Tms700e13 Om CTRL511-01 PDF

Grove TMS700E
Operator Manual
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OPERATOR MANUAL 1
This manual has been prepared for and is considered part of -
TMS700E13
Crane Model Number
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This Manual is divided into the following sections:
SECTION 1 INTRODUCTION
SECTION 2 SAFETY INFORMATION
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SECTION 3 OPERATING CONTROLS AND PROCEDURES
SECTION 4 SET-UP AND INSTALLATION PROCEDURES
SECTION 5 LUBRICATION
SECTION 6 MAINTENANCE CHECKLIST
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NOTICE
The crane serial number is the only method your distributor or the factory
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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.
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DANGER
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!
An untrained operator subjects himself and others to death or
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serious injury. Do not operate this crane unless:

• You are trained in the safe operation of this crane. Manitowoc is not
responsible for qualifying personnel. 5
• You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.
• You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
• The Operator Manual and Load Chart are in the holder provided on
crane.
© 2015 Manitowoc
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Published 1-30-2015, Control # 511-01
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CALIFORNIA
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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.
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CALIFORNIA
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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.
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The original language of this publication is English.

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SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Noise/vibration test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Noise Level Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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Wheel and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Swing Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information

Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
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General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
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Operator Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Rated Capacity Limiter (RCL) Systems (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . 2-4
Anti-Two-Blocking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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Working Area Limiter (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
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Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Outrigger Lift Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
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Multiple Crane Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Pile Driving and Extracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Crane Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Crane Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Electrocution Hazard Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Special Operating Conditions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Personnel Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Service and Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Hoist Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Synthetic Hoist Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Transporting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Work Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Personal Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Crane Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
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Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Parking and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
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Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Temperature Effects on Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
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Overload Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Superstructure Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Carrier Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
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SECTION 3. . . . . . . . . . . . . . . . . . . Operating Controls and Procedures
Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Travel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
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Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Additional Carrier Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Superstructure Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Engine Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Crane Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
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Regen Initiate/Inhibit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

High Exhaust Temp Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Diesel Exhaust Fluid (DEF) Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Malfunction Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Hydraulic Oil Temperature Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
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Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Operating Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Breaking in a New Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Pre-Starting Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
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Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Swing Drive and Turntable Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Hydraulic Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
General Crane Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Using Your Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Crane Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Crane Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Trailing Boom (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Travel Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Crane Shutdown Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Unattended Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
SECTION 4 . . . . . . . . . . . . . . . . . . . Set-up And Installation Procedures

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installing Cable on the Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Installing Wedge and Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Erecting and Stowing the Bi-Fold Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Erecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Setting the Folding Swingaway Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
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Erecting and Stowing the Bi-Fold Boom Extension Using the 20 ft (6.1 m) Insert . . . . 4-19
Erecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
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Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Removable Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Mounting the Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Stowing the Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
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SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Arctic Conditions Below -9°C (15°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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All Weather Package & Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Arctic Conditions Down to -40°C (-40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Standard Lubricants Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
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Hydraulic Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Superstructure Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . 5-12
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
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SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Checklist

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
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TMS700E OPERATOR MANUAL INTRODUCTION
SECTION 1
INTRODUCTION 1
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Noise/vibration test results . . . . . . . . . . . . . . . . . . 1-1 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Noise Level Test Results . . . . . . . . . . . . . . . . . . . 1-1 Wheel and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-4 Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Hoists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
GENERAL
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counterweight removal, are controlled from the fully-
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enclosed cab mounted on the superstructure. The crane is
NOTE: Throughout this handbook, reference is made to equipped with a four-section boom. Additional reach is
left, right, front, and rear when describing locations. obtained by utilizing an optional swingaway boom extension.
These reference locations are to be considered as Lifting is provided by a main hoist and an optional auxiliary
those viewed from the operator’s seat with the hoist. For basic crane component locations, see Figure 1-1.
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superstructure facing forward over the front of the

carrier frame. New Owner
This manual provides important information for the operator If you are the new owner of a Manitowoc crane, please
of the TMS700E13 Series Grove Manitowoc Crane. register it with Manitowoc Crane Care so we have the ability
to contact you if the need arises. Go to:
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The mobile crane carrier incorporates an all welded steel

frame. The 8x4x4 carrier utilizes two drive axles and two www.manitowoccranes.com/MCG_CARE/Includes/EN/
steer axles. Axle steering is provided by a power steering changeofownership.cfm and complete the form.
pump, gearbox and control valve. The engine is mounted in
the front of the carrier and provides power through an 11 NOISE/VIBRATION TEST RESULTS
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speed forward and 3 speed reverse manual transmission.

Noise Level Test Results
Hydraulic, single stage double box telescopic beams with
inverted jack cylinder outriggers are integral with the carrier • When equipped with the CE certification package, the
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frame. The outriggers are utilized in three positions; fully guaranteed sound power level at the operator’s station
extended, intermediate (50%) extended, and fully retracted. with closed c ab operation, is L w a 10 5 dB(A) as
The carrier is also equipped with a center front jack that has measured by Directive 2000/14/EC and 80 db(A) at the
a permanently mounted pad. crane operator position as measured by Annex G.1 of
The superstructure is capable of 360° rotation in either EN 13000:2010+A1:2014.
direction. All crane functions, with the exception of
Grove Published 1-30-2015, Control # 511-01 1-1

INTRODUCTION TMS700E OPERATOR MANUAL
1 2 Item Description
1
3 1 Rear View Mirror
2 Cab
3 Counterweight
4 Outrigger Float
5 Outrigger Jack Cylinder
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6773-3
5 5
4
FIGURE 1-1
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1-2 Published 1-30-2015, Control # 511-01

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3 4
4 5 1
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9 8 6
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14 23 4
17 4 18
15 20
24
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16 19
21
FIGURE 1-1 continued

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Item Description
Item Description
13 Auxiliary Boom Nose
1 Folding Swingaway
14 Carrier Cab
2 Boom
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15 Center Front Jack

3 Section 4
16 Front Axles
4 Outrigger Jack
17 Outrigger Beam
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5 Removable Counterweight
18 Outrigger
6 Auxiliary Hoist
19 Hydraulic Oil Cooler
7 Main Hoist
20 Rear Tandem Axles
8 Boom Pivot
21 Fuel Tank
9 Superstructure Cab
22 Outrigger Float
10 Lift Cylinder
23 Diesel Exhaust Fluid (DEF) Tank
11 Boom Rest
24 Fuel Filter, Primary
12 Boom Nose Sheaves

LIST OF SPECIFICATIONS Engine

General Cummins ISX12-2013 or QSMT3 in-line 6 cyl.
Model . . . . . . . . . . . . . . . . . . . .TMS700E13 Series Turbo-Charged
Rated Capacity . . . . . . . . . . See Load Chart in cab
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 x 4 x 4 Displacement . . . . . . . . . . . . 11.9 l (729 cu in)(ISX)
Gross Weight . . . . . . . . . . . . 43,956 kg (96,906 lb) . . . . . . . . . . . . . . . . . . . . . .10.9 l (665 cu in)(QSM)
Firing Order. . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Lube Amount . . . . . . . . . . . . . . 41.6 l (11 gal)(ISX)
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 34 l (36 qt)(QSM)
NOTE: Dimensions listed are for a crane with all Coolant System . . . . . . . . . . . . . . . . . . . 54 l (57 qt)
components fully retracted in the travel mode. Axles
Wheelbase . . . . . . . . . . . . . . . . . 5639 mm (222 in)
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Overall Crane Length . . . . . . . .13,538 mm (533 in)
Overall Crane Width . . . . . . . . . . 2591 mm (102 in) Front
Overall Crane Height . . . . . . . . . 3586 mm (141 in) Type . . . . . . . . . . . . . . . . . . . . . . . . Non-drive steer
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Tail-Swing . . . . . . . . . . . . . . . . . . 4102 mm (162 in)
Outrigger Spread Rear
Retracted . . . . . . . . . . . . . . . . 2429 mm (96 in)
Mid Extend . . . . . . . . . . . . . . 4262 mm (168 in) Type . . . . . . . . . . . . . . . . . Single reduction tandem
Fully Extended . . . . . . . . . . . 6096 mm (240 in) Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38:1
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Capacities Brakes
Fuel Tank . . . . . . . . . . . . . . . . . . . . . .367 l (97 gal) Type . . . . . . . . . . . . . . . . . . . . Air operated S-Cam
Coolant System. . . . . . . . . . . . . . . . . . . See Engine Size. . . . . . . . . . . . . . 419 x 178 mm (16.5 x 7.0 in)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications
Wheel and Tires
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Engine Lubrication System . . . . . . . . . . See Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic Tank (Reservoir Capacity) Torque. . . . . . . . . . 610 to 678 Nm (450 to 500 lb-ft)
Total . . . . . . . . . . . . . . . . . . . . . .564 l (149 gal) Tire Size
at Full Level . . . . . . . . . . . . . . . .507 l (134 gal) Front . . . . . . . . . . . . . . . . . . . . . . 445/65R22.5
at Add Level . . . . . . . . . . . . . . . .477 l (126 gal) Rear. . . . . . . . . . . . . . . . . . . . . . . 315/80R22.5
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Expansion Space . . . . . . . . . . . . . .57 l (15 gal) For roading and lifting pressures, refer to the Tire
Hoists . . . . . . . . . . . . . . . . . . . . . . . .14.7 l (15.5 qt) Inflation Decal.
Swing Gearbox . . . . . . . . . . . . . . . . .1.30 l (2.75 pt)
Front Axle Hubs . . . . . . . . . . . . . . . . . . 0.95 l (1 qt) Swing Gearbox
Front Rear Axle Differentials . . . . . . . . . .27 l (57 pt) Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . 36:2
Rear Rear Axle Differentials . . . . . . . . 17.5 l (37 pt)
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Output Torque . . . . . . . . . . . 5.54 Nm (49,825 lb-in)

Transmission. . . . . . . . . . . . . . . . . . . . . .19 l (20 qt)
Pump Drive . . . . . . . . . . . . . . . . . . . . . .2.4 l (2.5 qt)
Boom
Transmission Length. . . . . . . . . . . . 10.84 to 33.5 m (35 to 110 ft)
Power . . . . . . . . . . . . . . . . . . 4 Section, Full Power
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Speeds . . . . . . . . . . . . . . . . . 11 forward - 3 reverse Elevation . . . . . . . . . . . . . . . . . . . -3 to +78 degrees

Gear Ratios Extensions
LL2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.85 Fixed* . . . . . . . . . . . . . . . . . . . . .9.75 m (32 ft)
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.30 Folding* . . . . . . . . 9.75 or 17.07 m (32 or 56 ft)
LL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.08 Lattice Extension . . . . . . . . . . . . . . . . . . . . . 20
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Low and 6.1 and 12.2 m (40 ft)

First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.41 *Extensions are offsettable at 0 or 45
Second. . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23 degrees
Third. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
Fourth. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.77
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swivel Assembly
Fifth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.95 Electrical . . . . . . . . . . . . . . . . . . . . . . . 49 Slip Rings
Sixth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38 Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ports
Seventh . . . . . . . . . . . . . . . . . . . . . . . . . . .1.00 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ports
Eighth. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.73
Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pumps
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.03
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43 NOTE: Pump output figures are theoretical.
Clutch Pump #1
Type . . . . . . . . . . . . . . . . . 2 plate pull type dry disc Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Output - @ engine speed 1800 rpm Section 1. . . . . . . . . . . . . .78.7 lpm (20.8 gpm)
Section 1 . . . . . . . . . . . . 184.3 lpm (48.7 gpm)
Section 2 . . . . . . . . . . . . . 70.4 lpm (18.6 gpm)
Section 3 . . . . . . . . . . . . . 88.9 lpm (23.5 gpm) Hoists
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Drum Dimensions
Pump #2 Diameter . . . . . . . . . . . . . . . . . .381 mm (15 in)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear Length. . . . . . . . . . . . . . . . .467 mm (18-3/8 in)
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Cable
Output - @ 1800 rpm Diameter . . . . . . . . . . . . . . . . . . 19 mm (3/4 in)
Section 1 . . . . . . . . . . . . . 88.2 lpm (23.3 gpm) Length-Main . . . . . . . . . . . . . . . .153 m (500 ft)
Priority flow of 37.9 lpm (10 gpm) at 2175 psi Length-Aux. . . . . . . . . . . . . . . . .153 m (500 ft)
Max. Permissible Line Pull (6x36)
Pump #3 . . . . . . . . . . . . . . . . . . . . . 90.1 kN (20,250 lb)
Hoist Motor Displacement
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear . . . . . . . .110 cm3 (6.7 in3) per revolution (low)
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Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Output - @ 1800 rpm . . . . . . . . 61 cm3 (3.7 in3) per revolution (high)
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TMS700E OPERATOR MANUAL SAFETY INFORMATION
SECTION 2
SAFETY INFORMATION
SECTION CONTENTS
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Environmental Protection . . . . . . . . . . . . . . . . . . .2-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . .2-14
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
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Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Hoist Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Operator Information . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
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Synthetic Hoist Rope . . . . . . . . . . . . . . . . . . . . . .2-16
Operator Qualifications. . . . . . . . . . . . . . . . . . . . . . 2-3
Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Rated Capacity Limiter (RCL) Systems
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Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Transporting the Crane . . . . . . . . . . . . . . . . . . . . .2-18
Anti-Two-Blocking Device . . . . . . . . . . . . . . . . . . . 2-4
Working Area Limiter (If Equipped) . . . . . . . . . . . . 2-5 Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Crane Stability/Structural Strength . . . . . . . . . . . . 2-5 Work Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
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Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Personal Considerations. . . . . . . . . . . . . . . . . . . .2-19
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
Wind Forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
Lifting Operations. . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
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Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Outrigger Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Multiple Crane Lifts . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Pile Driving and Extracting . . . . . . . . . . . . . . . . . . . 2-9 Parking and Securing. . . . . . . . . . . . . . . . . . . . . . .2-24
Crane Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
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Shut-Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Crane Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . .2-24
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . 2-11 Temperature Effects on Hook Blocks. . . . . . . . . .2-25
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Electrocution Hazard Devices . . . . . . . . . . . . . . . 2-11 Temperature Effects on Hydraulic Cylinders. . . .2-25

Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Overload Inspection . . . . . . . . . . . . . . . . . . . . . . . .2-27
Special Operating Conditions and Equipment . . . 2-12 Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Superstructure Inspection. . . . . . . . . . . . . . . . . . .2-30
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Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . .2-32
SAFETY MESSAGES and job site workers can result in their death or injury and
costly damage to the crane and property.
General To alert personnel to hazardous operating practices and
The importance of safe operation and maintenance cannot maintenance procedures, safety messages are used
be overemphasized. Carelessness or neglect on the part of throughout the manual. Each safety message contains a
operators, job supervisors and planners, rigging personnel, safety alert symbol and a signal word to identify the hazard’s
degree of seriousness.

