement will be felt at necessary and with the first few shifts, develop only the RPM
the last one inch of travel. needed to get rolling. Then as you upshift, increase crane
speed in each gear with a progressive increase in engine
The clutch brake is particularly useful for initial gear speed. It should seldom be necessary to go to governed
engagement in the lower gears when going uphill, when the engine speed in the lower gears except in a peak load
road speed drops off more quickly than the engine RPM situation such as starting up a grade.
requiring rapid shifts. The clutch brake MUST NOT BE
USED when making a downshift. The biggest task when climbing a grade generally will be
maintaining a reasonable rate of speed. When possible,
Clutch engagement should always be made smoothly while preplan the climb and probable shift requirements according
synchronizing accelerator movement necessary to move the to traffic conditions and grade to be climbed.
crane.
When approaching a hill, gradually move the throttle all the
way down if necessary to maintain governed RPM and
CAUTION remain at full throttle as the crane starts up the grade. If there
is sufficient power to maintain satisfactory road speed
Never fully depress the clutch pedal before the
without engine laboring, remain in that gear for the entire
transmission is put in neutral. If the clutch brake is applied
grade. Whenever a grade proves too great for the gear that
with the transmission still in gear, a reverse load will be
you are in and the engine begins to labor, ease off the throttle
put on the gears making it difficult to get the transmission
as necessary and allow speed to drop off to the next lower
out of gear. At the same time, it will have the effect of
shift point before downshifting to the next gear. Speed
trying to stop or decelerate the crane with the clutch
usually drops off quickly while shifting so the shift should be
brake, with resultant rapid wear and generation of
made rapidly. Additional downshifting should be performed in
excessive heat necessitating frequent replacement of the
the same way, as necessary. By riding each gear down to the
brake friction discs.
next shift point, you will get over your grades in the best
possible time with minimum shifts.
Double clutching is a means of bringing the speed of the
transmission gears into synchronization so the shift can be On downhill operation, the engine provides most efficient
made without clash. The engine is used to speed up the braking when run at or near top RPM in the operating range
countershaft for a downshift and to slow it down for an BUT REMEMBER the governor has no control over the

engine speed when it is being pushed by a heavy crane. 3. Allow air pressure to build up.
When the engine exceeds the rated governed RPM while
4. Apply the service brakes.
descending a grade or downshifting at the high end of the
operating range, engine overspeed can result in serious 5. Ensure the range control switch is down in the low
damage. On downhill operation, use the vehicle brakes and position.
gears in combination to keep crane speed under control and
6. If the crane is to be started in deep reduction (LL2 or
the engine below rated governed RPM.
LL1), move the deep reduction switch forward to IN
The transmission has 11 forward speeds and three reverse (Figure 3-13).
speeds. It has a five speed front section and a three speed
7. Depress the clutch pedal to the floor.
auxiliary section. The auxiliary section contains low and high
range ratios, plus three deep reduction gears. The three 8. Move the shift lever to the desired initial gear.
lowest (LL1, LO, LL2) gear sets are used for road speed
control and are not intended to be used as progressive shifts. 9. Release the parking brakes.
The other four ratios are used twice, once in low range and 10. Slowly release the clutch pedal and depress the foot
once in high range. throttle pedal.
As with any transmission gearing, shifting depends on Upshifting
proper synchronization. Adhere to the following:
• Never try to force the gear lever.
CAUTION
• During regular shifts, when moving the gear lever into
Never move the deep reduction switch or the range
the next gear position for engagement, the lever should
control switch with the shift lever in neutral while the crane
be held lightly against the gear to be engaged.
is moving.
• If gears are synchronized, engagement will be made
immediately. 1. To make a deep reduction switch shift from LL2 to 1st,
3
proceed as follows.
• If not synchronized, the flat gear teeth will rotate against
each other until synchronization is reached. a. Just before making the upshift, move the deep
reduction switch rearward to OUT while maintaining
• Do not jerk the shift lever into the next gear position or foot throttle position.
try to force gear engagement.
b. Immediately release the foot throttle pedal, depress
• If gears are out of synchronization, no amount of force is the clutch pedal once to break torque, release the
going to make the engagement before synchronization. pedal to engage the clutch, allow the engine to
All shifts are made with one lever and a range control switch decelerate until the shift is complete. Continue
which is used only once during an upshift sequence, and driving or upshifting. The transmission shifts from
only once during a downshift sequence. LL2 to 1st when synchronous is reached.
In the following instructions, it is assumed that the driver is 2. To shift in low range, proceed as follows.
familiar with motor trucks and tractors, and that he can a. Move the shift lever, double clutching, to the next
coordinate the necessary movements of the shift lever and desired gear position in low range (1st to 2nd to 3rd
clutch pedal to make progressive and selective gear to 4th).
engagements in either direction, up or down.
3. To shift from low (4th) to high (5th) range, proceed as
Crane Transmission follows.
Initial Start-Up a. When in the last gear position for low range and
ready for the next upshift, pull the range control
switch up to high and move the shift lever, double
CAUTION clutching, to the next higher gear position. As the
Before moving the crane, make sure you understand the shift lever passes through neutral, the transmission
shift pattern configuration (see Figure 3-12), or see the will automatically shift from low to high range.
decal in the cab.
1. Ensure the shift lever is in neutral and the parking brake CAUTION
is set. Never move the shift lever to the low speed gear position
after high range preselection, or anytime the transmission
2. Start the engine.
is in high range.

4. To shift in high range, proceed as follows.

a. Move the shift lever, double clutching, to the next
OFF HIGHWAY RATIOS
desired gear position in high range (5th to 6th to 7th
to 8th).
Downshifting
These ratios are not CAUTION

progressively shifted.
Never move the deep reduction switch or range control
switch with the shift lever in neutral while crane is moving.
1. To shift in high range, proceed as follows.

desired gear position in high range (8th to 7th to 6th
ON HIGHWAY RATIOS to 5th).
2. To shift from high (5th) to low (4th) range, proceed as
These ratios are follows.
progressively shifted.
a. When in the 5th gear position for high range and
ready for the next downshift, push the range control
switch down to low range and move the shift lever,
Do not change range while double clutching, to the next lower gear position. As
moving in reverse t h e s h i ft l e v e r pa s s e s t h r o u g h n e u t r a l , t h e
transmission will automatically shift from high range
to low range.
3. To shift in low range, proceed as follows.
FIGURE 3-12
desired gear position (4th to 3rd to 2nd to 1st).
4. To make a deep reduction switch shift from low range
(1st) to low-low range (LL2), proceed as follows.
a. Just before making the downshift, move the deep
Deep Reduction reduction switch forward to IN while maintaining foot
Switch
throttle position.
b. Immediately release the foot throttle pedal, depress
the clutch pedal once to brake torque, release the
pedal to engage the clutch, and depress the foot
throttle pedal. The transmission shifts from 1st to
LL2 when synchronous speed is reached.
Shifting To Reverse
CAUTION
Never make a range shift or deep reduction shift while
moving in reverse.
1. With the transmission in neutral, determine which

reverse range is to be used. Move the range control
Range Control switch up for high reverse or down for low reverse.
Switch
FIGURE 3-13 2. Move the shift lever to the reverse position.

3. To engage deep low reverse, put the range control When adverse conditions have passed, do the following:
switch in the down (low) position. Move the deep
1. Stop the crane and position the switch to the unlock
reduction switch to the forward (IN) position.
position.
4. Carefully release the clutch, making sure deep reverse
2. Resume driving at a safe speed.
is fully engaged.
Driving Tips Service/Parking Brakes
1. For a smooth start, always select an initial starting gear For the most effective braking and maximum life from the
that will provide sufficient reduction for the load and brake system components, the following suggestions are
terrain. made.
2. On later model cranes, progressively shift the road 1. Air brakes have light pedal operation and the driver is
control ratios. cautioned to use extreme care in application until a good
feel is achieved.
3. Always use normal double clutching procedures when
making lever shifts. 2. Use the engine as a brake when approaching a stop or
going down a long grade. On a downgrade, use the
4. Never slam or jerk the shift lever to complete gear
same transmission gear as would be needed to go up
engagement.
the same grade.
5. Never coast with the gear shift lever in the neutral
3. When necessary to use brakes to reduce crane speed
position.
on downgrades, use a on-and-off application to
6. Never move the deep reduction switch or the range minimize heat and wear. Do not hold a continuous brake
control switch with the gear shift lever in the neutral application or slide the wheels.
position while the vehicle is moving.
4. When driving on slippery pavement or under icy 3
7. Never make a range shift while operating in reverse. conditions, alternately and smoothly apply and release
the brakes to prevent skidding.
8. Never downshift at too high of a road speed.
5. Keep the tires properly inflated. Improperly inflated tires
9. When slowing down, the proficient operator can can reduce the efficiency of the brakes.
downshift through all the individual gear speeds to
prolong the life of the brakes. 6. After driving through water, dry the brakes by applying
them lightly while maintaining a slow forward speed with
10. In most cases, depending on the engine and axle ratios, an assured clear distance ahead until brake
fuel can be saved by operating the crane at less than performance returns to normal.
governed rpm while in 8th gear.
Rear Tandem Inter-Axle/Cross-Axle Locks

DANGER
CAUTION Stop immediately if low air pressure warning sounds and
determine cause of air loss, Stop by downshifting and use
Do not operate differential locks on dry roads.
engine as a brake. Make final stop using a single brake
pedal movement to avoid excessive loss of air and
To engage the inter-axle or cross axle differential locks for
sudden engagement of parking brakes.
maximum pulling power when approaching slippery or poor
road conditions, do the following:
NOTE: If the pressure drops below 14 kPa (2 psi) per
minute with the engine stopped, have the air
system checked for leaks.
CAUTION
Do not engage or disengage differential locks while 7. Regularly check the air pressure gauge. System air
wheels are spinning or at speeds over approximately 16 pressure should never drop below 310 kPa (45 psi). If
km/h (10 mph). both systems drop below 310 kPa (45 psi), the
automatic spring brakes will actuate. Normal operating
1. Stop the crane and position the switch to the lock pressure is 725 to 825 kPa (105 to 120 psi).
position.
2. Proceed over the poor road conditions cautiously.

Stowing and Parking
DANGER
Do not use parking brake for stopping crane except in DANGER
case of an emergency, as a severe sudden stop will occur. Never park crane near holes, on rocky surfaces, or on soft
spots. This may cause crane to overturn, resulting in
injury or death to personnel.
CAUTION When parking the crane, do the following.
Release brakes before moving crane, or drive train
damage will result. 1. Remove the load from the hook.
2. Remove or stow boom extensions if so equipped.
NOTE: Park brake must be set before outrigger controls
can be operated. 3. Fully retract all boom sections.
8. The parking brakes are controlled by a push-pull knob 4. Lower the boom to normal travel position.
on the front console. Pull the knob out to apply and push 5. Engage the swing brake, swing lock pin, and 360 degree
the knob in to release the parking brake. swing lock.
Engine Braking 6. Retract all stabilizer cylinders and outrigger beams.
By energizing the engine brake, the power producing diesel 7. Turn the crane function power switch to the off position
e n g i n e , i n e ff e c t , b e c o m e s a p o w e r a b s o r b i n g a i r (press bottom of switch).
compressor. To retard a crane on a downgrade using the
8. Park the crane on a stable surface.
engine brake, the operator selects a gear which will provide
a balance between engine speed and road speed, then 9. Apply the parking brakes and if necessary, chock
engages the engine brake. If the engine speed exceeds wheels.
maximum rated rpm for a desired speed, a lower gear can be
10. Ensure all operating controls are in neutral position.
selected or intermittent use of the service brakes can be
made. This selection of a lower gear will generally allow 11. Shut down engine following proper procedures specified
complete control of the crane by the engine brake leaving the in this handbook and the applicable engine manual.
service brakes in reserve to be used for emergency stops.
12. Remove the keys.
With the engine brake turned on, the engine brake will not be
energized until the momentum is driving the engine. 13. Close and lock, if applicable, all windows, covers, and
doors.
1. Position the engine brake On/Off switch to on (push top
of switch).
Crane Shutdown Procedures
2. Position the engine brake switch to either high (press top
The following procedures will extend serviceable life of
of switch) or low (press bottom of switch) position,
various crane components, reduce vandalism, and accidents
depending on the amount of braking desired.
during crane shutdown periods or anytime the crane is left
3. Leave off the throttle to activate the engine braking unattended.
system and slow the crane.
1. Perform the procedures found under Shutdown
NOTE: The engine braking system will automatically Procedure in this handbook.
deactivate when the throttle is depressed.
CAUTION DANGER
Before engaging engine brake on slippery roads, be sure Never park crane near holes, on rocky surfaces, or on soft
crane is maintaining traction. spots. This may cause crane to overturn, resulting in
injury or death to personnel.
2. Park the crane on a proper surface with the outrigger

stabilizers and beams fully retracted. Do not park in a
location where it may become frozen to the ground or
settle unevenly and overturn.

3. Apply parking brakes and if necessary, chock the

wheels.
4. Position all controls to neutral or off.
DANGER
5. Shut down the engine using the proper procedures as Step 10 does not take the place of the prestarting checks
specified by this Handbook and the engine manual. which must be performed just prior to using the crane at
6. Perform any other specified procedures required at the the next working day.
end of the workday, i.e., drain water from the fuel filter -
water separator, refueling, etc. 10. Make a thorough walk around inspection to ensure that
all cylinders that can be retracted are retracted. The only
7. Close all windows. exceptions are those cylinders which cannot be fully
8. Remove the keys from the crane. retracted, i.e., steer cylinders. Also, look for anything
that could hinder or prevent starting the next day’s work.
9. Lock the crane. Install vandal guards, if used.

PAGE LEFT BLANK

SECTION 4
SET-UP AND INSTALLATION
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installing Cable On The Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Installing Wedge and Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Mounting The Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Stowing The Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Checking the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Transport condition with lattice extension folded at the side . . . . . . . . . . . . . . . 4-9
Boom Extension Erecting and Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Preparing the Crane for Boom Extension Erection Procedure . . . . . . . . . . . . . . . . 4-11
Requirements for Boom Extension Erection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Requirements for Stowing the Boom Extension . . . . . . . . . . . . . . . . . . . . . . . 4-11
Erecting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
33 ft (10.1 m) Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Raising and Lowering the Hydraulic Boom Extension . . . . . . . . . . . . . . . . . . . . . . 4-20
Transportation on a Separate Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Lifting Limit Switch on the Lattice Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Folding Out/In the Deflection Sheaves on the 33 ft (10.1 m) Section . . . . . . . . . . . 4-21
Folding Rear Deflection Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Folding Out Deflection Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Folding In Deflection Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Positioning/Remove the Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4
Removing Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Setting the Folding Swingaway Extension Offset . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Installing the 16 ft (4.9 m) Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Removing the 16 ft (4.9 m) Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Boom Extension (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Identification and Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Assembly Of Boom Extensions (Figure 4-60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Electrical Connection at the Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Transport Condition of the Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Unfolding/Folding the Deflection Sheave on the 16 ft (4.9 m) Section . . . . . . . . . . 4-27
Folding Out Deflection Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Folding In Deflection Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Positioning/Removing the Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Positioning Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Removing Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Traveling with Manually Offsettable Boom Extension and/or Inserts Erected . . . . 4-29
33 ft (10.1m)/56 ft (17.1m) Extension Plus 16 ft (4.9m) or 32 ft (10m) Inserts 4-29
Auxiliary Single-Sheave Boom Nose (Additional Equipment) . . . . . . . . . . . . . . . . . . . . 4-29
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
GROVE 4-i
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL
Installing/Removing Auxiliary Single-Sheave Boom Nose. . . . . . . . . . . . . . . . . . . 4-29

Installing Auxiliary Single-Sheave Boom Nose . . . . . . . . . . . . . . . . . . . . . . . 4-29
Removing the Auxiliary Single-Sheave Boom Nose . . . . . . . . . . . . . . . . . . . . . . . 4-30
Rigging The Auxiliary Single-Sheave Boom Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Rigging in Transport Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Rigging in Working Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Attaching and Removing Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose . . . . . . . 4-32
Lifting Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Raising And Setting Down The Main Boom With Rigged Lattice Extension . . . . . . . . 4-33
Operating With The Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Procedure if the Permissible Wind Speed is Exceeded. . . . . . . . . . . . . . . . . . . . . 4-33
Monthly Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-ii
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION
SECTION 4
SET-UP AND INSTALLATION
GENERAL CABLE REEVING
This section provides procedures for installing the hoist NOTE: There are two types of cable (wire rope) available
cable on the hoist drum, cable reeving, and erecting and on this crane; 6 x 36 WS and 35 x 7 (non-rotating).
stowing the boom extension.
Within the limits of the load and range charts and permissible
line pull, multi-part lines allow the operator to raise a greater
INSTALLING CABLE ON THE HOIST load than can be raised with a single part line. Various cable
reeving (part line) is possible with the boom nose and hook
block Figure 4-6 and Figure 4-7. This reeving should be
CAUTION accomplished by a qualified rigger using standard rigging
If cable is wound from the storage drum, the reel should procedures.
be rotated in the same direction as the hoist.
NOTE: The cable should preferably be straightened before CAUTION

installation on the hoist drum. Do not reeve Auxiliary Hoist rope through the rope grab.
Install cable on the hoist drum in accordance with the Do reeve the Main Hoist rope through the rope grab. If
following procedure. both Main & Auxiliary Hoists are being reeved, neither one
may be reeved trough the rope grab. Keep it in the down
1. Position the cable over the boom nose sheave and route position. Figure 4-2
to the hoist drum.
2. Position the hoist drum with the cable anchor slot on top.
3. Insert the cable through the slot and position around the Rope Grab
anchor wedge Figure 4-1.
NOTE: The end of the cable should be even with the
bottom of the anchor wedge.
4. Position the anchor wedge in the drum slot; pull firmly on
NOTE:
the free end of the cable to secure the wedge.
If the wedge does not seat securely in the slot,
4
carefully tap the top of the wedge with a mallet.
5. Slowly rotate the drum, ensuring the first layer of cable is

evenly wound onto the drum.
6. Install the remainder of the cable, as applicable.
6769
Anchor
Wedge
FIGURE 4-2
NOTE: Also use the rope grab when using the Main Hoist
with lattice extensions to quick reeve the hook
block without removing the wedge socket on the
end of the cable Figure 4-3.
3155a
FIGURE 4-1

CAUTION
If the socket is not positioned with the flat face away from
the boom sections, structural damage will occur.
When anchoring the socket to the boom, ensure the flat face
of the socket is in position, as shown, away from the boom
sections Figure 4-4.
.
FIGURE 4-3
DEAD-END RIGGING/WEDGE SOCKETS

Wedge socket assemblies are popular rigging accessories
and have been successfully used for decades to terminate
wire ropes on mobile cranes. A wedge socket assembly is
easily installed and dismantled but it must be installed and
6754 FIGURE 4-4
used correctly. It is essential to use only a wedge and socket
of the correct size for the rope fitted. Failure to do so may
result in the rope pulling through the fitting. Installing Wedge and Socket
Since state and local laws may vary, alternate attachment 1. Inspect the wedge and socket. Remove any rough
methods may be necessary depending upon work edges and burrs.
conditions. If alternate methods are selected, the user is 2. The end of the wire rope should be seized using soft, or
responsible and should proceed in compliance with the annealed wire or strand. If the end of the rope is welded,
regulations in force. If there are any questions, contact your the welded end should be cut off. This will allow the
local Grove Distributor or Manitowoc CraneCARE. distortion of the rope strands, caused by the bend
Do not mix components from different manufacturers. The around the wedge, to adjust themselves at the end of the
selection, installation and use of a wedge socket assembly line.
must be in accordance with the requirements of the wedge
socket manufacturer and the wire rope manufacturer upon
whose wire rope the wedge socket assembly will be used. Live End
Manitowoc/Grove Crane specifies the size, type, class and
line pulls for wire rope, predominately rotation resistant wire Dead End
rope, and rigging accessories such as overhaul balls and
hook blocks for use with each new crane that it
manufactures. Other wire ropes and rigging accessories are
available from various vendors. Different wire rope
man uf ac ture rs ha ve differ ing re qu ire men ts fo r t he 5337
construction, handling, cutting, seizing, installation, Right Wrong
termination, inspection and replacement of the wire ropes FIGURE 4-5
they produce. Their advice should be sought for each
specific type of wire rope a crane user intends to install on a
mobile crane. 3. Make sure the live-loaded side Figure 4-5 of the rope is
directly in line with the ears of the socket and the
When assembly is complete, raise the boom to a working direction of pull to which the rope will be subjected. If the
position with a load suspended to firmly seat the wedge and rope is loaded into the socket incorrectly, under a load
rope into the socket before the crane is used operationally. the rope will bend as it leaves the socket, and the edge
of the socket will wear into the rope causing damage to
the rope and eventual failure.

4. Insert the end of a wire rope into the socket, form a loop dead end. DO NOT CLAMP THE LIVE END. The U-bolt
in the rope, and route the rope back through the socket should bear against the dead end. The saddle of the clip
allowing the “dead” end Figure 4-5 to protrude from the should bear against the short extra piece. Torque the U-bolts
socket. Ensure the dead end of the rope is of sufficient according to the figures listed in the chart titled Wire Rope
length to apply end treatment to the dead end after the Clip Torque Values (Table 4-1).
wedge has been seated.
Other sources for information with which crane users should
5. Insert the wedge into the loop and pull the live end of the be familiar and follow is provided by the American Society of
rope until the wedge and rope are snug inside the Mechanical Engineers, American National Standard, ASME
socket. It is recommended that the wedge be seated B30.5, latest revised. ASME (formerly ANSI) B30.5 applies
inside the socket to properly secure the wire rope by to cableways, cranes, derricks, hoists, hooks, jacks, and
using the crane’s hoist to first apply a light load to the live s ling s. I t stat es , in s ec tio n 5 -1 .7 .3, “ (c) Swag ge d,
line. compressed, or wedge socket fittings shall be applied as
recommended by the rope, crane or fitting manufacture.”
6. After final pin connections are made, increase the loads Wire ropes are addressed in ASME B30.5, section 5-1.7.2,
gradually until the wedge is properly seated. ROPES, It states, in pertinent part, “(a) The ropes shall be of
a c onst ruction rec ommende d by the ro pe or crane
7. The wire rope and wedge must be properly secured manufacturer, or person qualified for that service.” Additional
inside the socket before placing the crane into lifting information is published by the Wire Rope Technical Board in
service. It is the wedge that secures the wire rope inside the Wire Rope Users Manual, latest revised.
the socket whereas the dead-end treatment is used to
restrain the wedge from becoming dislodged from the Table 4-1
socket should the rope suddenly become unloaded from
the headache ball or hook block striking the ground, etc. WIRE ROPE CLIP TORQUE VALUES
Sketches A through F Figure 4-6 illustrate various methods Clip Sizes *Torque
for treating the dead-ends of wire ropes which exit a wedge mm Inches Nm Ft-Lbs
socket assembly. While use of the loop-back method is 3.18 1/8 6 4.5
acceptable, care must be exercised to avoid the loop 4.76 3/16 10 7.5
b ec o m i n g e n ta n g l e d w i t h t r e e br a nc h e s a nd o t he r 6.35 1/4 20 15
components during crane transport and with the anti-two 7.94 5/16 40 30
block system and other components during use of the crane. 13.28 3/8 60 45
Of the methods shown below, Grove prefers that method A 11.11 7/16 90 65
or B or F be used on Grove cranes, i.e., clipping a short piece 12.70 1/2 90 65
14.29 9/16 130 95
of wire rope to the dead-end or using a commercially
a v a i l a b l e s p e c i a l t y c l i p o r w e d g e . Ty p i c a l l y, i t i s 15.88 5/8 130 95 4
recommended that the tail length of the dead-end should be 19.05 3/4 175 130
a minimum of 6 rope diameters but not less that 15.2 cm (6 22.23 7/8 300 225
in) for standard 6 to 8 strand ropes and 20 rope diameters 25.40 1 300 225
but not less than 15.2 cm (6 in) for rotation resistant wire 28.58 1-1/8 300 225
ropes. 31.75 1-1/4 490 360
When using method A, place a wire rope clip around the 38.68 1-3/8 490 360
dead end by clamping a short extra piece of rope to the rope 38.10 1-1/2 490 360
Specialty Clip
Specialty Wedge
A B C D E F FIGURE 4-6

Upper Boom Nose Sheaves
To Main Hoist
Lower Boom Nose Sheaves
Auxiliary Nose
Hookblock Dead End
Hookblock Sheaves
9 PARTS LINE 6453
6453-3
One Part Line Using Boom One Part Line Using Boom
Extension Shown at 20° Offset Extension Shown at 40° Offset
FIGURE 4-7

33 Ft (10 m) FIXED BOOM EXTENSION
EXTENSION
SHOWN AT 0o OFFSET
SHOWN AT 0o OFFSET
56 Ft (17 m) BI-FOLD BOOM
6453-1

76 Ft (23 m) BI-FOLDBOOM EXTENSION
96 Ft (29 m) BI-FOLDBOOM EXTENSION

SHOWN AT 0o OFFSET
SHOWN AT 0o OFFSET
6453-2

REMOVABLE COUNTERWEIGHT counterweight using the attach pins in the cylinders.