SAFETY INFORMATION TMS700E OPERATOR MANUAL
Safety Alert Symbol Because you are the only part of the crane that can think and
reason, your responsibility is not lessened by the addition of
operational aids or warning devices. Indeed, you must guard
against acquiring a false sense of security when using them.
They are there to assist, not direct the operation. Operational
This safety alert symbol means ATTENTION!
aids or warning devices can be mechanical, electrical,
Become alert - your safety is involved! Obey all safety
electronic, or a combination thereof. They are subject to
messages that follow this symbol to avoid possible death
failure or misuse and should not be relied upon in place of
or injury.
good operating practices.
Signal Words You are the only one who can be relied upon to assure the
safety of yourself and those around you. Be a professional
and follow the rules of safety.
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Remember, failure to follow just one safety precaution could
DANGER cause an accident that results in death or serious injury to
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Identifies hazards that will result in death or serious injury personnel or damage to equipment. You are responsible for
if the message is ignored. the safety of yourself and those around you.
ACCIDENTS
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Following any accident or damage to equipment, the
WARNING Manitowoc dealer must be immediately advised of the
Identifies hazards that may result in death or serious incident and consulted on necessary inspections and
injury if the message is ignored. repairs. Should the dealer not be immediately available,
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contact should be made directly with Manitowoc Product
Safety at the address below. The crane must not be returned
to service until it is thoroughly inspected for any evidence of
damage. All damaged parts must be repaired or replaced as
CAUTION authorized by your Manitowoc distributor and/or Manitowoc
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Identifies hazards that could result in minor or moderate Crane Care.

injury if the message is ignored.
If this crane becomes involved in a property damage and/or
personal injury accident, immediately contact your
Manitowoc distributor. If the distributor is unknown and/or
cannot be reached, contact Product Safety at:
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CAUTION
Without the safety alert symbol, identifies hazards that The Manitowoc Company, Inc.
could result in property damage if the message is ignored. 1565 East Buchanan Trail
Shady Grove, PA 17256-0021
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NOTE: Emphasizes operation or maintenance Phone: 888-777-3378 (888-PSR.DEPT)

procedures. Fax: 717-593-5152
E-mail: [email protected]
GENERAL
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It is impossible to compile a list of safety precautions OPERATOR INFORMATION

covering all situations. However, there are basic principles You must read and understand this Operator Manual and
that must be followed during your daily routine. Safety is the Load Chart before operating your new crane. You must
your primary responsibility, since any piece of equipment also view and understand the supplied safety video. This
is only as safe as the person at the controls. manual and Load Chart must be readily available to the
Read and follow the information located in Model Specific operator at all times and must remain in the cab (if equipped)
Information near the end of this section. or operator’s station while the crane is in use.
This information has been provided to assist in promoting a The Operator Manual supplied with and considered part of
safe working atmosphere for yourself and those around you. your crane must be read and completely understood by each
It is not meant to cover every conceivable circumstance person responsible for assembly, disassembly, operation
which could arise. It is intended to present basic safety and maintenance of the crane.
precautions that should be followed in daily operation.

No personnel shall be allowed to climb onto the crane or Refer to the Parts Manual for this crane for the locations of all
enter the crane cab or operator’s station unless performance safety decals.
of their duties require them to do so, and then only with
You must be familiar with the regulations and standards
knowledge of the operator or other qualified person.
governing cranes and their operation. Work practice
Allow No One other than the operator to be on the crane requirements may vary slightly between government
while the crane is operating or moving, unless they are regulations, industry standards, and employer policies so a
seated in a two-man cab. thorough knowledge of all such relevant work rules is
necessary.
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or serious injury.
You must not operate this crane unless:
• You have been trained in the safe operation of this
crane.
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Do not remove the Load Chart, this Operator Manual, or

any decal from this crane. • You read, understand, and follow the safety and
operating recommendations contained in the
Inspect the crane every day (before the start of each shift). manufacturer’s manuals, your employer’s work rules,
Ensure that routine maintenance and lubrication are being and applicable government regulations.
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dutifully performed. Don’t operate a damaged or poorly

maintained crane. You risk lives when operating faulty • You are sure the crane has been inspected and
machinery - including your own. maintained in accordance with the manufacturer’s
manuals and is operating properly.
If adjustments or repairs are necessary, the operator shall
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notify the next operator. • You are sure that all safety signs, guards, and other
safety features are in place and in proper condition.
OPERATOR QUALIFICATIONS Do not attempt to operate the crane unless you are trained
and thoroughly familiar with all operational functions.
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Qualified person is defined as one who by reason of Controls and design may vary from crane to crane; therefore,
knowledge, training and experience is thoroughly familiar it is important that you have specific training on the particular
with crane operations and the hazards involved. Such a crane you will be operating.
person shall meet the operator qualifications specified in
Occupational Safety and Health Administration (OSHA) Training is ESSENTIAL for proper crane operation. Never
Regulations (United States Federal Law), in ASME B30.5 jeopardize your own well-being or that of others by
American National Standard, or in any other applicable attempting to operate a crane on which you have not been
federal, state or local laws. trained.
Ensure that all personnel working around the crane are You must be mentally and physically fit to operate a crane.
thoroughly familiar with safe operating practices. You must Never attempt to operate a crane while under the influence
be thoroughly familiar with the location and content of all of medication, narcotics, or alcohol. Any type of drug could
placards and decals on the crane. Decals provide important 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
instructions and warnings and must be read prior to any capabilities.
operational or maintenance function.

As operator of this crane, you are granted the authority to This does not apply when lifting personnel in load-line
stop and refuse to lift loads until safety is assured. supported personnel platforms. Personnel shall not be
lifted when anti-two-block devices are not functioning
OPERATIONAL AIDS properly.
Operational aids are accessories that provide information to • When a Boom Length Indicator is inoperative or
facilitate operation of a crane or that take control of particular malfunctioning, the designated person responsible for
functions without action of the operator when a limiting supervising the lifting operations shall establish the
condition is sensed, as stated in the latest revision of the boom lengths at which the lift will be made by actual
ASME B30.5, and ASME B30.8 standards. Examples of measurements or marking on the boom.
such devices include, but are not limited to, the following: • When a Level Indicator is inoperative or malfunctioning,
anti-two-block device, rated capacity indicator, rated capacity other means shall be used to level the crane.
limiter, boom angle or radius indicator, boom length indicator,
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crane level indicator, hoist drum rotation indicator, load Rated Capacity Limiter (RCL) Systems (If
indicator, and wind speed indicator. Equipped)
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Manitowoc remains committed to providing reliable products
Your crane may be equipped with an RCL system which is
that enable users and operators to safely lift and position
intended to aid the operator. An RCL is a device that
loads. Manitowoc has been an industry leader in the
automatically monitors radius, load weight, and load rating
incorporation of operational aids into the design of its cranes.
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and prevents movements of the crane, which would result in
Federal law requires that cranes be properly maintained and
an overload condition.
kept in good working condition. The manuals that Manitowoc
provides that are specific for each crane and the Test daily for proper operation. Never interfere with the
manufacturer’s manuals for the operational aids shall be proper functioning of operational aids or warning devices.
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followed. If an operational aid should fail to work properly, the
Under no condition should it be relied upon to replace the
crane user or owner must assure that repair or recalibration
use of Load Charts and operating instructions. Sole reliance
is accomplished as soon as is reasonably possible. If
upon these electronic aids in place of good operating
immediate repair or recalibration of an operational aid is not
practices can cause an accident.
possible and there are exceptional circumstances which
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justify continued short-term use of the crane when Know the weight of all loads and always check the capacity
operational aids are inoperative or malfunctioning, the of the crane as shown on the Load Chart before making any
following requirements shall apply for continued use or lifts.
shutdown of the crane:
NEVER exceed the rated capacity shown on the Load Chart.
• Steps shall be taken to schedule repairs and Always check the Load Chart to ensure the load to be lifted
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recalibration immediately. The operational aids shall be at the desired radius is within the rated capacity of the crane.
put back into service as soon as replacement parts, if
For detailed information concerning the operation and
required, are available and the repairs and recalibration
maintenance of the RCL system installed on the crane, see
can be carried out. Every reasonable effort must be
the RCL manufacturer’s manual supplied with the crane.
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made to expedite repairs and recalibration.

Manufacturers of rated capacity limiters may refer to them in
• When a Load Indicator, Rated Capacity Indicator, or their manuals as a load moment indicator (LMI), a hydraulic
Rated Capacity Limiter is inoperative or malfunctioning, capacity alert system (HCAS), a safe load indicator (SLI), or
the designated person responsible for supervising the an EKS5; Manitowoc refers to these systems as a rated
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lifting operations shall establish procedures for capacity limiter (RCL) throughout its Operator and Service
determining load weights and shall ascertain that the Manuals.
weight of the load does not exceed the crane ratings at
the radius where the load is to be handled. Anti-Two-Blocking Device
• When a Boom Angle or Radius Indicator is inoperative This crane should have a functional Anti-Two-Block and
or malfunctioning, the radius or boom angle shall be Control Lock-Out System. Test daily for proper operation.
determined by measurement.
Two-blocking occurs when the load block (hook block,
• When an Anti-Two-Blocking Device, Two-Blocking headache ball, rigging, etc.) comes into physical contact with
Damage Prevention Device or Two-Block Warning the boom (boom nose, sheaves, boom extension, etc.). Two-
Device is inoperative or malfunctioning, the designated blocking can cause hoist rope (wire rope or synthetic rope),
person responsible for supervising the lifting operations rigging, reeving, and other components to become highly
shall establish procedures, such as assigning an stressed and overloaded in which case the hoist rope may
additional signal person to furnish equivalent protection. fail allowing the load, block, etc. to free fall.

Two-blocking is more likely to occur when both the main and intended to assist the operator in preventing dangerous two-
auxiliary hoist lines are reeved over the main boom nose and block conditions. It is not a replacement for operator
b o o m e x t e n s i o n n o s e r e s p e c t i v e l y. A n o p e r a t o r, awareness and competence.
concentrating on the specific line being used, may telescope
Never interfere with the proper functioning of operational
or lower the boom allowing the other hoist line attachment to
aids or warning devices.
contact the boom or boom extension nose, thus causing
damage to the sheaves, or causing the hoist rope to fail,
Working Area Limiter (If Equipped)
dropping the lifting device to the ground and possibly injuring
personnel working below. This crane may be equipped with a working area limiter as
part of the RCL system, designated as either Work Area
Caution must be used when lowering the boom, extending
Definition System (WADS) or Working Range Limiter (WRL).
the boom or hoisting up. Let out load line(s) simultaneously
You must read and understand the operator manual before
to prevent two-blocking the boom tip(s) and the hook block,
operating the working area limiter system. Become familiar
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etc. The closer the load is carried to the boom nose the more
with all proper operating procedures and with the
important it becomes to simultaneously let out hoist rope as
identification of symbol usage.
the boom is lowered. Keep load handling devices a minimum
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of 107 cm (42 in) below the boom nose at all times. The working area limiter is intended to be used as an aid to
the operator. It is not a substitute for safe crane operating
Two-blocking can be prevented. Operator awareness of the
practices, experience and good operator judgements.
hazards of two-blocking is the most important factor in
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preventing this condition. An Anti-Two-Block System is
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CRANE STABILITY/STRUCTURAL capacity as shown on the crane’s Load Chart and notes.
STRENGTH Ensure all pins and floats are properly installed and outrigger
beams are properly extended before lifting on outriggers. On
To avoid death or serious injury, ensure that the crane is on a
models equipped with outriggers that can be pinned at the
firm surface with load and crane’s configuration within
mid-extend position (vertical stripe, if applicable), the

outriggers must also be pinned when operating from the mid-

extend position.
Use adequate cribbing under outrigger floats to distribute
weight over a greater area. Check frequently for settling.
Read and follow the following safety decal for cranes with
center front stabilizers.
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KEEP THE BOOM SHORT. Swinging loads with a long line
can create an unstable condition and possible structural
failure of the boom.
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Load Charts
Carefully follow the procedures in this Operator Manual
Load Charts represent the absolute maximum allowable
when extending or retracting the outriggers. Death or serious
loads, which are based on either tipping or structural
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injury could result from improper crane setup on outriggers.

limitations of the crane under specific conditions. Knowing
The operator must select the proper Load Chart and Rated the precise load radius, boom length, and boom angle
Capacity Limiter (RCL) System program for the outrigger should be a part of your routine planning and operation.
position selected. Actual loads, including necessary allowances, should be
kept below the capacity shown on the applicable Load Chart.
Before swinging the superstructure over the side when the
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outriggers are retracted, check the Load Chart for backwards Load Chart capacities are based on freely suspended loads.
stability.
You must use the appropriate Load Chart when determining
Long cantilever booms can create a tipping condition when the capability of the crane in the configuration required to
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in an extended and lowered position. Retract the boom perform the lift.
proportionally with reference to the capacity of the applicable
Maximum lifting capacity is available at the shortest radius,
Load Chart.
minimum boom length, and highest boom angle.
Check crane stability before lifting loads. Ensure the
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Do not remove the Load Charts from the crane.

outriggers (or tires if lifting on rubber) are firmly positioned on
solid surfaces. Ensure the crane is level, brakes are set, and
Work Site
the load is properly rigged and attached to the hook. Check
the Load Chart against the weight of the load. Lift the load Prior to any operation, you must inspect the entire work site,
slightly off the ground and recheck the stability before including ground conditions, where the crane will travel and
proceeding with the lift. Determine the weight of the load operate. Be sure that the surfaces will support a load greater
before you attempt the lift. than the crane’s weight and maximum capacity.
Unless lifting within On Rubber capacities, outrigger beams Be aware of all conditions that could adversely effect the
and jack cylinders (plus center front stabilizer, if equipped) stability of the crane.
must be properly extended and set to provide precise
leveling of the crane. Tires must be clear of the ground Wind Forces
before lifting on outriggers.
Wind can have a significant effect on loads that may be lifted
by a crane. Wind forces act differently on a crane depending

upon the direction from which the wind is blowing (e.g., wind a loss of control in handling the load. Manitowoc
on the rear of the boom can result in decreased forward recommends that, if the wind speed (velocity) is between
stability, wind on the underside of the boom can result in 32 km/h (20 mph) to 48 km/h (30 mph), the load capacities
decreased backward stability, wind on the side of the boom shall be reduced to account for the size and shape of the
can result in structural damages, etc.). To assist you in load and the wind direction in relation to the machine for all
determining prevailing wind conditions, refer to Table 2-1. boom and boom extension lengths. Further, operation of the
crane in wind velocities over 48 km/h (30 mph) is not
Wind forces can exert extreme dynamic loads. Manitowoc
recommended.
recommends that a lift not be made if the wind can cause
Table 2-1 Beaufort Wind Scale
Wind Force
Wind Velocity Visible Indicator
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Beaufort km/h (mph) Effects of wind as observed on land
Designation
Scale
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Zero (0) Calm less than 1 (<1) Calm; smoke rises vertically
Smoke drift indicates wind direction. Leaves and wind vanes
1 Light Air 1.1-5.5 (1-3)
are stationary.
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Wind felt on exposed skin. Leaves rustle. Wind vanes begin to
2 Light Breeze 5.6-11 (4-7)
move.
3 Gentle Breeze 12-19 (8-12) Leaves/small twigs constantly moving. Light flags extended.
Moderate
4 20-28 (13-17) Dust and loose paper raised. Small branches begin to move.
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Breeze
Reduce crane load ratings and operating parameters at 32 km/h (20 mph)
Branches of a moderate size move. Small trees in leaf begin to
5 Fresh Breeze 29-38 (18-24)
sway.
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Large branches in motion. Whistling heard in overhead wires.

6 Strong Breeze 39-49 (25-30)
Umbrella use becomes difficult. Empty plastic bins tip over.
Cease all craning operations at 48 km/h (30 mph); lower & retract boom
7 Moderate Gale 50-61 (31-38) Whole trees in motion. Effort needed to walk against the wind.
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Lifting Operations Be sure the load is properly rigged and attached. Always
determine the weight of the load before you attempt to lift it
Before lifting, position the crane on a firm surface, properly and remember that all rigging (slings, etc.) and lifting devices
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extend and set the outriggers, and level the crane. (hook block, boom extension, etc.) must be considered part
Depending on the nature of the supporting surface, of the load.
adequate cribbing may be required to obtain a larger bearing
surface. Measure the load radius before making a lift and stay within
approved lifting areas based on the range diagrams and
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The crane is equipped with a bubble level that should be working area diagrams on the crane’s Load Chart.
used to determine whether the crane is level. The load line
can also be used to estimate the levelness of the crane by Always keep the load as near to the crane and as close to
checking to be sure it is in-line with the center of the boom at the ground as possible.
all points on the swing circle. Do not overload the crane by exceeding the capacities
If the boom extension, or auxiliary boom nose is to be used, shown on the appropriate Load Chart. Death or serious
ensure the electrical cable and the weight for the Anti-Two- injury could result from the crane tipping over or failing
Block Switch are properly installed and the Rated Capacity structurally from overload.
Limiter (RCL) is programmed for the crane configuration. The crane can tip over or fail structurally if:
Refer to the RCL operator manual supplied with the crane.
• The load and crane’s configuration is not within the
Verify the crane’s capacity by checking the Load Chart capacity as shown on the applicable Load Chart and
against the weight of the load. Then, lift the load slightly at notes.
first to ensure stability before proceeding with the lift.

• The ground is soft and/or the surface conditions are Outrigger Lift Off
poor.
Regarding “lifting” of an outrigger pad during craning
• Outriggers are not properly extended and set. On activities, be advised that the rated loads for these cranes,
models equipped with outriggers that can be pinned at as indicated on the crane’s Load Chart, do not exceed 85%
the mid-extend position, the outriggers must also be of the tipping load on outriggers as determined by SAE J765
pinned when operating from the mid-extend position. OCT90 “Cranes Stability Test Code.” An outrigger pad may
• Cribbing under the outrigger pads is inadequate. lift off the ground during operation of the crane within the
capacity limits of the Load Chart, yet the crane will not have
• The crane is improperly operated. reached instability. The “balance point” for stability testing
Do not rely on the crane’s tipping to determine your lifting according to SAE and Manitowoc criteria is a condition of
capacity. loading wherein the load moment acting to overturn the
crane is equal to the maximum moment of the crane
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Be sure the hoist line is vertical before lifting. Do not subject available to resist overturning. This balance point or point of
the crane to side loading. A side load can tip the crane or instability for a crane does not depend on “lifting” of an
cause it to fail structurally.
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outrigger but rather on comparison of the “opposing” load
Load Chart capacities are based on freely suspended loads. moments.
Do not pull posts, pilings, or submerged articles. Be sure the The occurrence of an outrigger lifting from the ground is often
load is not frozen or otherwise attached to the ground before attributed to the natural flex in the crane’s frame. This may
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lifting. happen when lifting a load in certain configurations within the
If you should encounter a tipping condition, immediately capacity limits of the Load Chart and is not necessarily an
lower the load with the hoist line and retract or elevate the indication of an unstable condition.
boom to decrease the load radius. Never lower or extend the Provided the crane is properly set up, the crane is in good
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boom; this will aggravate the condition. working condition, that all operator’s aids are properly
Use tag lines whenever possible to help control the programmed, that the qualified crane operator adheres to
movement of the load. the instructions found in the applicable Load Chart, Operator
Manual and decals on the crane, the crane should not be
When lifting loads, the crane will lean toward the boom and unstable.
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the load will swing out, increasing the load radius. Ensure the
crane’s capacity is not exceeded when this occurs. Multiple Crane Lifts
Do not strike any obstruction with the boom. If the boom Multiple crane lifts are not recommended.
should accidentally contact an object, stop immediately.
Inspect the boom. Remove the crane from service if the Any lift that requires more than one crane must be precisely
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boom is damaged. planned and coordinated by a designated person. If it is

necessary to perform a multi-crane lift, the operator shall be
Never push or pull with the crane boom. responsible for assuring that the following minimum safety
precautions are taken:
Avoid sudden starts and stops when moving the load. The
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inertia and an increased load radius could tip the crane over • Secure the services of a designated person to direct the
or cause it to fail structurally. operation.
Use only one hoist at a time when lifting loads. • Use one qualified signal person.
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Always use enough parts-of-line to accommodate the load to • Coordinate lifting plans with the operators, designated
be lifted. Lifting with too few parts-of-line can result in failure person, and signal person prior to beginning the lift.
of the hoist rope.
• Maintain communication between all parties throughout
Counterweight the entire operation. If possible, provide approved radio
equipment for voice communication between all parties
On cranes equipped with removable counterweights, ensure engaged in the lift.
the appropriate counterweight sections are properly installed
for the lift being considered. • Use outriggers on cranes so equipped.
Do not add material to the counterweight to increase • Calculate the amount of weight to be lifted by each crane
capacity. United States Federal law prohibits modification or and attach slings at the correct points for proper weight
additions which affect the capacity or safe operation of the distribution.
equipment without the manufacturer’s written approval.
[29CFR 1926.1434]

• Ensure the load lines are directly over the attach points • The load lines shall be kept vertical at all times during
to avoid side loading and transfer of loading from one pile driving and pile extraction operations.
crane to the other. • The operator and other personnel associated with the
• Do not travel. Lift only from a stationary position. pile driving and pile extraction operation shall have read
and understood all safety standards applicable to crane
PILE DRIVING AND EXTRACTING operations as well as being thoroughly trained in the
safe operation of pile driving and extracting equipment.
Pile driving and extracting are applications approved by
Manitowoc, provided all equipment is operated within factory Crane Equipment
guidelines. The following operating requirements must be
• Hoists shall be equipped with a cable follower to aid in
used during pile driving and extracting with a Manitowoc
proper spooling of cable.
mobile hydraulic crane:
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Pile driving and pile extraction using a mobile crane • All cable retainer pins and cable guides/retainers shall
introduces many variable and unknown factors that must be be in place.
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considered when using a crane for this application. Because • All boom extensions or jibs must be removed from the
of these factors, discretion must be exercised when pile machine before pile driving or extraction begins.
driving or pile extraction is being considered.
• All hoist hooks shall be equipped with a positive locking
It is not the intention of Manitowoc to recommend specific latch.
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types or makes of pile driving and pile extraction equipment,
but rather to advise of the operational requirements to help Crane Inspection
avoid the detrimental effects that pile driving and pile
extraction can have on the crane. • In addition to the crane's frequent and periodic
inspections, dated daily records shall be maintained
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In addition to the operating requirements that are detailed in showing inspections were performed on the crane
the operating manuals and on the load capacity chart, pile during the time it was used for pile driving or extraction.
drivin g and ex tracting operations are approve d by
Manitowoc, provided all guidelines outlined below are • All anti-two block warning devices and RCL systems
followed: shall be inspected daily and verified to be functional.
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• All pile driving and extracting operations shall be • All areas of the crane subject to fatigue shall be
restricted to fully extended outriggers with all tires clear inspected monthly, and before the crane is to return to
of the ground. lifting service.
• The combined weight of the driver or extractor, piling, • The boom shall be inspected daily to ensure all wear
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leads, attachments, etc., shall not exceed 80% of the pads remain in place. Cranes which utilize pinned boom
published load chart values for on-outriggers operation. sections shall be inspected daily to ensure the pinning
• The pile driver or pile extractor and attachments shall be mechanism operates properly and to check for undue
kept clear of the boom nose at all times. wear at the pins and pinning plates. The hoist cable shall
be inspected daily to ensure no chafing or wear is
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• The pile driver and piling shall be suspended from a occurring.

hoist cable with sufficient line speed to meet or exceed
the rate of descent of the driver and piling to preclude
impact loading or vibration from being induced into the
ELECTROCUTION HAZARD
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boom and crane structure. Thoroughly read, understand, and abide by all applicable
• Pile driving or extracting shall be restricted to over the federal, state, and local regulations regarding operation of
main boom only and shall not be permitted over a boom cranes near electric power lines or equipment.
extension or jib. United States federal law prohibits the use of
cranes closer than 6 m (20 ft) to power sources
• Pile extraction using only the crane’s hoist line is unsafe up to 350 kV and greater distances for higher
and not permitte d s inc e load values can not be voltages unless the line’s voltage is known
accurately determined. Only pile extraction devices that [29CFR1910.180 and 29CFR1926, subpart CC].
do not transmit vibration or shock loading into the crane
To avoid death or serious injury, Manitowoc rec-
are permitted. All possible precautionary measures shall ommends that all parts of crane, boom, and
be taken to prevent shock loads or vibration from being load be kept at least 6 m (20 ft) away from all
imposed on crane components, either directly through electrical power lines and equipment less than
the hoist cable or indirectly from ground borne vibration. 350 kV.
NOTE: For detailed guidelines on operating near power
line s, re fer to th e c urr ent ed it io n o f OSHA

29 C F R 19 26 , su bpart C C a nd A S M E B 3 0. 5 If operation within 3 m (10 ft) of any power lines cannot be

American National Standard. avoided, the power utility must be notified and the power
l i n e s m us t b e d e - e n e r g i z e d a n d g r o u n d e d bef o re
performing any work.
If contact is ever accidentally made with a power line and any
DANGER part of this crane, its rigging or load, never touch the crane or
Electrocution Hazard! even approach or come near the crane.
Manitowoc cranes are not equipped with all features Electrocution can occur even without direct contact with the
required to operate within OSHA 29CFR1926.1408, Table crane.
A clearances when the power lines are energized.
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Crane operation is dangerous when close to an energized If the load, hoist rope, boom, or any portion of the crane
electrical power source. Exercise extreme caution and contacts or comes too close to an electrical power source,
prudent judgement. Operate slowly and cautiously when in everyone in, on, and around the crane can be seriously
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the vicinity of power lines. injured or killed.

Before operating this crane in the vicinity of electrical power Most overhead power lines are not insulated. Treat all
lines or equipment, notify the power utility company. Obtain overhead power lines as being energized unless you have
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positive and absolute assurance that the power has been reliable information to the contrary from the utility company
turned off. or owner.
This crane is not insulated. Always consider all parts of the The rules in this Operator Manual must be followed at all
load and the crane, including the hoist rope, wire rope, times, even if the electrical power lines or equipment have
pendant cables, and tag lines, as conductors. You, the been de-energized.
operator, are responsible for alerting all personnel of
The safest way to avoid electrocution is to stay away from
dangers associated with electrical power lines and
electrical power lines and electrical power sources.
equipment. Do not allow unnecessary personnel in the
vicinity of the crane while operating. Permit no one to lean It is not always necessary to contact a power line or power
against or touch the crane. Permit no one, including riggers source to become electrocuted. Electricity, depending on
and load handlers, to hold the load, load lines, tag lines, or magnitude, can arc or jump to any part of the load, load line,
rigging gear. or crane boom if it comes too close to an electrical power
source. Low voltages can also be dangerous.