Insert the retaining pins in the attach pins.
4. Push in, turn, and remove the long attach pins from the
counterweight and carrier frame lugs.
DANGER 5. Using the control levers, raise the counterweight up
Ensure that all mounting pins are properly installed and under the superstructure frame.
locked, during, and after operating the counterweight
removal system. NOTE: It may be necessary to jog the counterweight
removal control levers Figure 4-8 to install the
• The 5443 kg (12,000 pound) removable counterweight upper attach pins.
consists of three slabs, each weighing 1814 kg (4000 6. Remove the upper attach pins from the stowage
pounds). bushings and install them into the upper counterweight
• The 8165 kg (18,000 pound) removable counterweight and superstructure frame lugs.
consists of three slabs each weighing 1814 kg (4000 7. Push in on the pins and turn to lock pin in the notch.
pounds) and one slab weighing 2721 (6000 pounds).
8. Insert the long pins into the bottom of the counterweight.
• An optional 10,885 kg (24,000 pound) removal Push in on the pins and turn to lock pin in the notch.
counterweight consists of two 1,360 kg (3000 pound)
“wing weights” that hang on the existing 8,165 kg 9. The crane is now ready for operation with the
(18,000 pound) counterweight stack. counterweight installed.
NOTE: This extra counterweight is not roadable due to the Stowing The Counterweight
overall width of the machine when installed, but you
can move around the jobsite with the full 1. Position the crane on a firm level surface. Fully extend
counterweight installed. and set the outriggers.
NOTE: The following procedures are applicable for 2. Rotate the superstructure to align the counterweight with
removal and installation of any or all pieces the stowage area. Engaging the pin type turntable lock
Figure 4-8. will aid alignment.
The counterweight contains lugs for attachment to the NOTE: It may be necessary to jog the counterweight
removal cylinders and lugs to pin it under the hoist mounting. removal control levers to remove the weight of the
The additional slabs pin the structure to each other. The counterweight from the upper attach pins.
counterweights can be pinned to the carrier deck and are 3. Using the counterweight removal control valve levers,
transferred between the turntable and the carrier deck and
by two hydraulic removal cylinders. The cylinders are
raise the counterweight cylinders to relieve weight on
the upper attach pins. Push in, turn, and remove the
4
controlled from a valve assembly located under the hoist upper attach pins from the superstructure frame lugs
mounting. The valve contains an inlet section, an outlet and the counterweight
section with relief valve, and a working section for each
cylinder. The valve is manually controlled by levers 4. Stow the upper attach pins in the bushings on the side of
extending through the turntable side plates on each side. the superstructure.
5. Push in, turn, and remove the long pins from the bottom
Mounting The Counterweight of the counterweight.
1. Position the crane on a firm level surface. Fully extend 6. Using the removal control levers, slowly lower the
and set the outriggers. counterweight onto the carrier stowage area.
2. Rotate and align the rear of the superstructure above the 7. Insert the long pins through the carrier lugs and
removable counterweight stowed on the carrier deck. counterweight. Push in and turn to lock pin in the notch.
Engaging the pin type turntable lock will aid alignment.
8. Remove the attach pins from the counterweight lugs and
3. Using the counterweight removal control valve levers cylinder ends. Raise the cylinders and stow the attach
located on either side of the turntable, lower the pins in cylinder and insert retainer clip pins.
counterweight cylinders. Pin the cylinders to the
9. The carrier is now ready for highway travel with the
counterweight stowed.

13
12
10 14
16 11
6, 8 1
11
2, 3, 4
6 5
10
7 6533
9
15 FIGURE 4-8

1 Counterweight Removal Cylinder 9 Counterweight Weldment (18,000# Only)
2 Spacer 10 Box Attach Pin
3 Bolt 11 Counterweight Weldment Attach Pin
4 Washer 12 Hoist
5 Cylinder Attach Pin Assembly 13 Turntable
6 Capscrew 14 Counterweight Removal Valve Control Levers
7 Counterweight Weldment 15 Counterweight Weld - LH (Optional)
8 Nut 16 Counterweight Weld - RH (Optional)

INSTALLING THE BI-FOLD MANUAL BOOM - is folded up at the side of the main boom for
EXTENSION transportation or
- is completely removed for transportation.
DANGER
To prevent serious injury or death, always wear personal DANGER
protective equipment; i.e., a hard hat, eye protection, Be careful not to damage the lattice extension and the
gloves and metatarsal boots. main boom. Always put the lattice extension into transport
condition when folded at the side or working with the main
1. Before installing the boom extension make sure the boom. Only then is the lattice extension secured against
crane is set up on outriggers using normal setup slipping. This way you prevent the partly fastened lattice
p r o c e d u r e s . R e f e r t o S e c t i o n 3 - O P E R AT I N G extension hitting the main boom or the individual
CONTROLS and PROCEDURES. components of the lattice extension hitting each other and
becoming damaged.
NOTE: An auxiliary crane with sling is required to install
the bi-fold boom extension. You must check transport condition:
2. Check the transport condition of the bi-fold extension. - After stowing the lattice extension, before you drive
3. Using an auxiliary crane, attach sling to the bi-fold the crane with the lattice extension folded at the side
extension. or work with the main boom.
4. Lift the bi-fold extension in front of the main boom with - Before installation and before erecting the lattice
the auxiliary crane and lock the 33 ft (10.1 m) section to extension.
the right of the main boom head Figure 4-9.
Transport condition with lattice extension folded at
the side
The transport condition with the lattice extension folded at
the side is created when all of the following connections are
established.
• Check the connections and establish them if
necessary Figure 4-10.
If 23 ft (7 m) section and 33 ft (10.1 m) section are

folded at the side: 4
FIGURE 4-9 - The 33 ft (10.1 m) section is locked at the front
5. Pin the left side to the boom nose. mount (2) on the main boom Figure 4-10.
6. Establish electrical connection between the extension - The pins (4) are inserted on the pivot point between
and the main boom. the 23 ft (7 m) section and the 33 ft (10.1 m) section
Figure 4-10.
7. For units equipped with hydraulic luffing boom
extension, establish hydraulic connections between the - The connection (8) in the middle area is between
extension and the main boom. the 23 ft (7 m) section/33 ft (10.1 m) section
Figure 4-10.
NOTE: You can also install the bi-fold swingaway boom
extension in front of a 16 ft (4.9 m) section when - The connection (8) between 23 ft (7 m) section and
you are changing directly from the 56 ft (17.1 m) bi- m a i n b o o m i n t h e r e a r a r e a i s e s ta b l i s h e d
fold swingaway extension to a boom extension. Figure 4-10.
If the 23 ft (7 m) section only is folded at the side:

Checking the Transport Condition
- The connection (8) in the middle area is between
For transportation you must establish certain connections t h e 2 3 ft ( 7 m ) s e c t i o n a n d t h e m a i n b o o m
between both parts of the lattice extension. The connections Figure 4-10.
which need to be established depend on whether the lattice
extension: - The connection (5) between the 23 ft (7 m) section
and the main boom in the rear area is established.

10
11
12
9 6510-3
7 1 3
6
2
6510-8 6510-7
8 8
6916-1

1 Stinger 7 Bumper Pad
2 Front Mount 8 Holding Plate
3 Upper Hangar 9 Boom Extension
4 Lower Support 10 Pin
5 Rear Hangar 11 Pin
6 Carrier 12 Bracket
FIGURE 4-10

BOOM EXTENSION ERECTING AND - No other load is raised apart from the hook block.
STOWING PROCEDURE - The counterweight required according to the lifting
capacity chart for the planned operation with the
General Warnings lattice extension is rigged.
- The crane is supported with the outriggers
prescribed for operation with the erected lattice
extension according to the lifting capacity chart.
DANGER
- The main boom is fully retracted.
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection, Securing Lattice Extension With Tag Line (Rope)
gloves and metatarsal boots.
DANGER
Always secure the lattice extension with a tag line (rope)
DANGER on the main boom before removing any connections. This
Boom angles are used to control speed at which will prevent the lattice extension from slipping off the run-
extensions swing during erecting and stowage. Improper up rail, swinging around and knocking you off the carrier
boom angles will cause uncontrollable swing speeds of or injuring other persons in the swing range.
extension.
The lattice extension may swing out on its own accord when
NOTE: Tag line used in these procedures is to control the the boom extension is removed from its stowage brackets.
movement of the boom extension.
You must therefore secure the lattice extension before you
Preparing the Crane for Boom Extension begin with the erection procedure.
Erection Procedure Secure the lattice extension as follows:
NOTE: The data in this section also applies to the erection • Attach a tag line (rope) at the front of the lattice
of the boom extension. extension.
• Guide the tag line (rope) underneath the lattice
Requirements for Boom Extension Erection
extension, via the holding rod on the main boom and
Before you erect a lattice extension or the boom extension, back again.
the following requirements must be met:
- The swingaway lattice extension is mounted on the
• Secure the other end of the tag line (rope) on the
crane (e.g. on the steps of the access ladder to the
4
side of the main boom and is in transport condition. carrier or to the hole in the superstructure). Leave
enough play in the tag line (rope) that it is tight only
- The crane is supported by the outriggers according
when you swing the lattice extension towards the
to the lifting capacity chart for the planned operation
main boom head later on. Refer to ERECTION AND
with the lattice extension and is aligned horizontally.
STOWING PROCEDURE.
- The main boom is completely retracted and has
been lowered into horizontal position. Erecting Procedure
- If the crane is equipped with two hoists with 33 ft (10.1 m) Boom Extension
additional equipment, the hook block is unreeved on
the hoist, which is not used for working with the
lattice extension.
Requirements for Stowing the Boom Extension DANGER

To prevent serious injury or death, do not stand on
Before you lower a lattice extension or the boom extension decking until extensions are secure.
into a horizontal position, the following requirements must be
met: 1. Visually check to ensure all pins are installed.

2. Crane should be set up on outriggers using normal 4. If not using the bi-fold 7m (23 ft) section, remove pin (1,
setup procedures Figure 4-11. Refer to Section 3 - Figure 4-13, photo 6642-8) from the locking bar (2).
OPERATING CONTROLS and PROCEDURES. Move locking bar (2, photo 6642-9) to the base section
attachment bar (1) and install pin (3). Secure with
retaining pin.
1
2
6645-1
FIGURE 4-11 1
a. Fully retract boom.

b. Lower boom to horizontal for erecting over the front 6642-8 6642-9
of the crane.
NOTE: Tag line is used to control movement of the boom
extension during erecting procedure. FIGURE 4-13
3. Attach tag line (1, Figure 4-12) to tip of extension and to 5. If not using the bi-fold 7m (23 ft) section, remove the
the superstructure. retainer clip and bi-fold stowage pin (1, Figure 4-14) at
the base section connection. Stow pin on bi-fold. Leave
the pin (2) attaching the 7m (23 ft) section to the base
1 section to retain the 7m (23 ft) section.
.
2 1
6645-2 FIGURE 4-12
NOTE: If erecting the 10.1 m (33 ft) section without the 7 m

(23 ft) section, perform steps 4 and 5, otherwise
proceed to step 6.
6642-41 FIGURE 4-14
NOTE: Steps 6, 7 and 8 apply when erecting the 7m (23 ft)

section together with the 10.1 m (33 ft) section. If
not using the bi-fold 7 m (23 ft) section, proceed to
step 11.

6. Remove retainer clip (1, Figure 4-15) from the pin 10. Use the controller to pivot the boom extension so that
attaching the 7m (23 ft) section to the base section. lugs (1, Figure 4-18) on boom extension align with the
. holes in the lugs (2) on the boom nose.
1
6642-5 FIGURE 4-15
6642-11 FIGURE 4-18
7. Remove the stowage pin (1,Figure 4-16).
11. Remove pins (1, Figure 4-19) stowed in extension and
install in holes (right side of boom nose) and secure with
retainer clips (2).
6642-6 1 FIGURE 4-16

4
2
8. Stow the pin (1, Figure 4-17) in pin holder (2) provided 6642-13
on the swingaway extension. FIGURE 4-19

12. Remove the clip pin (1, Figure 4-20) from the stowage
pin (2) at the front mount. Unpin the stowage pin (2) and
store in holder (3).
2
3
1
6642-7
1 FIGURE 4-17
9. Remove the jib stowage controller from behind the seat 6642-46 FIGURE 4-20
in the superstructure cab.

13. Extend the boom approximately 60.9 cm (2 feet) to NOTE: Step 17 is with the 7m (23 ft) section stowed on
move extension (1, Figure 4-21) off of the ramp (2). boom.
17. While maintaining control with the tag line, swing
extension into position on boom nose. The 7m (23 ft)
section will remain on the boom.
18. Remove pins from holders and install pins (1,
Figure 4-23) on left side of boom nose and secure with
retainer clips. Lower pin (2) is shown in pin holder,
remove from holder and install on boom nose.
1 2
6642-47 FIGURE 4-21
14. Remove tag line from superstructure.

2
NOTE: Tag line is used to control movement of the boom
extension during erecting procedure.
6642-18 FIGURE 4-23

DANGER
To prevent serious injury or death, do not stand on the Relieving the Load on Bearing Points
crane deck to pull extension off ramp. NOTE: The dead weight of the lattice extension can cause
the bearing points on the left side to be misaligned
NOTE: If erecting the 7 m (23 ft) section with the 10.1 m or the pins to get weighted which makes it
(33 ft) section, perform steps 18 and 19. If erecting impossible to knock them out.
the 10.1 m (33 ft) section without the 7 m (23 ft)
section, proceed to step 17. When establishing or disconnecting the connections,
proceed as follows:
15. Using the tag line (rope), pull the extension away from
the boom Figure 4-22. • Lower the lattice extension until it is on the ground with
the supports (1, Figure 4-24). If necessary, override the
16. While maintaining control of the extension with the tag lifting limit switch.
line, swing extension into position on boom nose
Figure 4-22. • Continue to lower carefully until the connecting points (1,
Figure 4-25) align or until the load has been removed
7m (23 ft) section with the from the pins.
10.1 m (33 ft) section
6645-3 FIGURE 4-22

b. Remove dummy plug (1, Figure 4-27) from junction

box on boom nose.
6642-20
FIGURE 4-27
6642-44
1 FIGURE 4-24
c. Install cable end connector (1, Figure 4-28) from
boom extension where dummy plug was removed.
6642-21
FIGURE 4-28
6642-45
FIGURE 4-25
20. Lower boom and remove tag line (1, Figure 4-29) from
the tip of the extension. Figure 4-29 shows the 7 m (23 4
ft) and 10.1 m (33 ft) section together.
19. Connect LMI cables:
a. Remove LMI cable end connector (1, Figure 4-26)
from extension and route through boom extension.
1
6642-22
FIGURE 4-29
1
6642-19
FIGURE 4-26

56 ft (17.1 m) Boom Extension NOTE: Do not lower boom until stinger has been
completely swung in front of the 33 ft (10.1 m)
1. Secure tag line to (1, Figure 4-30) bi-fold nose.
section.
5. Lower the boom.
6. Remove pin (1, Figure 4-33) from swingaway. Install pin
in stinger and retain with clip pin.
6642-23 FIGURE 4-30

6642-26 FIGURE 4-33
2. Raise boom slightly above horizontal.
7. Connect LMI connector (1, Figure 4-34) to LMI
3. Remove retainer clip (1, Figure 4-31) and remove bi-fold
connection box. The cable is stowed in the 23 ft (7m)
stowage pin (2).
section.
6642-24 FIGURE 4-31 6642-27
4. Using the tag line (1, Figure 4-32) to maintain control of 1 FIGURE 4-34
the bi-fold (stinger), swing stinger into erected position.
8. Remove tag line before operating crane.
1 NOTE: Reeve the hoist cable as described under rigging

and unrigging procedure in this section.
Stowing Procedure
56 ft (17.1 m) Boom Extension
DANGER
6642-25
To prevent serious injury or death, do not stand on
FIGURE 4-32 decking until extensions are secure.