Set-Up and Operation not assure that electrical contact will not occur. Even if codes
or regulations require the use of such devices, failure to
During crane use, assume that every line is energized (“hot” follow the rules listed here may result in serious injury or
or “live”) and take the necessary precautions. death. You should be aware that such devices have
Set up the crane in a position such that the load, boom, or limitations and you should follow the rules and precautions
any part of the crane and its attachments cannot be moved to outlined in this manual at all times even if the crane is
within 6 m (20 ft) of electrical power lines or equipment. This equipped with these devices.
includes the crane boom (fully extended to maximum height, Insulating links installed into the load line afford limited
radius, and length) and all attachments (boom extensions, protection from electrocution hazards. Links are limited in
rigging, loads, etc.). Overhead lines tend to blow in the wind their lifting abilities, insulating properties, and other
so allow for lines’ movement when determining safe properties that affect their performance. Moisture, dust, dirt,
operating distance. oils, and other contaminants can cause a link to conduct
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A suitable barricade should be erected to physically restrain electricity. Due to their capacity ratings, some links are not
the crane and all attachments (including the load) from effective for large cranes and/or high voltages/currents.
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entering into an unsafe distance from electrical power lines The only protection that may be afforded by an insulated link
or equipment. is below the link (electrically downstream), provided the link
Plan ahead and always plan a safe route before traveling has been kept clean, free of contamination, has not been
under power lines. Rider poles should be erected on each scratched or damaged, and is periodically tested (just before
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side of a crossing to assure sufficient clearance is use) for its dielectric integrity.
maintained. Boom cages and boom guards afford limited protection from
electrocution hazards. They are designed to cover only the
boom nose and a small portion of the boom. Performance of
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boom cages and boom guards is limited by their physical
size, insulating characteristics, and operating environment
(e.g. dust, dirt, moisture, etc.). The insulating characteristics
of these devices can be compromised if not kept clean, free
of contamination, and undamaged.
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Proximity sensing and warning devices are available in

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

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

United States OSHA regulations require a flagman when
operating in close proximity to energized power lines. Some variables you must know and understand are:
Appoint a reliable and qualified signal person, equipped with • Proximity devices are advertised to detect the existence
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a loud signal whistle or horn and voice communication of electricity and not its quantity or magnitude.
equipment, to warn the operator when any part of the crane • Some proximity devices may detect only alternating
or load moves near a power source. This person should current (AC) and not direct current (DC).
have no other duties while the crane is working.
• Some proximity devices detect radio frequency (RF)
Tag lines should always be made of non-conductive energy and others do not.
materials. Any tag line that is wet or dirty can conduct
electricity. • Most proximity devices simply provide a signal (audible,
visual, or both) for the operator; this signal must not be
Do not store materials under power lines or close to ignored.
electrical power sources.
• Sometimes the sensing portion of the proximity devices
Electrocution Hazard Devices becomes confused by complex or differing arrays of
power lines and power sources.
The use of insulated links, insulated boom cages/guards,
proximity warning devices, or mechanical limit stops does

Do not depend on grounding. Grounding of a crane affords Consultant. Also refer to local, state, and federal codes
little or no p rotec tio n f rom elect ric al h aza rds. The and regulations.
effectiveness of grounding is limited by the size of the
When operating cranes equipped with electromagnets, you
conductor (wire) used, the condition of the ground, the
must take additional precautions. Permit no one to touch the
magnitude of the voltage and current present, and numerous
magnet or load. Alert personnel by sounding a warning
other factors.
signal when moving a load. Do not allow the cover of the
Electrical Contact electromagnet power supply to be open during operation or
at any time the electrical system is activated. Shut down the
If the crane should come in contact with an energized power crane completely and open the magnet controls switch prior
source, you must: to connecting or disconnecting magnet leads. Use only a
non-conductive device when positioning a load. Lower the
1. Stay in the crane cab. Don’t panic.
magnet to the stowing area and shut off power before
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2. Immediately warn personnel in the vicinity to stay away. leaving the operator’s cab (if equipped) or operator’s station.
3. Attempt to move the crane away from the contacted
PERSONNEL HANDLING
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power source using the crane’s controls which may have
remained functional. The American Society of Mechanical Engineers issued a
4. Stay in the crane until the power company has been new American National Standard entitled, Personnel Lifting
contacted and the power source has been de-energized. Systems, ASME B30.23-2011:
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No one must attempt to come close to the crane or load This Volume establishes the design criteria, equip-
until the power has been turned off. ment characteristics, and operational procedures
that are required when hoisting equipment within
Only as a last resort should an operator attempt to leave the the scope of the ASME B30 Standard is used to lift
crane upon contacting a power source. If it is absolutely personnel. Hoisting equipment defined by the
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ASME B30 Standard is intended for material han-
necessary to leave the operator’s station, jump completely dling. It is not designed, manufactured, or intended
clear of the crane. Do not step off. Hop away with both feet to meet the standards for personnel handling equip-
together. Do not walk or run. ment, such as ANSI/SIA A92 (Aerial Platforms).
The equipment and implementation requirements
Following any contact with an energized electrical source, listed in this Volume are not the same as that estab-
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the Manitowoc distributor must be immediately advised of lished for using equipment specifically designed
the incident and consulted on necessary inspections and and manufactured for lifting personnel. Hoisting
equipment complying with the applicable Volumes
repairs. Thoroughly inspect the hoist rope and all points of of the ASME B30 Standard shall not be used to lift
contact on the crane. Should the dealer not be immediately or lower personnel unless there are no less hazard-
available, contact Manitowoc Crane Care. The crane must ous alternatives to providing access to the, area
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not be returned to service until it is thoroughly inspected for where work is to be performed. The lifting or lower-
any evidence of damage and all damaged parts are repaired ing of personnel using ASME B30-compliant hoist-
ing equipment is prohibited unless all applicable
or replaced as authorized by your Manitowoc distributor or requirements of this volume have been met.
Manitowoc Crane Care.
This new standard is consistent with the U.S. Department of
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Special Operating Conditions and Labor, Occupational Safety and Health Administration
(O SHA) re gu lat io n s fo r Con st ru c tion th at s tat e, in
Equipment
29CFRI926.1431:
Never operate the crane during an electrical thunderstorm.
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General requirements. The use of a crane or der-

rick to hoist employees on a personnel platform is
When operating near transmitter/communication towers prohibited, except when the erection, use, and dis-
where an electrical charge can be induced into the crane or mantling of conventional means of reaching the
load: worksite, such as a personnel hoist, ladder, stair-
way, aerial lift, elevating work platform or scaffold,
• The transmitter shall be deenergized OR, would be more hazardous or is not possible
because of structural design or worksite conditions.
• Tests shall be made to determine if an electrical charge
will be induced into the crane or load. Additional requirements for crane operations are stated in
ASME B30.5, Mobile and Locomotive Cranes, ASME B30.8,
• The crane must be provided an electrical ground. Floating Cranes and Floating Derricks, and in OSHA
• If taglines are used, they must be non-conductive. regulations 29CFRI910.180 for General Industry and
29CFRI926.1431 for Construction.
• Every precaution must be taken to dissipate induced
voltages. Consult a qualified RF (radio frequency) Use of a Manitowoc crane to handle personnel is acceptable
provided:

• The requirements of the applicable national, state and • NEVER get on or off a moving crane.
local regulations and safety codes are met.
• NEVER allow anyone other than the operator to be on
• A determination has been made that use of a crane to this crane while the machine is operating or traveling.
handle personnel is the least hazardous means to
• NEVER allow anyone on the hoist access platform while
perform the work.
traveling.
• The crane operator shall be qualified to operate the
The following standards and regulations regarding personnel
specific type of hoisting equipment used in the
handling are available by mail at the following addresses:
personnel lift.
• ASME (formerly ANSI) B30 Series American National
• The crane operator must remain at the crane controls at
Safety Standards For Cableways, Cranes, Derricks,
all times when personnel are off the ground.
Hoists, Hooks, Jacks, and Slings; ASME B30.5, Mobile
• The crane operator and occupants have been instructed And Locomotive Cranes, and ASME B30.23, Personnel
2
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in the recognized hazards of personnel platform lifts. Lifting Systems, are available by mail from the ASME, 22
Law Drive, Fairfield, New Jersey, 0700-2900
• The crane is in proper working order.
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• US DOL/OSHA Rules and Regulations are available by
• The crane must be equipped with a boom angle
mail from the Superintendent of Documents, PO Box
indicator that is visible to the crane operator.
371954, Pittsburgh, PA, 15250-7954.
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• The crane's Load Chart is affixed at the operator’s
station and readily accessible to the operator. The total ENVIRONMENTAL PROTECTION
weight of the loaded personnel platform and related
rigging shall not exceed 50 percent of the rated capacity Dispose of waste properly! Improperly disposing of waste
for the radius and configuration of the crane. can threaten the environment.
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• The crane is level within one percent of level grade and Potentially harmful waste used in Manitowoc cranes includes
located on a firm footing. Cranes with outriggers shall — but is not limited to — oil, fuel, grease, coolant, air
have them all deployed following manufacturer's conditioning refrigerant, filters, batteries, and cloths which
specifications. have come into contact with these environmentally harmful
substances.
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• The crane's Operator Manual and other operating

manuals are at the operator ’s station and readily Handle and dispose of waste according to local, state, and
accessible to the operator. federal environmental regulations.
• The platform meets the requirements as prescribed by When filling and draining crane components, observe the
applicable standards and regulations. following:
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• For hoist rope suspended platforms: • Do not pour waste fluids onto the ground, down any
drain, or into any source of water.
- The crane is equipped with a hook that can be
closed and locked, eliminating the throat opening. • Always drain waste fluids into leak proof containers that
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are clearly marked with what they contain.

- The crane is equipped with a functional anti-two-
block device. • Always fill or add fluids with a funnel or a filling pump.
- The platform is properly attached and secured to the • Immediately clean up any spills.
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load hook.
MAINTENANCE
• For boom mounted platforms:
The crane must be inspected prior to use on each work shift.
- The platform is properly attached and secure.
The owner, user, and operator must ensure that routine
To avoid death or serious injury: maintenance and lubrication are being dutifully performed.
Never operate a damaged or poorly maintained crane.
• NEVER use this crane for bungee jumping or any form
of amusement or sport. Manitowoc continues to recommend that cranes be properly
maintained, regularly inspected and repaired as necessary.
• NEVER handle personnel on the loadline unless the
Manitowoc reminds crane owners to ensure that all safety
requirements of applicable national, state and local
decals are in place and legible. Manitowoc continues to urge
regulations and safety codes are met.
crane owners to upgrade their cranes with rated capacity
• NEVER permit anyone to ride loads, hooks, slings or limiter and control lever lockout systems for all lifting
other rigging for any reason. operations.

Shut down the crane while making repairs or adjustments. the hydraulic system is under pressure. Fluid in the
hydraulic system can be under enough pressure that it
Always perform a function check after repairs have been
will penetrate the skin, causing serious injury or death.
made to ensure proper operation. Load tests should be
Use a piece of cardboard, or piece of paper, to search
performed when structural or lifting members are involved.
for leaks. Wear gloves to protect your hands from
Follow all applicable safety precautions in this manual when spraying fluid.
performing crane maintenance as well as crane operations.
• If any hydraulic fluid is injected into the skin, obtain
Keep the crane free of mud, dirt, and grease at all times. medical attention immediately or gangrene may result.
Dirty equipment introduces hazards, wears-out faster, and
• Do not attempt to repair or tighten any hydraulic hose or
makes proper maintenance difficult. Cleaning solutions used
fitting while the engine is running, or when the hydraulic
should be non-flammable, non-toxic and appropriate for the
system is under pressure.
job.
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• Never disconnect any hydraulic lines unless the boom is
Routine maintenance and inspection of this crane must be
fully lowered, the engine is shut off, and the hydraulic
performed by a qualified person(s) according to the
pressure is relieved. To relieve hydraulic pressure, stop
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recommendations in the Manitowoc Crane Care
the engine, turn the ignition switch to RUN and move the
Maintenance and Inspection Manual. Any questions
hydraulic controls in both directions several times.
regarding procedures and specifications should be directed
to your Manitowoc distributor. • Hot hydraulic fluid will cause severe burns. Wait for the
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fluid to cool before disconnecting any hydraulic lines.
Service and Repairs
• Hydraulic fluid can cause permanent eye injury. Wear
appropriate eye protection.
Moving Parts:
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WARNING • Do not place limbs near moving parts. Amputation of a
Fall Hazard! body part may result. Turn off the engine and wait until
Working at elevated heights without using proper fall the fan and belts stop moving before servicing crane.
protection can result in severe injury or death. • Pinch points, which result from relative motion between
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Always use proper fall protection as required by local, mechanical parts, are areas of the machine that can
state or federal regulations. cause personal injury or death. Do not place limbs or
your body in contact with pinch points either on or
Service and repairs to the crane must only be performed by a around the machine. Care must be taken to prevent
qualified person. All service and repairs must be performed m o t i o n b e t w e e n p i n c h p o i n ts w h e n p e r f o r m i n g
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in accordance with manufacturer’s recommendations, this maintenance and to avoid such areas when movement
manual, and the service manual for this machine. If there is is possible.
any question regarding maintenance procedures or • Do not allow persons to stand near extending or
specifications, contact your Manitowoc distributor for
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lowering outriggers. Foot crushing could occur

assistance.
Before performing any maintenance, service or repairs on
Qualified person is defined as one who by reason of the crane:
knowledge, training and experience is thoroughly familiar
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with the crane’s operation and required maintenance as well • The boom should be fully retracted and lowered and the
as the hazards involved in performing these tasks. load placed on the ground.
Training and qualification of maintenance and repair • Do not get under a raised boom unless the boom is
personnel are crane owner’s responsibility. blocked up safely. Always block up the boom before
doing any servicing that requires the boom to be raised.
Any modification, alteration, or change to a crane which
affects its original design and is not authorized and approved • Stop the engine and disconnect the battery.
by Manitowoc is strictly prohibited. All replacement parts
• Controls should be properly tagged. Never operate the
must be Manitowoc approved. Such action invalidates all
crane if it is tagged-out nor attempt to do so until it is
warranties and makes the owner/user liable for any resultant
restored to proper operating condition and all tags have
accidents.
been removed by the person(s) who installed them.
Hydraulic Fluid:
After maintenance or repairs:
• Do not use your hand or any part of your body to check
• Replace all guards and covers that have been removed.
for hydraulic fluid leaks when the engine is running or

• Remove all tags, connect the battery, and perform a Wire Rope
function check of all operating controls.
Always make daily inspections of the wire rope, keeping in
• Consult with Manitowoc Crane Care to determine if load mind that all wire rope will eventually deteriorate to a point
testing is required after a structural repair is performed. where it is no longer usable. Refuse to work with worn or
damaged wire rope. Wire rope shall be taken out of service
Lubrication when any of the following conditions exist:
The crane must be lubricated according to the • For rotation-resistant running ropes: more than two (2)
manufacturer’s recommendations for lubrication points, time broken wires in a length of rope equal to six (6) times the
intervals, and types. Lubricate at more frequent intervals rope diameter, or more than four (4) broken wires in a
when working under severe conditions. length of rope equal to thirty (30) times the rope
Exercise care when servicing the hydraulic system of the diameter.
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crane, as pressurized hydraulic oil can cause serious injury. • For running ropes other than rotation resistant: six (6)
The following precautions must be taken when servicing the broken wires in one rope lay or three (3) broken wires in
hydraulic system:
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one strand.
• Follow the manufacturer’s recommendations when • One valley break where the wire fractures between
adding oil to the system. Mixing the wrong fluids could strands in a running rope is cause for removal.
destroy seals, causing component failure.
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• Abrasion of the rope resulting in a 5% reduction in the
• Be certain all lines, components, and fittings are tight original wire diameter.
before resuming operation.
• Any kinking, bird caging, crushing, corrosion, or other
Tires damage resulting in distortion of the rope structure.
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• Rope that has been in contact with a live power line or
has been used as a ground in an electric circuit (eg.
welding) may have wires that are fused or annealed and
WARNING must be removed from service.
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Possible equipment damage and/or • In standing ropes, more than three (3) breaks in one
personal injury! rope lay in sections beyond the end connection or more
Driving the crane with a tire and split-rim assembly under than two (2) broken wires at an end connection.
inflated at 80% or less of its recommended pressure can • Core deterioration, usually observed as a rapid
cause the wheel and/or tire to fail. Per OSHA Standard reduction in rope diameter, is cause for immediate
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1910.177(f)(2), when a tire has been driven under inflated removal of the rope.
at 80% or less of its recommended pressure, it must first
b e c o m p l e t el y d e fl a t e d , r em o v ed f r o m t h e ax l e , The following is a brief outline of the basic information
disassembled, and inspected before re-inflation. required to safely use wire rope.
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• Wire ropes wear out. The strength of a wire rope begins

Inspect the tires for nicks, cuts, embedded material, and to decrease when the rope is put to use and continues to
abnormal wear. decrease with each use. Wire rope will fail if worn-out,
Ensure all lug nuts are properly torqued. overloaded, misused, damaged or improperly
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maintained.
Ensure pneumatic tires are inflated to the proper pressure
(refer to the Load Chart). When inflating tires, use a tire • The nominal strength, sometimes called catalog
gauge, clip-on inflator, and extension hose which will permit strength, of a wire rope applies only to a new, unused
standing clear of the tire while inflating. rope.
• The nominal strength of a wire rope should be
HOIST ROPE considered the straight line pull which will actually break
Use only the hoist rope specified by Manitowoc as indicated a new unused rope. The nominal strength of a wire rope
on the crane’s Capacity Chart. Substitution of an alternate should never be used as its working load.
hoist rope may require the use of a different permissible line • Each type of fitting attached to a wire rope has a specific
pull and, therefore, require different reeving. efficiency rating which can reduce the working load of
NOTE: Hoist rope may be purchased by contacting the wire rope assembly or rope system.

• Never overload a wire rope. This means never use the - Rope stretch (elongation).
wire rope where the load applied to it is greater than the
- Integrity of end attachments.
working load determined by the rope manufacturer.
- Evidence of abuse or contact with another object.
• Never “shock load” a wire rope. A sudden application of
force or load can cause both visible external and internal - Heat damage.
damage. There is no practical way to estimate the force
- Corrosion.
applied by shock loading a rope. The sudden release of
a load can also damage a wire rope. NOTE: A more detailed wire rope inspection procedure is
given in the Service Manual.
• Lubricant is applied to the wires and strands of a wire
rope when it is manufactured. The lubricant is depleted • When a wire rope has been removed from service
when the rope is in service and should be replaced because it is no longer suitable for use, it must not be
periodically. Refer to the Service Manual for more reused on another application.
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information.
When installing a new rope:
• In the U.S.A., regular inspections of the wire rope and
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keeping of permanent records signed by a qualified • Keep all parts of your body and clothing away from
person are required by OSHA for almost every wire rope rotating hoist drums and all rotating sheaves.
application. The purpose of the inspection is to • Never handle the wire rope with bare hands.
determine whether or not a wire rope may continue to be
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safely used on the application. Inspection criteria, • Follow proper instructions for removing rope from a reel.
including number and location of broken wires, wear and • Apply back tension to the storage/payoff reel of the new
elongation, have been established by OSHA, ANSI, rope to insure tight, even spooling onto the hoist drum.
ASME and similar organizations. See the Service
• Operate the new rope - first through several cycles at
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Manual for inspection procedures.
light load and then through several cycles at
When inspecting ropes and attachments, keep all parts intermediate load to allow the rope to adjust to operating
of your body and clothing away from rotating hoist drums conditions.
and all rotating sheaves. Never handle the rope with
bare hands. When using a wedge socket:
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Some conditions that lead to problems in wire rope • Always inspect socket, wedge, and pin for correct size
systems include: and condition.
- Sheaves that are too small, worn or corrugated • Do not use parts that are damaged, cracked, or
cause damage to a wire rope. modified.
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- Broken wires mean a loss in strength. • Assemble the wedge socket with live end of rope aligned
with the centerline of pin and assure proper length of tail
- Kinks permanently damage a wire rope and must be (dead end) protrudes beyond the socket.
avoided.
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- Wire ropes are damaged by knots. Wire rope with

Synthetic Hoist Rope
knots must never be used. For detailed information concerning synthetic hoist rope,
- Environmental factors such as corrosive conditions refer to KZ100 Synthetic Crane Hoist Line Manual P/N
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and heat can damage a wire rope. 9828100734 available by contacting Manitowoc Crane Care.
- Lack of lubrication can significantly shorten the During installation and setup, care must be taken to avoid
useful life of a wire rope. overlap and crossing of wire rope and synthetic hoist ropes.
- Contact with electrical wires and resulting arcing will Always make daily inspections of the hoist rope, keeping in
damage a wire rope. mind that all hoist rope will eventually deteriorate to a point
where it is no longer usable. Refuse to work with worn or
• An inspection should include verification that none of the damaged hoist rope.
specified removal criteria for this usage are met by
checking for such things as: During regular inspections, operator shall ensure that crane
surfaces such as wear pads, sheaves, etc have not been
- Surface wear; nominal and unusual. damaged in a manner that can then damage the synthetic
- Broken wires; number and location. hoist rope.
- Reduction in diameter. NOTE: Example; if usage of a wire rope has cut grooves
with sharp edges in a wear pad, they need to be

addressed before the synthetic hoist rope is used • If equipped, disconnect battery with the battery
in that same position. disconnect switch before disconnecting the ground
battery cable. For cranes with a Cummins engine using
Sheaves an engine ECM:
a. Ensure that the key switch has been off for 2
minutes.
b. Turn the battery disconnect switch to the OFF
position.
c. Remove the ECM power fuse.
d. Remove negative battery cables.
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• Do not break a live circuit at the battery terminal.
Disconnect the ground battery cable first when removing
a battery and connect it last when installing a battery.
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• Do not short across the battery posts to check charge.
Short circuit, spark, or flame could cause battery
explosion.
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Inspect the boom nose and hook block sheaves for proper
operation, excessive wear, and damage every 50 hours or • If applicable, maintain battery electrolyte at the proper
weekly. Inoperable, damaged and/or worn sheaves cause level. Check the electrolyte with a flashlight.
rapid deterioration of rope. • If applicable to your crane, check battery test indicator
on maintenance-free batteries.
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Ensure sheaves carrying ropes that can be momentarily
unloaded are equipped with close fitting guards or other • Check battery condition only with proper test equipment.
devices to guide the rope back into the groove when the load Batteries shall not be charged except in an open, well-
is reapplied. Ensure sheaves in the lower load block are ventilated area that is free of flame, smoking, sparks,
equipped with close fitting guards that will prevent the ropes and fire.
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from becoming fouled when the block is lying on the ground

with loose ropes. Engine
To attain maximum hoist rope life and minimize hook block Fuel the crane only with the engine turned off. Do not smoke
rotation, it is recommended that even numbers of parts-of- while fueling the crane. Do not store flammable materials on
line be used in multiple-part reeving whenever possible. the crane.
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The use of nylon (polyamide) sheaves, as compared with Be familiar with the location and use of the nearest fire
metallic sheaves, may change the replacement criteria of extinguisher.
rotation-resistant hoist rope.
Be careful when checking the engine coolant level. The fluid
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NOTE: The use of cast nylon (polyamide) sheaves will may be hot and under pressure. Shut down the engine and
substantially increase the service life of rope. allow the radiator time to cool before removing the radiator
However, conventional rope retirement criteria cap.
based only upon visible wire breaks may prove
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inadequate in predicting rope failure. The user of Shut down the engine and disconnect the battery before
cast nylon sheaves is therefore cautioned that a performing maintenance. If unable to do so for the task
retirement criteria should be established based required, keep hands clear of the engine fan and other
upon the user’s experience and the demands of his moving parts while performing maintenance.
application. Be careful of hot surfaces and hot fluids when performing
maintenance on or around the engine.
Batteries
Do not use ether to start the engine on cranes equipped with
Battery electrolyte must not be allowed to contact the skin or intake manifold grid heaters.
eyes. If this occurs, flush the contacted area with water and
consult a doctor immediately. The engine can enter into a engine exhaust cleaning mode
where the exhaust temperature can be high, ensure the
When checking and maintaining batteries, exercise the exhaust is not pointed at materials that can melt, burn or
following procedures and precautions: explode.
• Wear safety glasses when servicing batteries.

TRANSPORTING THE CRANE TRAVEL OPERATION

Before transporting the crane, check the suitability of the Only the crane operator shall occupy the crane when
proposed route with regard to the crane height, width, length, traveling.
and weight.
When traveling, the boom should be completely retracted
Check load limits of bridges on the travel route and ensure and lowered to the travel position and the turntable pin swing
they are greater than the combined weight of the crane and lock, if equipped, should be engaged. If equipped with boom
transporting vehicle. rest, lower the boom into the boom rest and engage the
turntable lock.
When loading or unloading the crane on a trailer or railroad
car, use a ramp capable of supporting the weight of the Strictly adhere to the guidelines and restrictions in the Load
crane. Chart for pick and carry operations.
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Ensure the crane is adequately secured to the transporting RT and Shuttlelift cranes are manufactured with no axle
vehicle. suspension system. Traveling at high speeds, especially on
rough ground, may create a bouncing effect that can result in
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Do not use the dead end lug (1, Figure 2-1) on the boom
loss of control. If bouncing occurs, reduce travel speed.
nose for tying down the boom during transport. Damage to
the lug and boom can result from usage as a tie down point. Death or serious injury could result from being crushed by
revolving tires.
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Stunt driving and horse-play are strictly prohibited. Never
allow anyone to hitch a ride or get on or off a moving crane.
Follow the instructions in this manual when preparing the
crane for travel.
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If using a boom dolly/trailer, thoroughly read and understand
all the steps and safety precautions in this manual for setup
and travel.
When driving the crane, ensure the cab is down, if equipped
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with a tilting cab.

Secure the hook block and other items before moving the
crane.
1 Watch clearances when traveling. Do not take a chance of
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running into overhead or side obstructions.
7116-1A FIGURE 2-1 When moving in tight quarters, post a signal person to help
guard against collisions or bumping structures.
Before transporting the crane on a road or highway, first
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check state and local restrictions and regulations. Before traveling a crane, check suitability of proposed route
with regard to crane height, width, and length.
Either the hook block may be reeved over the main boom
nose or the headache ball may be reeved over the main Never back up without the aid of a signal person to verify the
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boom nose or auxiliary boom nose; the other must be area behind the crane is clear of obstructions and/or
removed. If the hook block or headache ball remains reeved personnel.
on the boom, it must be secured at the tie down on the carrier
On cranes equipped with air-operated brakes, do not attempt
to prevent swinging.
to move the crane until brake system air pressure is at
When using hookblock tie downs, excessive loading can be operating level.
applied by pulling the cable too tight, particularly when
Check load limit of bridges. Before traveling across bridges,
reeved with multiple part lines. When the cable is hooked
ensure they will carry a load greater than the crane’s weight.
into the hookblock tie down, the cable should be merely
“snugged-up” with adequate slack provided at the center line If it is necessary to take the crane on a road or highway,
of sheave to anchor point. Do not draw cable taut. Care must check state and local restrictions and regulations.
be exercised anytime any crane function is being performed
Keep lights on, use traffic warning flags and signs, and use
while the cable is hooked into the hookblock tie down.
front and rear flag vehicles when necessary. Check state and
local restrictions and regulations.