1. Lower boom below horizontal. 6. Using tag line to control movement of stinger, swing
stinger into stowed position Figure 4-38.
2. Attach tag line to stinger nose Figure 4-35.
6642-29 FIGURE 4-38

6642-23 FIGURE 4-35
7. Raise boom slightly above horizontal.
3. Disconnect LMI connection (1, Figure 4-36). Stow the
8. Connect stowage link (1, Figure 4-39) to stinger using
cable in the 23 ft (7 m) section.
pin (2) and retainer clip (3).
6642-24 FIGURE 4-39

4
6642-28 1 FIGURE 4-36
9. Remove tag line from stinger.
4. Remove retainer clip and remove the left side stinger
retaining pin (1, Figure 4-37). Place pin in holder. 33 ft (10.1 m) Boom Extension
1. Lower boom and secure tag line (1, Figure 4-40) to tip of
boom extension. shows the 7 m (23 ft) and 10.1 m (33 ft)
extension together.
6642-26 FIGURE 4-37

6642-30 1
5. Raise boom to slightly above horizontal. FIGURE 4-40

2. Disconnect LMI Cable. the boom extension pin holders (1) and install the
retainer clips.
a. Remove connector (1, Figure 4-41) from junction
box on boom nose.
2
1
6642-21 FIGURE 4-41

6642-31 FIGURE 4-44
b. Install dummy plug (1, Figure 4-42) on junction box.
4. Completely retract boom.
5. Extend boom approximately 60.9 cm (2 feet).
6. Raise boom above horizontal.
NOTE: Step 7 is stowing with the 7 m (23 ft) section and
10.1 m (33 ft) section together. If the 7 m (23 ft)
section remained on the boom, proceed to step 9.
7. Use the tag line to maintain control of the boom
extension, and swing the extension into the stowed
position Figure 4-45.
1
6642-20
FIGURE 4-42
c. Route cable through boom extension and stow
connector (1, Figure 4-43).
6645-5 FIGURE 4-45
NOTE: Step 8 is with the 7 m (23 ft) section stowed on

boom. If stowing the 7 m (23 ft) section and 10.1 m
(33 ft) section together, proceed to step 10.
8. Use the tag line to maintain control of the boom
extension Figure 4-45, and swing the extension into
stowed position until tag line can be attached to
1 superstructure.
9. Raise the boom to ensure wear pad rests against
bumper plate on ramp Figure 4-46.
6642-19 FIGURE 4-43
10. Completely retract boom so that the boom extension (1,
3. Remove two pins attaching the boom extension to the Figure 4-46) stows on the ramp (2) and front stowage
left side of boom nose (2, Figure 4-44). Stow the pins in brackets.

12. Remove the stowage pin from the holder at the front
mount. Secure the lattice extension (1, Figure 4-47) to
boom front stowage bracket (2) using stowage pin (3)
and clip pin (4).
2 3
1 2
6642-46 FIGURE 4-47
6642-47 FIGURE 4-46
11. Lower the boom.
DANGER
Never remove the stowage pins from the right side boom
DANGER nose lugs (1, Figure 4-48) until the 10.1 (33 ft) lattice
If the 33 ft lattice extension (1, Figure 4-46) does not extension has been properly secured to the stowage
engage the ramp (2, Figure Figure 4-46) correctly or does ramp (2, Figure 4-46) and front stowage bracket (2,
not align with the front stowage bracket (2, Figure 4-47) Figure 4-47).
correctly, STOP. DO NOT continue to stow the boom
Sever injury or death may occur, boom extensions will fall
extensions until they are properly secured at these two
from the main boom if not secured properly.
points.
DO NOT climb onto decking or walk under boom 13. Remove pins from right side boom nose lugs (1,
extensions. Figure 4-48). Stow the pins in pin holders (2) on boom
Sever injury or death may occur if the front stowage
bracket and ramp are not properly attached to the boom
extension and install retainer clips. 4
a. If the 7 m (23 ft) was left stowed, use controller to
extensions; the boom extensions may fall or swing away
pivot boom extension in towards boom so that the
from the main boom stowage brackets.
lugs on 10.1 m (33 ft) section align with 7 m (23 ft)
Contact Manitowoc CraneCARE for correct adjustments if section.
unable to align the lattice extension with the stowage
brackets. b. If using both the 10.1 m (33 feet) and 7 m (23 ft)
sections, use the controller to pivot boom extension
towards boom such that the lugs on the 7 m (23 ft)
section align with rear stowage bracket.

6642-38 FIGURE 4-48

6642-41 FIGURE 4-50
NOTE: Perform steps 14 and 15 if stowing the 10.1 m (33
ft) section when the 7 m (23 ft) section remained on NOTE: Step 16 applies when the 7m (23 ft) section was
the boom, otherwise proceed to step 19. erected with the 10.1 m (33 ft) section.
14. If the bi-fold 7m (23 ft) section was not used, remove pin 16. Install rear stowage pin (1, Figure 4-51) and retainer clip
(1, Figure 4-49, photo 6642-9) from the base section (2).
locking bar (2). Move locking bar (3, Figure 4-49, photo
6642-8) to the 7 m (23 ft) section (4) and install pin (1).
Secure with retaining pin.
1
1 1
2 6642-39 FIGURE 4-51
6642-8
17. Lower boom.
6642-9
18. Remove tag line.
Reeve the hoist cable as described in this section
FIGURE 4-49
Raising and Lowering the Hydraulic Boom
15. If the bi-fold 7m (23 ft) section was not used, remove bi-
Extension
fold stowage pin (1, Figure 4-50) from bi-fold and install
at the lattice/bi-fold connection. Install retainer clip to pin. NOTE: For more information on operation of the boom
extension switches, refer to Section 3 - Operating
Controls and Procedures.

When erecting
To remotely raise or lower the lattice extension when CAUTION
erecting there are two control units each with two push
Risk of damaging the lattice extension.
buttons on the 33 ft (10.1 m) section.
Always secure the lattice extension by tying it down with
• Press the top push-button to raise the lattice extension suitable belts when it is transported on the separate
(1). vehicle. This prevents the two-stage swingaway lattice
• Press the bottom push-button to lower the lattice extension tipping and becoming damaged during
extension (2). transportation.
During operation Lifting Limit Switch on the Lattice Extension

During operation the lattice extension is raised or lowered
The functions raise hoist, extend main boom and lower main
from the crane cab. The lattice extension can be raised or
boom are monitored during operation with the lattice
lowered, only when the power for the lattice extension is
extension by the lifting switch on the lattice extension and
switched on.
are switched off when the lifting limit switch is actuated.
When the power is switched on:
NOTE: The same lifting limit switch is used for lattice
- The indicator lamp in the on/off rocker switch on the extension and main boom.
lattice extension lights up brightly.
Overriding Connection on Main Boom
- Activation of the power is shown on the LMI display.
For operation with the lattice extension you must remove the
• If necessary, switch on the power of the lattice lifting limit switch on the main boom and override the
extension, by pressing the lattice extension on/off rocker connection.
switch.
• Insert the short-circuit plug (1) in the socket for the
To raise, press the switch to the rear. connection of the lifting limit switch Figure 4-52.
To lower, press the switch to the front. The connection is now overridden.
Transportation on a Separate Vehicle
DANGER
Risk of accidents from a falling lattice extension. 4
Only attach the lattice extension in such a way that it is 1
positioned in the center of gravity and always use lifting
gear with sufficient lifting capacity. This prevents the
lattice extension from falling and injuring people while
loading.
4
• Check if all the required connections for transport 2
condition are established.
3
• For transportation, place the lattice extension on the skid w1525a FIGURE 4-52
at the front and onto the lower cross strut at the rear of
the 33 ft (10.1 m) section.
On 33 ft (10.1 m) swingaway lattice extension
• Always secure the lattice extension on the separate
• Attach the lifting limit switch (3) in the holder (4) and
vehicle with belts as well as to prevent slipping and
secure it with a retaining pin. Figure 4-52
overturning.
• Remove the short-circuit plug (2) from the socket (1).
• Connect the lifting limit switch on the socket (1).
• When unrigging you must insert the short-circuit plug (2)
back in the socket (1).

On the 56 ft (17.1 m) Two-Stage Swingaway Lattice On the 33 ft (10.1 m) section, there is a deflection sheave at
Extension the rear (1) Figure 4-54. Fold out the deflection sheave if the
boom extension offset angle is 20° or 40°.
NOTE: For zero (0) degree offset, leave the mast
assembly in the stowed position.
The sheave must be folded out:
• for operation with the swingaway lattice extension,
• for operation with the 56 ft (17.1 m) two-stage
swingaway lattice extension.
For transportation the mast sheave must be folded in.
Folding Rear Deflection Sheave
1
3
2
DANGER
Risk of crushing.
w1525a FIGURE 4-53 Always hold the deflection sheave by the handle, when
NOTE: For operation with the 56 ft (17.1 m) two-stage removing the pin. You might get your fingers crushed if
swingaway lattice extension the connection for the you hold the sheave by the side plates.
lifting limit switch on the 33 ft (10.1 m) section must
be overridden with a short-circuit plug. Folding Out Deflection Sheave
• Attach the lifting limit switch (2) on the shackle (1) and
secure it with a retaining pin Figure 4-53.
3
• Connect the lifting limit switch on the socket (3).
• When stowing, close the socket (3) with the protective
cap. 1
Folding Out/In the Deflection Sheaves on the

33 ft (10.1 m) Section
1
2
6568-4
FIGURE 4-55
• Remove the pin (2) from the bore (1).Figure 4-55
• Fold the deflection sheave up and secure it with the pin
in the bore (3).
• Secure the pin with a retaining pin.
6621 Folding In Deflection Sheave

• Remove the pin (2) from the bore (1).
FIGURE 4-54 • Fold the deflection sheave down and insert the pin in the
bore (3).
To prevent the hoist rope dragging on the main boom or
lattice extension during operation with the lattice extension • Secure the pin with a retaining pin.
or boom extension, the hoist rope is guided via deflection
sheaves.

Positioning/Remove the Hoist Cable • Take the hoist cable off the head sheave (2) and the
deflection sheaves (3) and place it onto the ground on
the left side.
Setting the Folding Swingaway Extension

DANGER
Offset
Risk of accidents due to falling parts.
Always secure the hoist cable holding rollers and rods
with retaining pin. This prevents elements from coming
loose, falling down and injuring people. DANGER
Ensure any blocking material used is adequate to support
Positioning Hoist Cable the weight of the extension assembly without tipping or
• Remove the hoist cable holding rollers and rod (1) falling.
Figure 4-56.
1. Extend and set the outriggers and swing the boom to
• Guide the hoist rope via the deflection sheaves (3) and over the front. Position the boom to above horizontal.
via the head sheave (2) on the 33 ft (10.1 m) section or Figure 4-57
on the 23 ft (7 m) section. Put all hoist cable holding
rollers and rods back in place and secure these with 2. Block up under the tip of the extension assembly
retaining pins. section.
• Attach the overhaul ball. 3. To set the offset from a lesser degree to higher degree,
• Install the A2B weight assembly. perform the following procedures.
Removing Hoist Cable

CAUTION
• Unpin the overhaul ball.
Do not overload the extension anchor fittings or the
• Remove the hoist cable holding rollers and rods (1). extension base section when lowering the boom.
1
4
3 6622-1
2
6622-2
3
FIGURE 4-56

Pin Assembly Mast Assembly
Shown At 0° Offset
6568-2
To obtain maximum
degree offset, remove
pin and stow in lug.
Offset
Offset
Link
Link
Pin
Pin
Shown At 20 ° Offset 6568-4 Shown At 40 ° Offset 6568-3

FIGURE 4-57
a. Slowly lower the boom until the pressure is relieved REMOVING THE BI-FOLD MANUAL BOOM
on the offset link pins. EXTENSION
NOTE: For 20 or 40 degree offset, make sure the mast is in
the raised position.
b. Remove the offset link clip pins and attach pins
securing the offset links in the lesser degree offset DANGER
position. If going to maximum offset, stow them in To prevent serious injury or death, always wear personal
the stowage lugs. If going to the intermediate (20 protective equipment; i.e., a hard hat, eye protection,
degree) offset, install them in the offset links for that gloves and metatarsal boots.
degree of offset.
c. Slowly elevate and telescope the boom at the same 1. Before removing the boom extension make sure the
time so that the extension does not move off of the crane is set up on outriggers using normal setup
blocking until the offset links take the full weight of p r o c e d u r e s . R e f e r t o S e c t i o n 3 - O P E R AT I N G
the extension. CONTROLS and PROCEDURES.
d. Reeve the hoist cable as described under normal NOTE: An auxiliary crane with sling is required to remove
erecting procedures. the bi-fold boom extension.