Always drive the crane carefully obeying speed limits and Do not make modifications or additions to the crane’s access
highway regulations. system that have not been evaluated and approved by
Stay alert at the wheel.
Do not step on surfaces on the crane that are not approved
If equipped, ensure that the hoist access platform hand rail
or suitable for walking and working. All walking and working
and step are in the travel configuration.
surfaces on the crane should be clean, dry, slip-resistant,
Slopes: and have adequate supporting capacity. Do not walk on a
surface if slip-resistant material is missing or excessively
- Pick and carry on level surfaces only.
worn.
- Refer to the Operation Section for more detailed
Do not use the top of the boom as a walkway.
information on traveling on slopes.
Do not step on the outrigger beams or outrigger pads (floats)
- Driving across a slope is dangerous, as unexpected
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to enter or exit the crane.
changes in slope can cause tip over. Ascend or
descend slopes slowly and with caution. Use the hoist access platform (if equipped) when working in
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the hoist area.
- When operating on a downhill slope, reduce travel
speed and downshift to a low gear to permit Wear shoes with a highly slip-resistant sole material. Clean
compression braking by the engine and aid the any mud or debris from shoes before entering the crane cab/
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application of the service brakes. operator’s station or climbing onto the crane superstructure.
Excessive dirt and debris on the hand-holds, access steps,
WORK PRACTICES or walking/working surfaces could cause a slipping accident.
A shoe that is not clean might slip off a control pedal during
Personal Considerations operation.
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Always adjust the seat and lock it in position, and fasten the Do not allow ground personnel to store their personal
seat belt securely before you start the engine. belongings (clothing, lunch boxes, water coolers, and the
like) on the crane. This practice will prevent ground
Do not wear loose clothing or jewelry that can get caught on personnel from being crushed or electrocuted when they
controls or moving parts. Wear the protective clothing and attempt to access personal belongings stored on the crane.
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personal safety gear issued or called for by the job

conditions. Hard hat, safety shoes, ear protectors, reflective Job Preparation
clothing, safety goggles, and heavy gloves may be required.
Before crane use:
Crane Access • Barricade the entire area where the crane is working and
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keep all unnecessary personnel out of the work area.

• Ensure that the crane is properly equipped including
access steps, covers, doors, guards, and controls.
WARNING
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Fall Hazard! • Conduct a visual inspection for cracked welds, damaged

components, loose pins/bolts, and wire connections.
Working at elevated heights without using proper fall Any item or component that is found to be loose or
protection can result in severe injury or death. damaged (broken, chipped, cracked, worn-through, etc.)
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Always use proper fall protection as required by local, must be repaired or replaced. Inspect for evidence of
state or federal regulations. improper maintenance (consult your Service Manual).
You must take every precaution to ensure you do not slip • Check for proper functioning of all controls and operator
and/or fall off the crane. Falling from any elevation could aids (for example, RCL).
result in serious injury or death. • Check all braking (for example, wheel, hoist, and swing
Never exit or enter the crane cab or deck by any other means brakes) and holding devices before operation.
than the access system(s) provided (i.e., steps and grab You must ensure that the outriggers and jack cylinders are
handles). Use the recommended hand-holds and steps to properly extended and set before performing any lifting
maintain a three-point contact when getting on or off the operations. On models equipped with outriggers that can be
crane. pinned at the mid-extend position, the outriggers must also
If necessary, use a ladder or aerial work platform to access be pinned when operating from the mid-extend position.
the boom nose.

Clear all personnel from the outrigger area before extending Only the crane operator shall occupy the crane when in
or retracting the outriggers. Carefully follow the procedures operation.
in this Operator Manual when extending or retracting the
You must always be aware of everything around the crane
outriggers. Death or serious injury could result from improper
while lifting or traveling. If you are unable to clearly see in the
crane set up on outriggers.
direction of motion, you must post a look out or signal person
Be familiar with surface conditions and the presence of before moving the crane or making a lift. Sound the horn to
overhead obstructions and power lines. warn personnel
Working Operate the crane only from the operator’s seat. Do not
reach in a window or door to operate any controls.
Operator shall be responsible for all operations under his/her
Operate the crane slowly and cautiously, looking carefully in
direct control. When safety of an operation is in doubt,
the direction of movement.
operator shall stop the crane’s functions in a controlled
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manner. Lift operations shall resume only after safety A good practice is to make a “dry run” without a load before
concerns have been addressed or the continuation of crane making the first lift. Become familiar with all factors peculiar
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operations is directed by the lift supervisor. to the job site.
Know the location and function of all crane controls. Ensure the hoist rope is properly routed on the hook block
and boom nose and that all rope guards are in place.
Make sure all persons are away from the crane and the
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Travel Select Lever is in the “N” (Neutral) position with the
Parking Brake engaged before starting the engine.
Sparks from the crane’s electrical system and/or engine
exhaust can cause an explosion. Do not operate this crane
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in an area with flammable dust or vapors, unless good
ventilation has removed the hazard.
Carbon monoxide fumes from the engine exhaust can cause
suffocation in an enclosed area. Good ventilation is very
important when operating the crane.
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Before actuating swing or any other crane function, sound

the horn and verify that all personnel are clear of rotating and
moving parts.
Never operate the crane when darkness, fog, or other
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visibility restrictions make operation unsafe. Never operate a

crane in thunderstorms or high winds.
Always be aware of your working environment during
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operation of the crane. Avoid contacting any part of the crane

with external objects.
Clear all personnel from the counterweight and
superstructure area before removing the counterweight.
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Lifting
Use enough parts of line for all lifts and check all lines,
slings, and chains for correct attachment. To obtain
maximum lifting capacities, the hook block must be set up
with enough parts of line. Too few parts of line can result in
failure of the hoist rope or hoist. No less than three wraps
Keep unauthorized personnel clear of the working area of wire rope should remain on the hoist drum. No less than
during operation. eight wraps of synthetic rope should remain on the hoist

drum. When slings, ties, hooks, etc., are used, make certain Look before swinging your crane. Even though the original
they are correctly positioned and secured before raising or setup may have been checked, situations do change.
lowering the loads.
Never swing or lower the boom into the carrier cab (if
Be sure the rigging is adequate before lifting. Use tag lines applicable).
when possible to position and restrain loads. Personnel
Never push or pull loads with the crane’s boom; never drag a
using tag lines should be on the ground.
load.
Be sure good rigging practices are being used. Refuse to
Do not subject crane to side loading. A side load can tip the
use any poorly maintained or damaged equipment. Never
crane or cause it to fail structurally.
wrap the hoist cable around a load.
If the boom should contact an object, stop immediately and
If using a clam bucket, do not exceed 80% of the crane’s
inspect the boom. Remove the crane from service if the
capacity.
boom is damaged.
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Make certain the boom tip is centered directly over the load
When lifting a load the boom may deflect causing the load
before lifting.
radius to increase—this condition is made worse when the
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Ensure that all slings, ties, and hooks are correctly placed boom is extended. Ensure weight of load is within crane’s
and secured before raising or lowering the load. capacity on Load Chart.
Be sure the load is well secured and attached to the hook Avoid sudden starts and stops when moving the load. The
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with rigging of proper size and in good condition. inertia and an increased load radius could tip the crane over
or cause it to fail structurally.
Check the hoist brake by raising the load a few inches,
stopping the hoist and holding the load. Be sure the hoist Use tag lines (as appropriate) for positioning and restraining
brake is working correctly before continuing the lift. loads. Check the load slings before lifting.
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When lowering a load always slow down the load’s descent Be sure everyone is clear of the crane and work area before
before stopping the hoist. Do not attempt to change speeds making any lifts.
on multiple-speed hoists while the hoist is in motion.
Never swing over personnel, regardless of whether load is
Watch the path of the boom and load when swinging. Avoid suspended from or attached to the boom.
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lowering or swinging the boom and load into ground

personnel, equipment, or other objects. Hand Signals
Lift one load at a time. Do not lift two or more separately A single qualified signal person shall be used at all times
rigged loads at one time, even if the loads are within the when:
crane’s rated capacity.
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• Working in the vicinity of power lines.

Never leave the crane with a load suspended. Should it
• The crane operator cannot clearly see the load at all
become necessary to leave the crane, lower the load to the
times.
ground and stop the engine before leaving the operator’s
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station. • Moving the crane in an area or direction in which the

operator cannot clearly see the path of travel.
Remember, all rigging equipment must be considered as
part of the load. Lifting capacities vary with working areas. If At all times use standardized hand signals - previously
applicable, permissible working areas are listed in the Load agreed upon and completely understood by the operator and
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Chart. When swinging from one working area to another, signal person.
ensure Load Chart capacities are not exceeded. Know your
If communication with the signal person is lost, crane
crane!
movement must be stopped until communications are
Stop the hook block from swinging when unhooking a load. restored.
Swinging rapidly can cause the load to swing out and Keep your attention focused on the crane’s operation. If for
increase the load radius. Swing the load slowly. Swing with some reason you must look in another direction, stop all
caution and keep the load lines vertical. crane movement first.
Obey a signal to stop from anyone.

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BOOM EXTENSION the ground. When a qualified person at a jobsite determines

that it is not practical to lower the boom to the ground, we
To avoid death or serious injury, follow the procedures in this recommend the following additional instructions be followed:
manual during erection, stowage, and use of the boom
extension. • The crane should be left in the smallest, most stable,
valid operational configuration that the job site
Install and secure all pins properly. practically allows.
Control movement of boom extension at all times. • The crane can not be left running, with a load on the
Do not remove right side boom nose pins unless boom hook, or in erection mode, or in wind conditions in
extension is properly pinned and secured on front and rear excess of allowed values.
stowage brackets. • The boom should be retracted as far as is practical, the
crane configured in as stable a configuration as possible
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(boom angle, superstructure orientation, boom
extension angle, etc.)
DANGER
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• In high winds the boom and boom extensions should be
Boom Extension Hazard! lowered, or secured. Changing weather conditions
To avoid death or serious injury, follow procedures in Load including but not limited to: wind, ice accumulation,
Chart, safety, and operation manuals during erection, precipitation, flooding, lightning, etc. should be
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stowage and use of boom extension. Install and secure all c on s id e r e d w he n d et e r m i n i ng t h e l oc a ti o n a nd
pins properly and control boom extension movement at all configuration of a crane when it is to be left unattended.
times.
SHUT-DOWN
Do not remove all the pins from both front and rear stowage
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brackets unless the boom extension is pinned to the right Use the following steps when shutting down the crane:
side of the boom nose. • Engage the parking brake.
Properly inspect, maintain, and adjust boom extension and • Fully retract and lower the boom.
mounting.
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• Engage the swing lock pin or 360 degree swing lock (if
When assembling and disassembling boom extension equipped).
sections, use blocking to adequately support each section
and to provide proper alignment. • Place crane function power switch to OFF (if equipped).
Stay outside of boom extension sections and lattice work. • Place controls in neutral position.
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Watch for falling or flying pins when they are being removed. • Shut down the engine and remove the ignition key.
• Chock the wheels, if not on outriggers.
PARKING AND SECURING
• Lock the operator’s cab (if applicable) and install vandal
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guards, if used.
! DANGER COLD WEATHER OPERATION

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Tipping Hazard! Cold weather operation requires additional caution on the

When parking the crane and leaving it unattended follow part of the operator.
the instructions in Section 3 of this manual.
Check operating procedures in this manual for cold weather
Failure to comply with these instructions may cause death starting.
or serious injury
Don’t touch metal surfaces that could freeze you to them.
When parking on a grade, apply the parking brake and chock Clean the crane of all ice and snow.
the wheels.
Allow ample time for hydraulic oil to warm up.
Section 3 of this manual provides instructions for parking and
securing a crane when it is to be left unattended. These In freezing weather, park the crane in an area where it
instructions are intended to allow the crane to be placed in cannot become frozen to the ground. The drive line can be
the most stable and secure position. However, Manitowoc damaged when attempting to free a frozen crane.
recognizes that certain jobsite conditions may not permit the If applicable to your crane, frequently check all air tanks for
boom and boom extension of a crane to be fully lowered to water in freezing weather.

If applicable to your crane, always handle propane tanks extended 7.6 m (25 ft) in which the oil cools 15.5°C (60°F)
according to the supplier’s instructions. would retract approximately 196 mm (7 3/4 in) [see Table 2-
2]. A cylinder extended 1.5 m (5 ft) in which the oil cools
Never store flammable materials on the crane.
15.5°C (60°F) would only retract approximately 38 mm (1 1/
If cold weather starting aids are provided on your crane, use 2 in). The rate at which the oil cools depends on many
them. The use of aerosol spray or other types of starting factors and will be more noticeable with a larger difference in
fluids containing ether/volatiles can cause explosions or fire. oil temperature verses the ambient temperature.
Thermal contraction coupled with improper lubrication or
TEMPERATURE EFFECTS ON HOOK improper wear pad adjustments may, under certain
BLOCKS conditions, cause a “stick-slip” condition in the boom. This
“stick-slip” condition could result in the load not moving
The following information applies to Gunnebo Johnston
smoothly. Proper boom lubrication and wear pad adjustment
crane hook blocks:
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is important to permit the boom sections to slide freely. Slow
“Never use a crane block in extreme movement of the boom may be undetected by the operator
temperatures...Sudden failure can occur. unless a load is suspended for a long period of time. To
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minimize the effects of thermal contraction or “Stick-slip” it is
Crane blocks shall not be heated above 82°C (180°F).
recommended that the telescope control lever is activated
Craneblock Working Load Limit is valid between 82°C
periodically in the extend position to mitigate the effects of
(180°F) and service temperature given on the identification
cooling oil.
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tag with normal lifting precautions.
If a load and the boom is allowed to remain stationary for a
Additional lifting precautions are required below the service
period of time and the ambient temperature is cooler than the
temperature given on the identification tag because cold
trapped oil temperature, the trapped oil in the cylinders will
temperature begins to affect the crane block material
cool. The load will lower as the telescope cylinder(s) retracts
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properties.
allowing the boom to come in. Also, the boom angle will
Lifting above 75% of the Working Load Limit (WLL), at decrease as the lift cylinder(s) retracts causing an increase
temperatures between the service temperature given on the in radius and a decrease in load height.
identification tag and -40°C (-40°F), must (be) done at a slow
This situation will also occur in reverse. If a crane is set up in
and steady rate to avoid stress spikes common in normal
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the morning with cool oil and the daytime ambient

hoisting dynamics.
temperature heats the oil, the cylinders will extend in similar
75% of the WLL must not be exceeded, when lifting in proportions.
temperatures below -40°C (-40°F).”
Table 2-2 and Table 2-3 have been prepared to assist you in
determining the approximate amount of retraction/extension
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TEMPERATURE EFFECTS ON HYDRAULIC that may be expected from a hydraulic cylinder as a result of
CYLINDERS change in the temperature of the hydraulic oil inside the
cylinder. The chart is for dry rod cylinders. If the cylinder rod
Hydraulic oil expands when heated and contracts when
is filled with hydraulic oil, the contraction rate is somewhat
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cooled. This is a natural phenomena that happens to all

greater.
liquids. The coefficient of expansion for API Group 1
hydraulic oil is approximately 0.00077 cubic centimeters per NOTE: Operators and service personnel must be aware
cubic centimeter of volume for 1°C of temperature change that load movement, as a result of this phenomena,
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(0.00043 cubic inches per cubic inch of volume for 1°F of can be easily mistaken as leaking cylinder seals or
temperature change). Thermal contraction will allow a faulty holding valves. If leaking seals or faulty
cylinder to retract as the hydraulic fluid which is trapped holding valves are suspected to be the problem,
in the cylinder cools. refer to Service Bulletin dealing with testing
telescope cylinders. (Service Bulletin 98-036
The change in the length of a cylinder is proportional to the
applies to TMS700 and Service Bulletin G06-005A
extended length of the cylinder and to the change in
applies to RT890 and RT9130.
temperature of the oil in the cylinder. For example, a cylinder

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
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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
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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
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Table 2-3 Boom Drift Chart (Cylinder length change in millimeters)
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(1/ °C)
Coef f . = 0.000774 M etri c
STROKE Temperature Change (°C)
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(m) 5 10 15 20 25 30 35 40 45 50 55
1.5 6 12 17 23 29 35 41 46 52 58 64
3 12 23 35 46 58 70 81 93 104 116 128
4.5 17 35 52 70 87 104 122 139 157 174 192
6 23 46 70 93 116 139 163 186 209 232 255
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7.5 29 58 87 116 145 174 203 232 261 290 319

9 35 70 104 139 174 209 244 279 313 348 383
10.5 41 81 122 163 203 244 284 325 366 406 447
12 46 93 139 186 232 279 325 372 418 464 511
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13.5 52 104 157 209 261 313 366 418 470 522 575
15 58 116 174 232 290 348 406 464 522 581 639
16.5 64 128 192 255 319 383 447 511 575 639 702
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18 70 139 209 279 348 418 488 557 627 697 766
Length change in mm = Stroke (m) X Temperature Change ( °C) X Coef f . (1/ °C) X 1000 mm/m
OVERLOAD INSPECTION These inspections apply only to overloads up to 50%. For

overloads of 50% or higher, crane operation must be
This information supplements the Rated Capacity Limiter stopped immediately and Crane Care must be contacted
(RCL) manual supplied with each Grove crane. for corrective action.
When the RCL system has acknowledged an overload The following illustrations may not be an exact
on your crane, you must carry out specified inspections representation of your crane and are to be used for reference
on the crane. only.

NOTE: If your crane is equipped with CraneSTAR, an

overload warning will be posted to the web site
for review by the crane owner.
WARNING Overload warnings do NOT indicate real time
Overload Hazard! events! Warnings could be sent 24 hours (or
more) after the actual event.
To avoid an accident caused by overload damage to
your crane:
• Perform the inspections outlined in this publication
for overloads up to 50%.
• Stop operating the crane and contact Manitowoc
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Crane Care immediately for overloads of 50% and
higher.
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Boom Inspection
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2
9, 10
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Overload less than 25%

1 Sheaves Inspect all for damage.
Luffing
2 Mechanism/ Inspect for damage/leaks.
Cylinder
Collar-wear
3 Inspect all for damage.
pads
Overload from 25% to 49%
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1 Sheaves Inspect all for damage.
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Luffing
2 Mechanism/ Inspect for damage/leaks.
Cylinder
Collar-wear
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3 Inspect all for damage.
pads
4 Collar-welds Inspect all for cracks.
Telescopic Inspect for bent or twisted sections. Check the boom
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Sections for straightness.
Lift Cylinder
6 Inspect for bends or cracked welds.
Head Area
Turret-Base
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7 Inspect for cracked welds.

Section
Locking Area
8 Inspect for elongated holes.
(Pin Booms)
9 Welds Inspect for cracks.
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Inspect for cracked paint which could indicate twisted,

10 Paint
stretched, or compressed members.
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Superstructure Inspection
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1 Lift Cylinder Inspect for leaking.
Turntable See topic in Swing section of
2 Check bolts for proper torque.
Bearing Service Manual.
See topic in Introduction section
3 Wire Rope Inspect all for damage.
of Service Manual.
1 Lift Cylinder Inspect for leaking.
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Turntable See topic in Swing section of
2 Check bolts for proper torque.
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Bearing Service Manual.
See topic in Introduction section
3 Wire Rope Inspect all for damage.
of Service Manual.
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4 Hoist/Drums Inspect each for damage.
5 Hoist Brakes Brakes must hold rated line pull.
Bearing Main
6 Boom Pivot Inspect for deformation, cracked welds.
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Pin
Lift Cylinder-
7 Inspect pin and welds.
lower mount
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8 Turntable Inspect for deformation, cracked welds.

10 Paint
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Carrier Inspection
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Stabilizer
1 Inspect for leaking.
Cylinders
Outrigger
2 Inspect for deformation and cracked welds.
Pads
Stabilizer
1 Inspect for leaking.
Cylinders
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Outrigger
Pads
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Outrigger
Beams
Outrigger
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Boxes
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TMS700E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES
SECTION 3
OPERATING CONTROLS AND PROCEDURES
SECTION CONTENTS
Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Engine Controls and Indicators. . . . . . . . . . . . . . . 3-1 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Travel Controls and Indicators . . . . . . . . . . . . . . . 3-3 Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Accessory Controls and Indicators . . . . . . . . . . . . 3-8 Swing Drive and Turntable Bearing . . . . . . . . . . . 3-23
Additional Carrier Controls and Indicators . . . . . . 3-9 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
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Superstructure Cab . . . . . . . . . . . . . . . . . . . . . . . 3-11 Hydraulic Oil System . . . . . . . . . . . . . . . . . . . . . . 3-23
Engine Controls and Indicators. . . . . . . . . . . . . . 3-11 Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . 3-24
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Crane Controls and Indicators . . . . . . . . . . . . . . 3-14 General Crane Operation . . . . . . . . . . . . . . . . . . 3-26
Regen Initiate/Inhibit Switch . . . . . . . . . . . . . . . . 3-15 Using Your Load Chart . . . . . . . . . . . . . . . . . . . . 3-26
High Exhaust Temp Indicator . . . . . . . . . . . . . . . 3-15 Crane Functions . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
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Diesel Exhaust Fluid (DEF) Level Gauge . . . . . . 3-15 Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Malfunction Indicator Lamp. . . . . . . . . . . . . . . . . 3-15 Crane Travel Operation . . . . . . . . . . . . . . . . . . . . 3-32
Hydraulic Oil Temperature Lamp . . . . . . . . . . . . 3-15 Trailing Boom (Optional) . . . . . . . . . . . . . . . . . . . 3-39
Accessory Controls and Indicators . . . . . . . . . . . 3-19 Travel Configuration . . . . . . . . . . . . . . . . . . . . . . 3-39
Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . 3-40
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Operating Procedures . . . . . . . . . . . . . . . . . . . . . 3-21
Breaking in a New Carrier. . . . . . . . . . . . . . . . . . 3-21 Crane Shutdown Procedures. . . . . . . . . . . . . . . . 3-41
Pre-Starting Checks . . . . . . . . . . . . . . . . . . . . . . 3-21 Unattended Crane . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Cold Weather Operation . . . . . . . . . . . . . . . . . . . 3-22
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The crane is equipped with two cabs, a carrier cab and a CARRIER CAB
superstructure cab. The carrier cab (Figure 3-1) contains all
controls and indicators necessary for crane traveling and Engine Controls and Indicators
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parking. The superstructure cab (Figure 3-3) contains all

controls and indicators necessary to perform all craning Gauge Cluster
operations. Both cabs utilize international symbols and
English text to label the various controls. For detailed The gauge cluster (5) is located in the center of the front
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information on either cab, refer to either CARRIER CAB or console assembly and contains a voltmeter, oil pressure
SUPERSTRUCTURE CAB in this Section. gauge, water temperature gauge, and a fuel quantity gauge.
NOTE: The following paragraphs describe all the available Voltmeter

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(standard and optional—some machines may not The voltmeter (VOLTS) is located on the lower right of the
be equipped with the optional controls shown) gauge cluster. With the ignition switch in the RUN (1) position
controls and indicators located in the cab. The and before starting the engine, the voltmeter indicates the
numbers in ( ) represent the index number from condition of the batteries. With the engine running, the
(Figure 3-1) through (Figure 3-3). voltmeter indicates output voltage of the alternator. The
All rocker switches, except the engine diagnostics voltmeter scale is from 10 to 16 volts.
switches, contain one or two LED lighted slots in
Engine Oil Pressure Gauge
the switch for illumination. In addition, all but the
hydraulic pump disconnect switch contains a LED The engine oil pressure (OIL) gauge is located on the upper
lighted square to indicate when the switch/function right of the gauge cluster. The gauge indicates the engine oil
is activated. pressure on a scale calibrated from zero (0) to 100 psi. It
receives a signal from an oil pressure sending unit on the
engine.

OPERATING CONTROLS AND PROCEDURES TMS700E OPERATOR MANUAL
Water Temperature Gauge Tachometer

The engine coolant temperature (TEMP) gauge is located on The tachometer (2) is located on the left side of the front
the lower left of the gauge cluster. The gauge indicates the console. The tachometer is calibrated in RPM x 100 with a
engine coolant temperature on a scale calibrated from 100 to range of zero (0) to 35 and receives a signal from the sender
240°F. The gauge receives a signal from a temperature unit on the engine.
sending unit in the engine cooling system.
Fuel Quantity Gauge Engine Brake Switches
The fuel quantity (FUEL) gauge is located on the upper left of The engine brake switches are located at the top of the right
the gauge cluster. The gauge indicates the quantity of fuel in hand console. The two position (ON/OFF) switch (22)
the tank and has a scale calibrated from empty (E) to full (F). energizes the engine brake. When the switch is in the ON
The fuel quantity gauge receives a signal from a sending unit position, the amber LED in the switch will be lit. The two
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in the fuel tank. position (HIGH/LOW) switch (20) controls the amount of
engine braking. When the switch is in the HIGH position, the
Engine Stop Indicator amber LED in the switch will be lit.
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The engine stop indicator (23) is located at the top middle left Ignition Switch
of the front console. It lights red when energized by a signal
from the engine ECM that signifies a serious engine problem The ignition switch (14) is located on the right side of the
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that requires the vehicle and the engine to be stopped as front console. The switch is key operated with four positions:
soon as safely possible. Also a warning buzzer will sound. ACCESSORY (ACC) (3), OFF (0), RUN (1), and START (2).
With ignition switches in both cabs in the OFF position, all
Besides alerting the operator of system faults, the engine electrical power is off except for the headlights, marker lights,
stop light, along with the engine warning light, is used in the gauge lights, turn and stop light, backup lights and alarm,
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diagnostic work of the engine control system. carrier and superstructure cab dome lights, carrier and
The diagnostic mode begins when the ignition switch and superstructure cab 12v accessory outlets, boom work lights,
engine diagnostics test switch are on and the engine is not superstructure cab work lights, and superstructure horn. The
running. The amber light flashes at the beginning of a fault ACC position energizes all electrical components except the
engine ECM and starter circuit components. The RUN
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code sequence, the red light flashes the three-digit or four-

digit code for the active fault and the amber light flashes position is the same as ACC except the engine ECM is
again to separate the previous red light sequence from the energized. The START position energizes the starter relay
next one. Each code will be flashed twice before moving to which in turn energizes the cranking motor solenoid and
the next code. When all codes have been flashed, the cranks the engine for starting. The switch will return to RUN
sequence will begin again. If no codes are present, both the when the switch is released after the engine is started. Turn
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engine warning and engine stop lights will remain on. the switch to OFF to shut down the engine.
Engine Warning Indicator Throttle Pedal

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The engine warning indicator (24) is located at the top middle The throttle pedal (38) is the right most pedal on the cab
left of the front console. It lights amber when energized by a floor. It is used to control engine RPM. The foot pedal is
signal from the engine ECM that gives the operator a signal electronically connected to the engine and modulates engine
that there is an engine problem which must be corrected. speed proportionately to the foot pressure applied. The
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pedal is angled for increased operator comfort.

Besides alerting the operator of system faults, the engine
warning light, along with the engine stop light, is used in Engine Diagnostics Switches
diagnostic work of the engine control system.
Two engine diagnostics (35, 36) switches are located on the
The diagnostic mode begins when the ignition switch and right side panel.
engine diagnostics test switch are on and the engine is not
running. The amber light flashes at the beginning of a fault Engine Diagnostics/ Idle +/– Switch
code sequence, the red light flashes the three-digit or four- This switch (35) is a three position (+/-) momentary rocker
digit code for the active fault and the amber light flashes switch that provides idle-control inputs that increase and
again to separate the previous red light sequence from the decrease the engine idle speed (when test mode switch is in
next one. Each code will be flashed twice before moving to the OFF position) or diagnostic mode fault codes (when the
the next code. When all codes have been flashed, the test mode switch is in the ON position and engine is not
sequence will begin again. If no codes are present, both the running).
engine warning and engine stop lights will remain on.