1. Retract the main boom completely and lower it into the

horizontal position.
2. Unreeve the hoist cable from the hook block and remove
it from the boom extension.
3. Fold in the deflection sheave on the 33 ft (10.1 m)
section.
4. Disconnect electrical connection between the lattice 3
extension and the main boom.
5. Attach auxiliary crane sling to bi-fold swingaway
extension. 1
WARNING
Lattice extension must be supported by an auxiliary crane
before removing pins.
2
6. Remove locking pins Figure 4-58 on both sides between w3361a
33 ft (10.1 m) section and main boom head and remove FIGURE 4-59
the bi-fold swingaway extension.
• Using an auxiliary crane with sling, lift the 16 ft (4.9 m)
section with support roller on an auxiliary crane and lift it
in front of the main boom head so that the bearing points
(2) and (3) align on both sides.
• Insert the securing pins into the bearing points (2) and
(3) on both sides.
• Secure all pins with retaining pins.
• Install the second 16 ft (4.9 m) section in front of the first
16 ft section for the 89 ft (27.1 m) boom extension in the
w3303a
same way.
FIGURE 4-58
7. Check the transport condition of the bifold swingaway
• Install 56 ft (17.1 m) section in front of the respective 16
ft (4.9 m) section per previous instructions in this
4
extension.
section.
INSTALLING/REMOVING 16 FT (4.9 M) Removing the 16 ft (4.9 m) Sections

SECTIONS
• Using an auxiliary crane with sling, lift the 16 ft (4.9 m)
- In order to rig the 72 ft (22 m) boom extension, you section until the bearing points (2) and (3) are relieved.
must install the 16 ft (4.9 m) section with support
• Release the pins and knock them out of the bearing
roller in front of the main boom head.
points (2) and (3) on both sides.
- In order to rig the 89 ft (27.1 m) boom extension, you
• Insert the pins into the holders at the foot of the 16 ft (4.9
must additionally install the 16 ft (4.9 m) section
m) sections and secure them with retaining needles.
without support roller in front for the 16 ft (4.9 m)
section with support roller.
BOOM EXTENSION (ADDITIONAL
NOTE: An auxiliary crane must be used to install and EQUIPMENT)
remove the 16 ft (4.9 m) sections.
Identification and Slinging Points
Installing the 16 ft (4.9 m) Sections
Identification
The securing pins (1) for the connection are secured with
retaining pins in the holders at the foot of the 16 ft (4.9 m) The boom extension consists of the 56 ft (17.1 m) bi-fold
sections Figure 4-59. swingaway lattice extension and two boom extension

sections. The boom extension is designed for the crane it Serial numbers on the 16 ft (4.9 m) sections
was delivered with. The parts which belong to the crane have
The serial number is on a plate at the front of the 16 ft
the same serial number as the crane.
sections.
The following sections are identified by the serial number:
Slinging Points
- All parts of the 56 ft (17.1 m) bi-fold swingaway
lattice extension.
- Both sections of the boom extension 16 ft (4.9 m) CAUTION
sections) This section shows the slinging points of the 16 ft (4.9 m)
. sections. Attach the sections only to these slinging points
because they will then automatically have the correct
CAUTION center of gravity. Use only lifting gear with sufficient load
Operate the crane only with those sections of the boom bearing capacity.
extension which have the same serial number as the
crane. This prevents malfunctions and damage. The 16 ft (4.9 m) sections have two slinging points (one
slightly offset on each side).
NOTE: For technical reasons a crane may only be set with NOTE: For electrical connections at the 16 ft (4.9 m)
one boom extension. sections, refer to Electrical Connections at the
If you wish to use the boom extension on several Manitowoc/ Boom Extension, in this section.
Grove cranes, the parts of the boom extension must be
adjusted for these cranes and labeled with all of the ASSEMBLY OF BOOM EXTENSIONS
respective serial numbers.
NOTE: FIGURE 4-60 The lengths of 72 ft (22.0 m) and 89
ft (27.1 m) respectively equal the distance between
the center of the locking pin (on the main boom
CAUTION head) and the front edge of the head sheave.
Have the adjustment of the boom extension only carried
out on site by Grove CraneCARE!

w3351a
FIGURE 4-60
The designation 33 ft (10.1 m) section, 23 ft (7 m)

section, and 16 ft (4.9 m) section have been
adjusted to these lengths.The total length of the
individual sections is greater or smaller.
4
Electrical Connection at the Boom
Extension
3
The following describes the electrical connections at the 16 ft
sections. Establish the electrical connection at the bi-fold
swingaway lattice extension per the following procedures
Transport Condition of the Connection

For transport, bring the electrical connections always into the
following condition.
2
There is a cable with a plug (3) at the rear of the 16 ft 1
sections Figure 4-61.
w3367a FIGURE 4-61
For transport, the cable is wound around the holders (1) and
the plug is inserted in the dummy socket (2).

Disconnecting
• Detach the electrical connection between the 33 ft (10.1
m) and front 16 ft (4.9 m) section.
• Detach the electrical connection between the two 16 ft
(4.9 m) sections.
• Detach the electrical connection between the rear 16 ft
(4.9 m) section and the main boom head.
• Prepare the electrical connections at the 16 ft (4.9 m)
section for transport.
1
Unfolding/Folding the Deflection Sheave on
the 16 ft (4.9 m) Section
w3368a FIGURE 4-62 This section describes only the unfolding and folding of the
deflection sheave on the 16 ft (4.9 m) section.
There is a plug socket (1) at the front of each 16 ft (4.9 m)
section Figure 4-62. For work with the boom extension, you must fold out the
deflection sheaves on the rear 16 ft (4.9 m) section.
For transport, the sockets are covered with protective caps.
Fold the deflection sheave for transport.
At the 72 ft (22.0 m) Boom Extension
Establishing a Connection Folding Out Deflection Sheave
• Connect the cable of the 33 ft (10.1 m) section to the

socket of the second 16 ft (4.9 m) section at the front. 1

socket at the main boom. 3
Disconnecting
• Detach the electrical connection between 33 ft (10.1 m)
and 16 ft (4.9 m) section.
2
• Detach the electrical connection between 16 ft (4.9 m)
section and main boom head.
At the 89 ft (27.1 m) Boom Extension
w3352a
Establishing a Connection
FIGURE 4-63
socket of the second 16 ft (4.9 m) section at the front. • Pull the pin (2) out of the bore (3) Figure 4-63.
• Connect the cable of the second 16 ft (4.9 m) section to • Fold the deflection sheave on the strut (1) upwards until
the socket of the first 16 ft (4.9 m) section at the front. the locking positions are aligned with the bore hole (3).
• Connect the cable of the first 16 ft (4.9 m) section to the • Fasten the deflection sheave for transport.
socket at the main boom head.

Folding In Deflection Sheave Positioning Hoist Cable

• Remove the hoist rope holding rollers and rods (1)
3 Figure 4-65.
2
1 • Guide the hoist rope via the deflection sheaves (3) and
via the head sheave (2) on the 33 ft (10.1 m) section or
on the 23 ft (7 m) section. Put all hoist cable holding
rollers and rod back in place and secure these with
retaining pins.
• Attach the overhaul ball.
• Install the A2B weight assembly.
Removing Hoist Cable
DANGER
w3353a
FIGURE 4-64
• Hold the deflection sheave by the strut (1) and remove with retaining pins. This prevents elements from
the pin (3) from the bore (2) Figure 4-64. becoming loose, falling down and injuring people.
• Fold the deflection sheave down as far as possible. • Unpin the overhaul ball.
• Insert the pin in the bore hole (3) and secure it with a • Remove the hoist rope holding rollers and rods (1)
retaining needle. Figure 4-65.
Positioning/Removing the Hoist Cable • Take the hoist cable off the head sheave (2) and the
deflection sheaves (3) and place it onto the ground on
the left side.
• Put all hoist cable holding rollers and rods back in place
DANGER and secure them with retaining pins.
with retaining pins. This prevents elements from
4
becoming loose, falling down and injuring people.
1 1 1
3 2
5
4
1
1
1
1
5 4 3
2
w3359a FIGURE 4-65

Traveling with Manually Offsettable Boom

Extension and/or Inserts Erected
33 ft (10.1 m)/56 ft (17.1 m) Extension Plus 16 ft (4.9 m)
or 32 ft (10 m) Inserts 1
Travel is permissible under the following conditions.
1. The 33 ft (10.1 m) or 56 ft (17.1 m) boom extension shall
be erected at minimum offset.
2. Jobsite travel only on firm, level surface.
3. Main boom shall be fully retracted.
4. Main boom angle: 0 degrees minimum, 40 degrees
6435-2
maximum.
FIGURE 4-66
5. Maximum travel speed: 2.5 mph (4 km/h).
6. Counterweight shall be installed. The serial number (1) is on a plate, in the front on the
auxiliary single-sheave boom nose Figure 4-66.
7. The boom shall be over the front.
8. Swing lock and pin shall be engaged.
Installing/Removing Auxiliary Single-Sheave
Boom Nose
9. Hookblock must be removed from main boom nose.
10. Headache ball may be reeved over boom extension,
hanging 3 feet (0.9 m) below sheave.
DANGER
11. The tires shall be properly inflated.
Risk of accidents if boom nose should fall off! During
installation and removal, always use the proper materials
AUXILIARY SINGLE-SHEAVE BOOM NOSE with sufficient load bearing capacities.
(ADDITIONAL EQUIPMENT)
Installing Auxiliary Single-Sheave Boom Nose
Identification
• Loosen the retaining pin (4) and remove the pins (1)
The auxiliary single-sheave boom nose is designed for the from the bearing point (2) Figure 4-67.
crane it was delivered with.
CAUTION
Operate the crane only with the auxiliary single-sheave
boom nose that has the identical serial number.
If you wish to use the auxiliary single-sheave boom nose on

several Manitowoc/Grove cranes, it needs to be adapted to
the corresponding crane and marked with all the serial
1
numbers.
CAUTION 3
The auxiliary single-sheave boom nose should only be
adjusted by Manitowoc CraneCARE at the particular 4
location. 6435
FIGURE 4-67

• Use an auxiliary crane to couple the holding device to

the connection eyes (3) on the auxiliary boom nose and 5
1
lift it to the left onto the main boom head. 2 6
3
• Align the auxiliary single-sheave boom nose so that the
bearing point (2) lines up to the front bore holes in the
holding device.
• Secure the auxiliary single-sheave boom nose to the
4
holding device using a pin (1).
• Secure the pin (1) with a retaining pin (4).
• Depending on the application, bring the auxiliary single-
sheave boom nose into transport position or working 6435-2
position. FIGURE 4-69
Removing the Auxiliary Single-Sheave • Remove the retaining pins and draw all the pins out of
Boom Nose the bores and bearing points.
• In the transport position, the auxiliary single-sheave
boom nose is positioned to the side of the main boom
head and is fastened with two pins.
• Lift the auxiliary single-sheave boom nose from the head
of the main boom.
• Insert the two thin pins (1) and (3) into the bearing points
(2) and (4) on the auxiliary single-sheave boom nose
1
Figure 4-69.
• Insert the two pins (5) into the mounting brackets (6) in
front on the auxiliary single-sheave boom nose.
• Secure all pins using retainer pins.
RIGGING THE AUXILIARY SINGLE-SHEAVE

BOOM NOSE
6435
Rigging in Transport Position
4
FIGURE 4-68
• Attach an auxiliary crane to the connection eyes of the

boom nose.
In the working position, the auxiliary single-sheave boom
nose is positioned in front of the main boom head and is 1
fastened with three pins (1) Figure 4-68.
• Remove the retaining pins and draw all the pins out of w2465a
the bores and bearing points. FIGURE 4-70
In the transport position, the auxiliary single-sheave boom On the left side of the main boom head there is a holding
nose is positioned to the side of the main boom head and is device. In transport position, the boom nose is connected to
fastened with two pins. the rear bore holes on the holding device Figure 4-70.

• Using the thin pin (1), fasten the auxiliary single-sheave

boom nose to the bearing point (2) Figure 4-72.
1 • Secure the pin with a retaining pin.
2
• The auxiliary single-sheave boom nose is now in
transport position.
Rigging in Working Position

4
w2725a w2466a
FIGURE 4-71 FIGURE 4-73
• Remove the retaining pins and take both pins (1) out of On the left side of the main boom head, there is a holding
the bearing points (2) at the front of the main boom head device. In working position, the auxiliary single-sheave boom
Figure 4-71. nose is attached to the main boom head at both bore holes
Figure 4-73.
• Insert both pins into the holders (3) and secure them
with retaining pins.
• Release the retaining pin and remove the thin pin from 1
the bearing point (4).
• Slew the auxiliary boom nose to the side of the main
boom head.
w2727a
2 FIGURE 4-74
• Release the retaining pin and remove the thin pin from
the bearing point Figure 4-74.
• Swing the auxiliary single-sheave boom nose in front of
the main boom head.
w2726a
FIGURE 4-72

• When reeving, guide the hoist cable over the left hand
upper sheave of the main boom.
1 • Insert the rope holding rod into the appropriate bore
2
holes and secure them with the corresponding retaining
pins.
• Fasten the cable end clamp on the hook tackle or the
4 hook block.
Reverse the sequence of operations to remove the hoist
cable before slewing the auxiliary boom nose into transport
position.
3
Possible Reeving Methods on the Auxiliary
Single-Sheave Boom Nose
NOTE: The hoist cable may only be simply reeved (single
drop).
w2728a • maximum load bearing capacity:
FIGURE 4-75
• for single-reeving 16,000 lbs (7.3 t)
• Remove the retaining pin and take out both thick pins
from the holders Figure 4-75. Lifting Limit Switch
• Insert both pins into the pivot points at the front of the In Operation
main boom head and secure them with retaining pins.
• Insert the thin pin into the bearing point and secure it
with a retaining pin.
The auxiliary single-sheave boom nose is now in working
position.
1
Attaching and Removing Hoist Cable
4
1 2
w2731a
1
FIGURE 4-77
• Pull the plug of the connecting cable from the dummy

socket (2) Figure 4-77.
• Unwind the connecting cable from the holders (3).
w2729a
• Insert the plug of the connecting cable into the socket (1)
FIGURE 4-76
on the main boom head.
• Remove the cable holding rods from the head of the • Guide the hoist cable through the lifting limit switch
main boom and from the auxiliary single-sheave boom weight.
nose Figure 4-76.

During Transport TELESCOPING WITH RIGGED LATTICE

• Insert the plug of the connecting cable into the dummy EXTENSION
socket (2) Figure 4-78
• Wind the connecting cable onto the holders (3).
CAUTION
• Plug the short-circuit plug into the socket (1). The main boom may become overloaded!
If you telescope the main boom with a rigged lattice
extension or boom extension. You must not rotate the
superstructure at the same time. This prevents the main
boom being subjected to additional side forces and
increased vibration and becoming overloaded.
1
NOTE: Do not actuate the slewing gear when telescoping.
OPERATING WITH THE LATTICE

EXTENSION
2 NOTE: The information in this section also applies to
operation with the boom extension. Observe the
following safety instruction before working with the
boom extension.
3 CAUTION
Risk of overturning when working with the boom
w2731a
extension!
FIGURE 4-78
When lifting over the swingaway and/or jib combinations,
deduct the total weight of all load handling devices reeved
RAISING AND SETTING DOWN THE MAIN over the main boom nose directly from the swingaway or
BOOM WITH RIGGED LATTICE EXTENSION jib capacity.
NOTE: The information in this section also applies for
NOTE: The hoisting, lowering, swinging, lifting and
raising and setting down the main boom with a
telescoping movements are done in the same way
rigged boom extension.
as when operating with the main boom.
NOTE: To raise and lower the main boom with a rigged Telescoping is permitted only at main boom angles
lattice extension, the main boom must be fully of approximately 75° - 80°, depending on the length
retracted. of the lattice extension.
For raising and lowering, the following prerequisites must be Procedure if the Permissible Wind Speed is
fulfilled:
Exceeded
- Apart from the hook block there is no load on the
lattice extension. Strong winds can overstrain the crane. Therefore, closely
observe the instructions in table.
If the maximum permissible wind speed according to the
lifting capacity table is exceeded during the main boom
operation, proceed per the following table (Table 4-2):

Table 4-2 NOTE: The information in (Table 4-3) applies to

malfunctions during operation with the 33/56 ft
with wind speed with wind speed (10.1/17.1 m) lattice extension.
up to 66 ft/s over 66 ft/s
• Set down the load. • Set down the load.
• Slew the superstructure • Fully retract the main
so that the main boom boom.
creates as little wind • Set down the lattice
resistance as possible. extension.
Table 4-3
Malfunction Cause Remedy

No function of the lifting limit switch Lifting limit switch not connected Connect the lifting limit switch.
Electrical connection between the
boom head and lattice extension and
Establishing electrical connection.
between 33 ft (10.1 m) section and 23
ft (7 m) section is not established.
Lifting limit switch on the main boom Override the lifting limit switch on the
head not overridden. main boom head.
When operating with a 56 ft (17.1 m)
lattice extension or boom extension,
Insert short-circuit plug.
the short-circuit plug is not inserted on
the head of the 33 ft (12.5 m) section.
The main boom cannot be telescoped The main boom is derricked to such an
Derrick the main boom to the required
with the rigged lattice extension or angle at which telescoping is not
angle.
boom extension. permissible
The lattice extension can not be Derricking gear of the lattice extension Switch on the derricking gear of the
derricked. is switched off. lattice extension.
MONTHLY MAINTENANCE WORK - the retaining pins used for fastening the lattice
extension sections for transport, 4
Pins
- the spring latch on the run-up rail.
Lubricate all attach, securing and retaining pins, in other
words: NOTE: The maintenance interval applies to average
operation. Also, lubricate the pins after high-
- the pins for the pin connection on the lattice pressure cleaning and generally at an interval that
extension, will prevent them getting dry.
- the retaining pins on the return pulleys,


SECTION 5
LUBRICATION
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hydraulic Oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Arctic Conditions Below -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Arctic Conditions Down To -40°C (-40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
GROVE 5-i
LUBRICATION TMS800E OPERATOR’S MANUAL
THIS PAGE BLANK
5-ii
TMS800E OPERATOR’S MANUAL LUBRICATION
SECTION 5
LUBRICATION
GENERAL To inspect hydraulic oil, fill a small glass container with a
sample of reservoir oil and another glass container with fresh
Following the designated lubrication procedures is important oil. Let the samples stand, undisturbed, for one to two hours
in ensuring maximum crane lifetime and utilization. The and then compare the samples. If the reservoir oil is heavily
procedures and lubrication charts in this section include contaminated with water the sample will appear "milky" with
information on the types of lubricants used, the location of only a small layer of transparent oil on top. If the "milky”
the lubrication points, the frequency of lubrication, and other appearance was due to air foaming, it will dissipate and the
information. oil should closely match the fresh oil. Should you have any
The service intervals specified are for normal operation questions, please contact your local Grove distributor or
where moderate temperature, humidity, and atmospheric Manitowoc CraneCARE.
conditions prevail. In areas of extreme conditions, the
service periods and lubrication specifications should be Arctic Conditions Below -18°C (0°F)
altered to meet existing conditions. For information on In general, petroleum based fluids developed especially for
extreme condition lubrication, contact your local Grove low temperature service may be used with satisfactory
distributor or Manitowoc CraneCARE. results. However, certain fluids, such as halogenated
hydrocarbons, nitro hydrocarbons, and phosphate ester
CAUTION hydraulic fluids, might not be compatible with hydraulic
Chassis grease lubricants must not be applied with air system seals and wear bands.If you are in doubt about the
pressure devices as this lubricant is used on sealed suitability of a specific fluid, check with your authorized
fittings. Grove distributor or Manitowoc CraneCARE.
NOTE: All fluids and lubricants may be purchased by
CAUTION contacting the Manitowoc CraneCARE Parts
Department.
The multipurpose grease installed during manufacture is
of a lithium base. Use of a noncompatible grease could Regardless of temperature and oil viscosity, always use
result in damage to equipment. suitable start-up procedures to ensure adequate lubrication
during system warm-up.
Hydraulic Oil Inspection
Arctic Conditions Down To -40°C (-40°F)
Environmental and other conditions can dramatically affect
the condition of hydraulic oil and filters. Therefore, specific ALL WEATHER PACKAGE & LUBRICANTS
intervals for servicing/changing hydraulic oil, filters and
hydraulic tank breathers cannot be set. However, it is Engineering recommends the following lubricants for
imperative for the continued satisfactory performance of components that will be operated in ambient temperatures to
Grove cranes that inspections be performed on the basis of -40°F. Special lubricants alone are not sufficient to operate at
how and where each crane is used. Air borne and ingested extreme low temperatures. We also recommend the use of
contaminants can significantly reduce the life of oil and the appropriately sized heaters for the hydraulic tank, engine oil
condition of hydraulic oil filters and tank breathers. pan, engine jacket water and batteries. The operator needs
to follow the guide lines as stated in the operator's manual.
Under normal operating conditions, it is recommended that
We assume that the customer has taken steps for use of an
hydraulic oil, filters and breathers be inspected and oils
sampled at least every 3 to 6 months and more frequently for
appropriate engine antifreeze coolant, taken care of the fuel,
fuel system and starting system, and has done whatever
5
severe operating conditions. The inspections should be for
they feel necessary to add insulation for under hood
air borne and/or ingested particles and water that deteriorate
temperatures and meet the engine manufacture's intake air
and contaminate the oil (e.g., oil appears “milky” or no longer
temperature requirements. Other lubricants may be used if
has a transparent clear to amber color). The return filter by-
they meet the specifications of the lubricant that is
pass indicator should be observed daily to determine if the
requested. Please consult the factory.
contaminants content may be high. If the indicator reaches
the red zone or indicates a by-pass condition, the hydraulic Axles and Swing Box - Spec 6829014058:
oil must be sampled. The hydraulic tank breather should also
• Petro- Canada Traxon E Synthetic 75W-90
be inspected to assure that it is not restricting air flow into
and out of the reservoir. • CITGO, Syntetic Gear Lube 75W-90

• Eaton, Roadranger EP75W-90 QSM engine burning ULSD fuel --Spec 6829104560 or Spec.
6829104412:
• Mobil, Mobilube SCH 75W-90
• Petro-Canada Duron Synthetic CI-4 5W-40
• Shell, Spirax S 75W-90
• Mobil Delvac 1 5W-40
• Sunoco Duragear EP75W-90
• Citgo Citgard Syndurance Synthetic Engine Oil CJ-4
Engine - QSM engine burning non-ULSD fuel --Spec
5W-40
6829104560:
• Maxtron DEO Synthetic Engine Oil CJ-4 5W-40
• Petro-Canada Duron Synthetic CI-4 5W-40
Transmission:
• Mobil Delvac 1 5W-40
• Use Standard Lubricants Package

Hydraulic tank - Spec 6829101559: • Shell Spirax GSX SAE 50

• Petro-Canada Duratran Synthetic THF • Texaco Syn-Star TL SAE 50
• Chevron All Weather THF • Petro-Canada Traxon E Synthetic CD50
• Texaco TDH Oil SS • Chevron Delo Transmission Fluid SAE 50
Hoist - Spec 6829103636: • Conoco/Phillips/Union 76 Triton Synthetic Transoil 50
• Petro-Canada ENDURATEX Synthetic EP 150 - Allison Automatic Spec 6829101690:
• Mobil SHC629 • Castrol - Allison Transynd TES295
Grease - Spec 6829104275: • Mobil Delvac Synthetic ATF
• Petro-Canada Precision Synthetic EP1 • BP Autran Syn 295
• Mobil: Mobilith SHC 220 Hydraulic Tank - Spec 6829006444:
Open Gear Lube (bearing/swingdrive teeth) - No Spec: • Hyden 052-10W-20
• Vultrex OGL Synthetic All Season • Exxon Torque Fluid 56- 10W-20
Antifreeze Coolant - Spec 6829104212: • Esso Torque Fluid 56- 10W-20
• Petro-Canada AFC 60/40 • BP-Eldoran UTH & Trak-Tran 9 - 10W20
• Old World Industries, Inc Fleet Charge SCA Pre- • BP- Blend- 7367 -10W20
charged Antifreeze/ Coolant-60/40
• Exxon Mobil 424- 10W-30
• Fleetguard Compleat EG Antifreeze/Coolant Premix 60/
Hoist - Spec 6829100213:
40
• AGMA No. 4 EP Extreme Pressure Gear Lube
STANDARD LUBRICANTS PACKAGE • Mobil: Mobilfluid 629
Axle and Swing Box - Spec 6829012964: • Texaco: Meropa 150
• Century Unigear Semi-synthetic SAE 80W-90 Grease - Spec 6829003477:
• Texaco Multigear SS 80W-90 • Citgo Lithoplex MP # 2
• Chevron DELO 80W-90 • Texaco Starplex Moly # 2
Engine - QSM engine burning non-ULSD fuel --Spec • Phillips 66 Philube M Grease
6829104560:
• Mobil Mobilgrese XHP 222 Special, # 53055-0
• Engine Oil Exxon XD-3 CI-4 15W-40
• Chemtool Inc, Lube-A-Boom-Grease
• Conoco Fleet Supreme CI-4 15W-40
Open Gear Lube (bearing/swingdrive teeth) - Spec
QSM engine burning ULSD fuel --Spec 6829003483 or Spec. 6829102971:
6829104182:
• FUCHS: CEPLATTYN 300 SPRAY
• Engine Oil Exxon XD-3 CI-4 15W-40
Antifreeze Coolant - Spec 6829101130:
•
•
Conoco Fleet Supreme CI-4 15W-40
Conoco Fleet Supreme EC CJ-4 15W-40
• AFC - 50/50 Old World Industries, Inc. 5
• Fleet Charge SCA Pre-charged Antifreeze/Coolant
• Mobil Delvac 1300 Super CJ-4 15W-40
• Caterpillar DEAC Antifreeze/Coolant
Transmission - Fuller Manual - Spec 6829013433:
• Fleetguard Complete EG Antifreeze/Coolant
• Citgo Synthetic Gear Lubricant CD50
Clutch - Spec 6829104275:
• Eaton Roadranger SAE50
• Mobil: Mobilith SHC 220
• Mobil Delvac Synthetic Transmission Fluid 50

LUBRICATION POINTS Grease fittings that are worn and will not hold the grease
gun, or those that have a stuck check ball, must be replaced.
A regular frequency of lubrication must be established for all
lubrication points. Normally, this is based on component Where wear pads are used, cycle the components and
operating time. The most efficient method of keeping track of relubricate to ensure complete lubrication of the entire wear
lube requirements is to maintain a job log indicating crane area.
usage. The log must use the engine hourmeter to ensure
coverage of lube points that will receive attention based on Surface Protection for Cylinder Rods
their readings. Other lubrication requirements must be made Steel cylinder rods include a thin layer of chrome plating on
on a time basis, i.e. weekly, monthly, etc. their surfaces to protect them from corroding. However,
All oil levels are to be checked with the crane parked on a chrome plating inherently has cracks in its structure which
level surface in transport position, and while the oil is cold, can allow moisture to corrode the underlying steel. At typical
unless otherwise specified. ambient temperatures, hydraulic oil is too thick to penetrate
these cracks. Normal machine operating temperatures will
On plug type check points, the oil levels are to be at the allow hydraulic oil to warm sufficiently to penetrate these
bottom edge of the check port. cracks and if machines are operated daily, protect the rods.
On all hoists with a check plug in the drum, the fill plug shall Machines that are stored, transported, or used in a corrosive
be directly on top of the hoist and the check plug level. environment (high moisture, rain, snow, or coastline
conditions) need to have the exposed rods protected more
All grease fittings are SAE STANDARD unless otherwise frequently by applying a protectant. Unless the machine is
indicated. Grease non-sealed fittings until grease is seen operated daily, exposed rod surfaces will corrode. Some
extruding from the fitting. 0.28 kg (1 oz) of EP-MPG equals cylinders will have rods exposed even when completely
one pump on a standard 0.45 kg (1 lb) grease gun. retracted. Assume all cylinders have exposed rods, as
Over lubrication on non-sealed fittings will not harm the corrosion on the end of the rod can ruin the cylinder.
fittings or components, but under lubrication will definitely It is recommended that all exposed cylinder rods be
lead to a shorter lifetime. protected using Boeshield® T-9 Premium Metal Protectant.
On sealed U-joints, care must be exercised to prevent Manitowoc CraneCARE has Boeshield® T-9 Premium Metal
rupturing seals. Fill only until expansion of the seals first Protectant available in 12 oz. cans that can be ordered
becomes visible. through the Parts Department.
Unless otherwise indicated, items not equipped with grease NOTE: Cylinder operation and inclement weather will
fittings, such as linkages, pins, levers, etc., should be remove the Boeshield® protectant; therefore,
lubricated with oil once a week. Motor oil, applied sparingly, inspect machines once a week and reapply
will provide the necessary lubrication and help prevent the Boeshield® to unprotected rods.
formation of rust. An anti-seize compound may be used if
Table 5-1
rust has not formed, otherwise the component must be
Lube Symbol Chart
cleaned first.
Symbol Description
AFC Antifreeze/Coolant - 50/50 Blended, Fully Formulated - SAE Grade J1941
EO Engine Oil - SAE 15W-40, API Service Classification CI-4.
EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2.
SGL-5 Synthetic Gear Lubricant - SAE Grade 50, API Gravity 23.
HYDO Hydraulic Oil - Must meet John Deere Standard JDM-J20C, Allison C4, and ISO 4406 level.
SSGL-5 Semi-Synthetic Gear Lubricant - SAE Grade 80W-90, API Service Designation GL-5.
ASC Anti-Seize Compound - Military Specifications MIL-A-907E.
EP-OGL Open Gear Lubricant - Fuchs Ceplattyn 300 Spray, NLGI Class 1-2
AGMA No. 4 EP Extreme Pressure Gear Lube

Table 5-2
Lube Description
Lubrication Description Lube Specification

50/50 Fully Formulated Anti-Freeze Coolant A6-829-101130
Engine Oil SAE 15W40 A6-829-003483
Extreme Pressure Multi-Purpose Grease A6-829-003477
Synthetic Gear Lube A6-829-013433
Hydraulic Oil A6-829-006444
Semi-Synthetic Gear Lube A6-829-012964
Anti-Seize Compound A6-829-003689
Open Gear Lube A6-829-102971
Extreme Pressure Gear Lube A6-829-100213
Wire Rope See Service Manual
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 CAUTION
corresponds to the index number shown on the Lubrication Improper filling of the engine coolant system can result in
Chart (refer to Figure 5-1 through 5-3, Table 5-1 and Table 5- engine damage.
2).
Application -
a. Open petcock in upper radiator tube to vent air
CAUTION during initial fill.
The following lube intervals are to be used as a guideline
only. Actual lube intervals should be formulated by the Fill slowly. Flows exceeding 12 l/min (3 gpm) can
operator to correspond accordingly to conditions such as give a false level. When coolant squirts out, close
continuous duty cycles and/or hazardous environments. petcock, then fill radiator to bottom of filler neck with
mixture of 50% AFC and 50% water.
CARRIER LUBRICATION Run engine through two (2) thermal cycles.
1. Engine Crankcase Wait 1 minute and recheck coolant level and refill as
required.
Lube Type - EO - 15W40
3. Transmission
Lube Interval - Check fluid level every 10 hours or daily,
whichever interval occurs first. Drain, fill and replace Lube Type - SGL-5
filter every 400 hours. Lube Interval - Check fluid level every 500 hours, 6
Lube Amount - Capacity - 37 liters (9.7 gallons) months, or 9,000 miles, whichever interval occurs first.
Drain, fill, and replace filter every 80,000 km (50,000 mi)
Application - Fill to full mark on dipstick. or 2 years, whichever interval occurs first.
2. Engine Cooling System Lube Amount - Capacity - 14 quarts (13 liters) 5
Lube Type - AFC Application - Fill to check plug on the left-hand side of
Lube Interval - Check coolant level every 10 hours or the transmission.
daily, whichever interval occurs first. Drain and refill
cooling system every 2000 hours or 12 months.
Lube Amount - Capacity - 49 liters (52 quarts)

4. Pump Drive Shaft 9. Front Aluminum Wheel Pilots

a. U-Joints Lube Type - ASC
Lube Type - EP-MPG Lube Interval - When wheels are removed for service.
Lube Interval - 250 hours Lube Amount - Generously coat the wheel pilot or hub
pads with anti-seize (ASC) compound. Do not apply
Lube Amount - Until grease extrudes
anti-seize compound to the face of the wheel of the hub.
Application - 2 grease fittings
Application - Brush on
b. Spline
Lube Type - EP-MPG CAUTION
Axle fluid levels shall be adjusted to bottom of fill plug
Lube Interval - 500 hours
threads. Check with crane on level ground, at its normal
Lube Amount - Until grease extrudes ride height, cold or room temperature oil only.
Application - 1 grease fitting
10. Front Axle Hubs
5. Clutch and Linkage
Lube Type - SSGL-5
L u b e Ty p e - h i g h t e m p e r a t u r e g r e a s e ( Sp e c .
Lube Interval - Check fluid level every 250 hours and
6829104275) for throw-out bearing; EP-MPG for each
refill as necessary.
flange bearing
Lube Amount - 0.95 liter (1.0 quart)
Lube Interval - 250 hours for throw-out bearing; 500
hours for each flange bearing Application - Fill to the oil level mark on the housing with
the fill plug and the oil level mark horizontal.
Lube Amount - Until grease extrudes from each flange
bearing; until grease extrudes for throw-out bearing 11. Front Axle Tie Rod Ends
(remove inspection plate to view throw-out bearing)
Lube Type - EP-MPG
Application - 1 grease fitting on flange bearing on each
side of clutch pedal shaft, 1 grease fitting in clutch Lube Interval - 1000 hours
housing of transmission for throw-out bearing Lube Amount - Until grease extrudes
6. Driveline Application - 4 grease fittings
Lube Type - EP-MPG 12. Front Axle King Pins
Lube Interval - 500 Hours or 10,000 miles whichever Lube Type - EP-MPG
interval occurs first
7. Power Steering Gearbox
13. Front Axle Brake Slack Adjusters
Lube Type - EP-MPG
Lube Type - EP-MPG
8. Steering Relay Arms
14. Front Axle Brake Camshafts
Lube Type - EP-MPG
Lube Type - EP-MPG

15. Rear Aluminum Wheel Pilots NOTE: Figure 5-1 pertains to the differentials and the
planetary hubs and wheel bearings.
Lube Type - ASC
17. Rear Rear Axle Differential
Lube Interval - When wheels are removed for service.
Lube Type - SSGL-5
Lube Amount - Generously coat the wheel pilot or hub
pads with anti-seize (ASC) compound. Do not apply Lube Interval - Check lubricant level every 250 hours
anti-seize compound to the face of the wheel of the hub. and refill as necessary. Drain, refill, and clean magnetic
drain plug every 80,00 km (50,000 mi) or 2 years,
Application - Brush on; 8 places
whichever interval occurs first.
16. Front Rear Axle Differential
Lube Type - SSGL-5 CAUTION
Lube Interval - Check lubricant level every 250 hours Axle fluid levels shall be adjusted to bottom of fill plug
and refill as necessary. Drain, fill, change filter, and threads. Check with crane on level ground, at its normal
clean magnetic drain plug every 80,00 km (50,000 mi) or ride height, cold or room temperature oil only.
2 years, whichever interval occurs first.
CAUTION CAUTION
Axle fluid levels shall be adjusted to bottom of fill plug If the makeup amount is substantially more than 0.23 liter
threads. Check with crane on level ground, at its normal (0.5 pint) check for leaks.
ride height, cold or room temperature oil only.
Lube Amount - Capacity - 17.5 liters (37 pints) Normal
makeup - less than 0.23 liter (0.5 pint)
CAUTION Application - Fill to bottom of fill plug threads.

If the makeup amount is substantially more than 0.23 liter 18. Rear Axle Brake Slack Adjusters
(0.5 pint) check for leaks.
Lube Type - EP-MPG
Lube Amount - Capacity - 27 liters (57 pints) Normal Lube Interval - 1000 hours
makeup - less than 0.23 liter (0.5 pint)
Application - Fill to bottom of fill plug threads.
NOTE: Lube level (Figure 5-1) close enough to the hole to 19. Rear Axle Brake Camshafts
be seen or touched is not sufficient. It must be level
Lube Type - EP-MPG
with the hole.
When checking lube level, also check and clean
housing breathers. Lube Amount - Until grease extrudes
5
___ Correct: Lube level at
bottom of filler hole.
- - - Incorrect: Lube level
6626 below filler hole.
FIGURE 5-1

21
7
22
8
13, 14
2
12
9, 10
26
11
1
13, 14
5
4
9, 10
8
12
28
11
21
22
20
23 24
27
6
6
18, 19
16
6 15
17
15
18, 19
21
20 22
6994-1
FIGURE 5-2

21. Jack Cylinder Support Tubes

Item Description Lube Type - EP-MPG
1 Engine Crankcase Lube Interval - 500 hours
2 Engine Cooling System Lube Amount - Brush on ID of jack cylinder support
3 Transmission tubes and wear bands before installing jack cylinders.
4 Pump Drive Shaft U-Joints and Spline Application -Brush on; 5 places
5 Clutch and Clutch Linkage 22. Jack Cylinder Barrels
6 Driveline Lube Type - EP-MPG
7 Power Steering Gearbox Lube Interval - 50 hours or 1 week, whichever interval
8 Steering Relay Arms occurs first
9 Front Aluminum Wheel Pilots Lube Amount - Fully extend outriggers and brush
lubricant onto cylinder barrels.
10 Front Axle Hubs
11 Front Axle Tie Rod Ends Application - Brush on; 5 places
12 Front Axle King Pins 23. Hydraulic Reservoir
13 Front Axle Brake Slack Adjusters Lube Type - HYDO
14 Front Axle Brake Camshafts Lube Interval - Check fluid level every 10 hours or daily,
using sight gauge on side of tank, with boom down and
15 Rear Aluminum Wheel Pilot
retracted and all outrigger cylinders retracted; drain and
16 Front Rear Axle Differential refill as necessary. Replace oil every 2000 hours or 2
years, whichever interval occurs first.
17 Rear Rear Axle Differential
18 Rear Axle Brake Slack Adjusters NOTE: After 2000 hours or 2 years of service, an oil
sample should be taken and laboratory analyzed. If
19 Rear Axle Brake Camshafts it continues to meet a minimum cleanliness level of
20 Outrigger Beams ISO 16/13, the service interval can be increased to
3000 hours or 3 years.
21 Jack Cylinder Support Tubes
Lube Amount - 656.6 liters (173.5 gal.) (tank only), To
22 Jack Cylinder Barrels
the FULL mark on sight gauge.
23 Hydraulic Reservoir
Application - Fill through filler cap on top of tank. When
24 Hydraulic Filter tank is drained, clean the magnetic pipe plug.
25 Fuel Filter Replace breather every 500 hours or 6 months,
26 Air Cleaner whichever interval occurs first.
27 Coolant Strainer (Superstructure Cab Heater) 24. Hydraulic Filter

28 Transmission Gearshift Linkage Check filter every 500 hours or 6 months, whichever
interval occurs first.
20. Outrigger Beams
Change the filter when the indicator is red.
CAUTION 25. Fuel Filter
5
Use of non-semi-synthetic lubricant may damage
Drain water trap every 10 hours or daily and change filter
components and/or invalidate published lubrication
every 500 hours or 6 months.
intervals.
26. Air Cleaner Filter
Lube Type - EP-MPG
Replace air cleaner filter element when indicator shows
Lube Interval - 50 hours or 1 week, whichever interval red (25” H2O).
occurs first
Lube Amount - Brush on bottom of outrigger beams.
Application - Brush on; 8 places

27. Coolant Strainer (Superstructure Cab Heater) 33. Auxiliary Hoist

Close the shutoff valves. Unscrew the hex plug and Lube Type - AGMA EP-4
clean the strainer screen after first 100 hours and every
Lube Interval - Check and fill every 1000 hours or 12
2000 hours or 12 months thereafter.
months, whichever interval occurs first. Drain and fill
28. Transmission Gear Shift Linkage annually.
Lube Type - EP-MPG for master unit; EP-MPG for each Lube Amount - Capacity - 14.7 liters (15.5 quarts)
U-joint
Application - Fill until level with the check plug opening.
Lube Amount - Until grease extrudes from each U-joint BOOM, BOOM EXTENSION, AND BOOM
bearing; until grease extrudes for master unit ACCESSORIES LUBRICATION
Application - 1 grease fitting on each U-joint, 1 grease NOTE: To service the boom at boom lengths longer than
fitting on master unit 120 ft (to access grease fittings, grease the
sections, or to change the holding valve), a
SUPERSTRUCTURE LUBRICATION minimum of 12,000 pounds of counterweight must
be installed on the turntable and the outriggers
29. Turntable Gear Box must be fully extended. Boom must be positioned
Lube Type - SSGL-5 over the right-hand side of the machine. No rigging,
no hook block, or overhaul ball may be installed on
Lube Interval - Check and fill every 50 hours. Drain and the nose of the boom.
fill after first 250 hours and every 500 hours or 12
months thereafter, whichever interval occurs first. Extend boom to desired length at a boom angle of
20 degrees. Lower boom until LMI limits the boom
Lube Amount -5.4 liters (1.4 gallons) lower function. Override LMI per LMI Operator’s
Application - Fill until oil level is at top of sight gauge Manual and lower boom to desired angle.
30. Turntable Gear and Drive Pinion 34. Boom Pivot Shaft
Lube Type - EP-OGL Lube Type - EP-MPG
Lube Interval - 500 hours or 6 months, whichever Lube Interval - 250 hours or 3 months, whichever
interval occurs first interval occurs first
Lube Amount - Coat all teeth Lube Amount - Until grease extrudes
Application - Spray on; 2 places Application - 2 grease fittings, one on each side
31. Turntable Bearing 35. Extend Cable Sheaves
Lube Type - EP-MPG Lube Type - EP-MPG
Lube Interval - 500 hours or 6 months, whichever Lube Interval - 250 hours or 3 months, whichever
interval occurs first interval occurs first
Lube Amount - Until grease extrudes the whole Lube Amount - Until grease extrudes
circumference of the bearing. Application - 1 grease fitting; extend boom for entry
Application - 2 grease fittings. Rotate the turntable 90° through access holes in fly and outer mid sections.
and apply grease to fittings. Continue rotating 90° and 36. Retract Cable Sheaves
grease the fittings until the whole bearing is greased.
Lube Type - EP-MPG
32. Main Hoist
Lube Interval - 250 hours or 3 months, whichever
Lube Type - AGMA EP-4 interval occurs first
Lube Interval - Check and fill every 1000 hours or 12 Lube Amount - Until grease extrudes
months, whichever interval occurs first. Drain and fill
annually. Application - 2 grease fittings; extend boom for entry
through access holes in front of inner mid section at
Lube Amount - Capacity - 14.7 liters (15.5 quarts) boom length of 39 m (128 feet)
Application - Fill until level with the check plug opening.

37. Telescope Cylinder Wear Pads 41. Upper Boom Nose Sheaves
Lube Interval - Every boom teardown. Lube Interval - 250 hours or 3 months, whichever occurs
first
Lube Amount - Thoroughly coat all areas the wear pads
move on. Lube Amount - Until grease extrudes
Application - By brush; 5 places. Application - 2 grease fittings per sheave
NOTE: Should boom chatter or rubbing noises in the boom 42. Lower Boom Nose Sheaves
occur, it will be necessary to lubricate the telescope
Lube Type - EP-MPG
cylinder wear pads. By adding an extension
adapter to a grease gun the wear pads and wear Lube Interval - 250 hours or 3 months, whichever occurs
areas can be reached through the lubrication first
access holes in the side of the boom and through
the access hole in the boom nose between the
sheaves. Application - 4 grease fittings per sheave
38. Internal Side and Bottom Wear Pads (Inner Sections) 43. Boom Extension Sheaves
Lube Interval - 250 hours or 3 months, whichever Lube Interval - 250 hours or 3 months, whichever occurs
interval occurs first. Lubricate more frequently if first
environmental conditions and/or operating conditions
necessitate. Lube Amount - Until grease extrudes
Lube Amount - Thoroughly coat all areas the wear pads Application - 2 grease fittings
move on. 44. Boom Extension Mast Sheave
Application - By brush: 14 places; with boom in extended Lube Type - EP-MPG
position through access holes in inner and outer mid
section. Lube Interval - 500 hours or 12 months, whichever
occurs first
39. Boom Section Upper Wear Pads
Lube Type - EP-MPG
Lube Interval - 50 hours or 1 week, whichever interval
occurs first. Lubricate more frequently if environmental 45. Auxiliary Boom Nose Sheave
conditions and/or operating conditions necessitate. Lube Type - EP-MPG
Lube Amount - Until grease extrudes Lube Interval - 250 hours or 3 months, whichever
Application - 8 places; with boom in extended position interval occurs first
through access holes. Lube Amount - Until grease extrudes
40. Boom Section Upper and Lower Wear Pads Application - 1 grease fitting
Lube Type - EP-MPG 46. Hook Block Swivel Bearing
Lube Interval - 50 hours or 1 week, whichever occurs
first. Lubricate more frequently if environmental
Lube Type - EP-MPG 5
conditions and/or operating conditions necessitate. Lube Interval - 250 hours or 3 months, whichever
interval occurs first
Lube Amount - Thoroughly coat all areas the wear pad
moves on. Lube Amount - Until grease extrudes
Application - By brush; 12 places; with boom in extended Application - 1 grease fitting

position.

47. Hook Block Sheaves

Lube Type - EP-MPG Item Description
Lube Interval - 250 hours or 3 months, whichever 29 Turntable Gearbox
interval occurs first 30 Turntable Gear and Drive Pinion
Lube Amount - Until grease extrudes 31 Turntable Bearing
Application - 1 grease fitting per sheave 32 Main Hoist
(4 fittings total - 75 ton) 33 Auxiliary Hoist
48. Overall Ball Swivel Top 34 Boom Pivot Shaft
Lube Type - EP-MPG 35 Extend Cable Sheaves
Lube Interval - 250 hours or 3 months, whichever 36 Retract Cable Sheaves
interval occurs first 37 Telescope Cylinder Wear Pads
Lube Amount - Until grease extrudes Internal Side and Bottom Wear Pads (Internal
38
Application - 1 grease fitting Sections)
39 Boom Section Upper Wear Pads
WIRE ROPE LUBRICATION 40 Boom Section Upper and Lower Wear Pads
Wire rope is lubricated during manufacturing so that the 41 Upper Boom Nose Sheaves
strands, and individual wires in strands, may move as the
rope moves and bends. A wire rope cannot be lubricated 42 Lower Boom Nose Sheaves
sufficiently during manufacture to last its entire life. 43 Boom Extension Sheaves
Therefore, new lubricant must be added periodically
44 Boom Extension Mast Sheave
throughout the life of a rope to replace factory lubricant which
is used or lost. 45 Auxiliary Boom Nose Sheave
NOTE: Wire rope may be purchased by contacting the 46 Hook Block Swivel Bearing
Manitowoc CraneCARE Parts Department. 47 Hook Block Sheaves
For more detailed information concerning the lubrication and 48 Overall Ball Swivel Top
inspection of wire rope, refer to WIRE ROPE in Section 1-
INTRODUCTION in the Service Manual.

45
33
41
32
48
42
34
44
38
31
Right Side View

39
Left Side View
43
39
36, 39
30
37
29
43
34
35
42
32
47
40
5
41
33
46
6556-3
6556-2
FIGURE 5-3


SECTION 6
MAINTENANCE CHECKLIST
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6
GROVE 6-i
MAINTENANCE CHECKLIST TMS800E OPERATOR’S MANUAL
THIS PAGE BLANK
6-ii
TMS800E OPERATOR’S MANUAL MAINTENANCE CHECKLIST
SECTION 6
MAINTENANCE CHECKLIST
GENERAL INSTRUCTIONS
This section contains a list of daily inspection and S e e S e r v i c e M a n ua l f or s pe c i f i c m a i nt e n an c e an d
maintenance checks. Performing the checks will help adjustment procedures.
maintain the safety, dependability, and productivity designed
See Section 5 (in this handbook) for lubrication intervals,
into your crane.
types of fluids, and lube point locations.
6
GROVE 6-1
MAINTENANCE CHECKLIST TMS800E OPERATOR’S MANUAL
INSPECTION SERVICE LOG

Reference
Interval
Items to be Inspected Daily DAY OF INSPECTION
December D 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 28 29 30 31
Verify Outrigger Float Pads are properly installed &

1 D
show no signs of structural damage
Verify Tire Condition has no excessive wear and

2 D
Pressure is at the proper level
Visually check machine for any Hydraulic
3 Components (including Hoses) with excessive D
wear, loose fittings, or leaks
4 Visually check for any loose or damaged Wiring D
5 Verify Engine Coolant is at the proper level D
Verify Crankcase and Transmission have the

6 D
proper fluid levels
Verify Hoists are installed properly with no signs of

7 D
damage, or leaks
8 Operator's Manual installed properly on machine. D
Verify that the "Operator Aids" are working

9 properly - Boom Angle Indicator, Load Moment D
Indicator (LMI), Antitwo-Block.
10 Gauges and Instruments are functional D
Back-up Alarm operates properly when operating

11 D
machine
12 Swing Brake operates properly D
Verify Brakes and Air System (if equipped) are

13
working properly
Lights and Horn are in good working order and not

14 D
damaged
15 Verify Hydraulic Reservoir has the proper fluid level D
16 Hydraulic Oil Filter (check back pressure) D
Verify Boom and Attachments are properly

17 D
installed with no signs of damage, or leaks
Verify Wire Rope has no damaged, frayed, or

18 D
broken strands
19 D
20 D
Inspector's Initials
22 0 D
23 0 D
24 0 D
25 0 D
Inspector's Initials

6-2
TMS800E OPERATOR’S MANUAL
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Assembly Of Boom Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Auxiliary Single-Sheave Boom Nose (Additional Equipment) . . . . . . . . . . . . . . . . . . . . 4-29
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Boom Extension (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Boom Extension Erecting and Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Installing Cable On The Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Monthly Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Operating With The Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Raising And Setting Down The Main Boom With Rigged Lattice Extension . . . . . . . . . 4-33
Rigging The Auxiliary Single-Sheave Boom Nose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Superstructure Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
GROVE 1
OPERATOR’S MANUAL TMS800E
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GROVE

To prevent death or serious injury:

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information

SECTION 3 . . . . . . . . . . . . . . . . . . . Operating Controls and Procedures

Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set-up And Installation

Rigging in Transport Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Checklist

THIS PAGE BLANK

THIS PAGE BLANK

The Grov e c rane ha s b een des ign ed for maximum

GROVE Published 12-23-2008, Control # 132-03 1-1

Left Side View

FIGURE 1-1 continued

1-2 Published 12-23-2008, Control # 132-03

Right Side View

Item Description Item Description

GROVE Published 12-23-2008, Control # 132-03 1-3

THIS PAGE BLANK

1-4 Published 12-23-2008, Control # 132-03

THIS PAGE BLANK

General NOTE: Highlights operation or maintenance procedures.

GROVE Published 12-23-2008, Control # 132-03 2-1

2-2 Published 12-23-2008, Control # 132-03

GROVE Published 12-23-2008, Control # 132-03 2-3

CRANE STABILITY/STRUCTURAL vertical stripe or fully extended position before beginning

2-4 Published 12-23-2008, Control # 132-03

Work Site If you should encounter a tipping condition, immediately

GROVE Published 12-23-2008, Control # 132-03 2-5

2-6 Published 12-23-2008, Control # 132-03

GROVE Published 12-23-2008, Control # 132-03 2-7

2-8 Published 12-23-2008, Control # 132-03

GROVE Published 12-23-2008, Control # 132-03 2-9

All four outrigger beam lock pins must be engaged before

Barricade the entire area where the crane is working and

2-10 Published 12-23-2008, Control # 132-03

GROVE Published 12-23-2008, Control # 132-03 2-11

2-12 Published 12-23-2008, Control # 132-03

TIRES When installing and inspecting wire ropes and attachments,

GROVE Published 12-23-2008, Control # 132-03 2-13

2-14 Published 12-23-2008, Control # 132-03

GROVE Published 12-23-2008, Control # 132-03 2-15

TRANSPORTING THE CRANE

2-16 Published 12-23-2008, Control # 132-03

TEMPERATURE EFFECTS ON HYDRAULIC

GROVE Published 12-23-2008, Control # 132-03 2-17

Table 2-2: BOOM DRIFT CHART (Cylinder length change in inches)

2-18 Published 12-23-2008, Control # 132-03

Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Control Lever Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

GROVE Published 12-23-2008, Control # 132-03 3-1

3-2 Published 12-23-2008, Control # 132-03

crane parking brakes are applied. It is illuminated by a Brake Pedal

GROVE Published 12-23-2008, Control # 132-03 3-3

3-4 Published 12-23-2008, Control # 132-03