Engine Diagnostics Test Switch Travel Controls and Indicators

This switch (36) is located on the right side console in the
carrier cab. It enables the operator to turn on or off the Dual Air Pressure Gauge
engine diagnostic testing mode. The dual air pressure gauge (1) is located on the left side of
the front console. The gauge is a direct reading pressure
High Exhaust Temp Indicator gauge with two indicating pointers, red for the primary
The high exhaust temp indicator (16) lights when an active system and green for the secondary system. The gauge has
exhaust regeneration has been initiated and the exhaust a dual scale calibrated from 100 to 1000 kPa and 0 to
temperatures will be elevated above normal levels for the 150 psi. The gauge is connected to each air system
vehicle operating conditions This can occur while driving or separately through tubing.
during a manually initiated “stationary regeneration”.
Low Air Pressure Indicator
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The low air pressure (AIR PRESSURE LOW) indicator (27)
WARNING is located on the upper center of the front console above the
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steering wheel. The indicator is a red light that lights when
While regenerating, ensure the exhaust is not aimed at
the pressure in either or both air systems is below 72-84 psi
any surface or material that will melt, burn, or explode.
(5-5.8 bar). The indicator is controlled by two pressure
switches electrically connected in parallel. To determine
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Diesel Exhaust Fluid (DEF) Level Gauge which system pressure is low, observe the dual air pressure
This gauge (10), located on the right center of the front gauge. In addition to illuminating the air pressure low
control panel indicates the amount of fluid in the DEF tank. indicator, the pressure switches also energize a warning
buzzer.
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Engine performance will be derated per the following
conditions: Speedometer
• 3% derated during inducement The speedometer (4) is located on the upper left side of the
• 5% derated during the warning level of the fluid front console above the steering wheel. The speedometer
indicates road speed in both km/h (kilometers per hour) and
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• 10% derated when the fluid level is low. mph (miles per hour). There is an odometer located at the
bottom of the speedometer that shows total distance
Regen Needed/Inhibit Indicator traveled.
This dual lamp indicator (42) is located on the right side of
Parking Brake Control
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the front console in the carrier cab.The upper lamp is used to

indicate when the first level of exhaust regeneration is NOTE: The park brake must be set before the outrigger
needed. The inhibit indicator is illuminated when regen controls will operate.
inhibit switch has been activated.
The parking brake control (12) is located on the right side of
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Regen Initiate/Inhibit Switch the front console. The control is a push-pull type air valve
used to apply and release the parking brakes on all four rear
This switch (41), located on the right side of the front console wheels.
in the carrier cab, is used to initiate or inhibit a stationary
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exhaust regeneration. The switch must be cycled on and off Park Brake On Indicator
to initiate regeneration. The regen inhibit switch is a
maintained ON switch, when selected to manually override The park brake on indicator (29) is located at the top of the
the regen process. front console on the right side above the steering wheel. The
indicator is a red light that lights when the crane parking
The clutch and brake pedals must also be released. The brakes are applied. It is energized by a pressure switch on
engine will automatically change speed as needed. The the parking brake valve. The pressure switch also controls
cycle will take approximately 20 minutes. the outrigger enable relay that permits operation of the
If regeneration (active or stationary) is not desired, press the outriggers.
inhibit side (bottom) of the switch. The regeneration inhibit
indicator should illuminate. When the switch is in the center Cross-Axle Differential Locked Indicators
position, the engine will perform an active regeneration as it The cross-axle differential locked (CROSS AXLE LOCKED
requires and is able. AXLE #3 & CROSS AXLE LOCKED AXLE #4) indicators
(26, 62) are located at the top of the front console above the

steering column. The amber indicators light to show that the Clutch Pedal
cross axle differentials are locked.
The clutch pedal (52) is located on the left side of the cab
floor. It is used to engage or disengage the clutch for starting
CAUTION and stopping the vehicle.
Do not operate the cross axle differential lock or the inter-
Transmission Shift Lever
axle differential lock on dry roads.
The transmission shift lever (40) is located on the right side
Cross-Axle Differential Lock Control of the cab. It is used to select the transmission gears.
The cross-axle differential lock control (17) is located on the Transmission Range Control Switch
lower left side of the front console and is used to lock the
right and left wheels in a tandem set. The cross-axle The transmission range control switch (39) is located on the
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differential lock increases traction on slippery roads. It is a shift lever knob. It provides for high and low range shifting.
two position lock/unlock lever actuated air valve.
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Transmission Deep Reduction Switch
The transmission deep reduction switch (59) is an air
CAUTION solenoid valve which can position the transmission for deep
Do not operate cross-axle differential lock while crane
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reduction. Pushing switch forward engages deep reduction,
wheels are spinning or at speeds over approximately 16 pulling switch backward disengages deep reduction.
km/h (10 mph). Release the throttle when locking or Operate only when machine is standing still.
unlocking.
Trailing Boom Trailer Emergency Brake Control
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Inter-Axle Differential Lock Control (Optional)
The inter-axle differential control (15) is located on the lower The trailing boom (TRAILER EMERGENCY) brake control
right side of the front console. In the LOCK position, both (11) is a push-pull type air valve located on the right side of
rear axles are locked together and turning at the same the front console. The control is used to set and release the
speed. In the UNLOCKED position, the axles operate
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brakes on the trailing boom trailer.

independently of each other. The control is a lever actuated
air valve. Suspension Control
The suspension control (34) is a lever operated air valve
CAUTION located on the right side console. When positioned to
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INFLATE, the suspension air bags are inflated. When

Do not operate inter-axle differential lock while crane
positioned to DEFLATE, the suspension air bags are
wheels are spinning or at speeds over approximately 16
deflated.
km/h (10 mph). Release the throttle when locking or
unlocking.
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NOTE: The suspension air bags should be inflated at all

times except when on outriggers or in a pick and
Inter-Axle DIfferential Lock Control Indicator carry mode.
The inter-axle differential locked control indicator (inter- axle Suspension Deflated Indicator
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locked) (32) is located on the right side of the front console

panel at the top. The amber indicator lights when the inter- The suspension deflated indicator (33) is located on the right
axle differential lock is engaged. side console above the suspension control lever. The amber
indicator lights when the air is removed from the suspension
Brake Pedal air bags. It is controlled by four pressure switches connected
in series.
The brake pedal (37) is located on the cab floor, to the left of
the foot throttle and is used to apply the service brakes.

Front Console 48
50
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38
52
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37
39
56
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40
47
55 59
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45
46
60
Right Hand
61 Console
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43
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54
7039
FIGURE 3-1

3 23 24 6
26 62 27 28 29 30 31 32
2 4
5
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10 41 16
1 42 51 11
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12
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21
18
17 8 7 49
19 15 13
Front Console 14
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22 20
33
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34
57
58
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36 35
Right Hand Console

Item Description Item Description

1 Dual Air Pressure Gauge 38 Throttle Pedal
2 Tachometer 39 Transmission Range Control Switch
3 Left Turn Signal Indicator 40 Transmission Shift Lever
4 Speedometer 41 Regen Initiate/Inhibit Switch
5 Gauge Cluster (Fuel, Temperature, Oil, Volts) 42 Regen Needed/Inhibit Indicator
6 Right Turn Signal Indicator 43 Fire Extinguisher
7 Heater Air Temperature Control 44 Cab Dome Light
8 Heater Fan Switch 45 Steering Wheel
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9 12 Volt Accessory Outlet 46 Horn Button
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10 DEF Fluid Level Gauge 47 Headlight Dimmer/Turn Signal Lever
11 Trailing Boom Trailer Emergency Brake Control 48 Windshield Wiper
12 Parking Brake Control 49 Air Conditioner Switch
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13 Windshield Wiper/Washer Switch 50 Cab Circulating Fan
14 Ignition Switch 51 Malfunction Indicator Lamp
15 Inter-Axle Differential Lock Control 52 Clutch Pedal
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16 High Exhaust Temperature Indicator 53 Not Used
17 Cross-Axle Differential Lock Control 54 Circuit Breaker and Relay Panel
18 Tire Inflator Control Switch 55 Hazard Light Switch
19 Beacon Light Switch 56 Steering Column Tilt/Telescope Lever
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20 Engine Brake High/Low Switch 57 Hydraulic Pump Engaged Indicator

21 Headlights Switch 58 Hydraulic Pump Switch
22 Engine Brake On/Off Switch 59 Transmission Deep Reduction Switch
23 Engine Stop Indicator 60 Seat Adjustment Lever
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24 Engine Warning Indicator 61 Seat Tilt Lever

25 Not Used 62 Cross-Axle Differential Locked Indicator, Axle #4
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26 Cross-Axle Differential Locked Indicator, Axle #3

Swing Brake On Indicator (Optional)
27 Air Pressure Low Indicator
The Swing Brake On Indicator (30) is located at the top of the
28 High Beam Indicator front console. The red indicator lights to warn the operator
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29 Park Brake On Indicator that the swing brake release pressure is not enough to hold
the swing brake disengaged during trailing boom operation.
30 Swing Brake On Indicator
In addition to illuminating the swing brake on indicator, the
31 Tire Inflator On Indicator pressure switch also energizes a warning buzzer.
32 Inter-Axle Differential Locked Indicator
Hydraulic Pump Engaged Indicator
33 Suspension Deflated Indicator
The Pump Engaged Indicator (57) is located on the right side
34 Suspension Control console. The amber indicator lights when the hydraulic
35 Engine Diagnostics/Idle Switch pumps are engaged.
36 Engine Diagnostics Test
Hydraulic Pump Switch
37 Brake Pedal
The Hydraulic Pump Switch (58) is located on the right side
console. Putting the switch at ENGAGE energizes the PTO
clutch solenoid to engage the transmission PTO that drives

the main hydraulic pumps. In some cases, the PTO may not switch counterclockwise to off stops the motor and returns
fully engage or disengage on the first attempt. When this the wiper blade to the parked position. Push in on the switch
occurs, place the hydraulic pump switch in the engaged to spray washing fluid on the windshield.
position and jog the crane’s engine starter to assist with
pump engagement. For disengagement, the hydraulic pump Headlights Switch
switch can be cycled and the engine momentary shut down
to fully disengage the pump. A pressure switch senses when The Headlights Switch (21) is located on the left side of the
the pump is engaged and sends a signal to the engine ECM front console. The switch is a push-pull type switch with a
to limit engine speed to 1800 rpm on QSM machines and rheostat control. Pull the switch to the first detent to light the
1600 rpm on ISX machines. When the hydraulic pump is marker and gauge lights. Pull the switch to the second detent
engaged, function of the foot throttle in the Carrier Cab is to light the headlights, marker lights and the gauge lights.
disabled. Rotating the switch knob controls the brightness of the
gauge lights.
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Malfunction Indicator Lamp
Beacon Light Switch (Optional)
The Malfunction Indicator Lamp (MIL) (51) illuminates amber
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when there is an emission related system error. When this The Beacon Light Switch (BEACON) (19) is a two position,
indicator illuminates have the crane serviced as soon as ON-OFF rocker switch located on the left side of the front
possible. console that controls the beacon light on the top of the carrier
cab. When the switch is in the ON position, the amber LED in
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Accessory Controls and Indicators the switch will be lit.
High Beam Indicator Headlights Dimmer Switch

The headlight High Beam Indicator (28) is located at the top The Headlight Dimmer Switch (47) is incorporated in the turn
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of the center front console. The indicator is a blue light that signal switch. It is located on the left side of the steering
lights when the headlights are on high beam. column. The switch is activated by pulling or pushing the turn
signal lever(s) toward you or away from you.
Heater Air Temperature Control
Turn Signal Lever
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The Heater Air Temperature Control (7) is located on the

right side of the front console. The control is a rotary The Turn Signal Lever (47) is located on the steering column.
thermostat that opens and closes the valve in the hot water Positioning the lever down causes the indicator light on the
supply line to the heater. column and the left front and left rear signals to flash.
Positioning the lever up causes the indicator light on the
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Fan Switch column and the right front and right rear signals to flash.
The Fan Switch (8) is located on the right side of the front Hazard Light Switch
console. This rotary switch controls the speed of the fan
(LOW, MED, and HI) which in turn regulates the volume of air The Hazard Light Switch (55) is located on the steering
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output. The far left position is OFF. The next two positions at column. Pushing forward on the switch (in the direction of the
90° increments are LOW and medium (MED). The far right arrow) causes all the turn signals and the turn signal
position is high (HI). indicator lights on the column to flash.
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Air Conditioner Switch Left Turn Signal Indicator

The Air Conditioner Switch (49) turns on the air conditioner The Left Turn Signal Indicator (3) is located on the top left
when the fan switch is in an on position. side of the front console. It is a green indicator light that
flashes when the turn signal lever is pulled down or the
Windshield Wiper/Washer Switch hazard light switch is on.
The Windshield Wiper/Washer Switch (13) is located on the Right Turn Signal Indicator
right side of the front console. The switch has three
positions; off, low, and high range. Rotating the switch The Right Turn Signal Indicator (6) is located on the top right
energizes the wiper motor on the windshield washer pump side of the front console. It is a green indicator light that
assembly. Rotating the switch to the first detent energizes flashes when the turn signal lever is pushed up or the hazard
the wiper motor at low speed and rotating it to the second light switch is on.
detent energizes the motor at high speed. Rotating the

Steering Column Tilt/Telescope Lever 12 VDC Accessory Outlet

The Steering Column Tilt/Telescope Lever (56) is located on The 12 VDC Accessory Outlet (9) is located on the right side
the steering column behind the turn signal lever. Pulling back console. It provides an outlet for the operator to plug in a 12
on the lever allows the steering column to be tilted, and VDC accessory. It is protected by a 10 amp fuse.
pushing forward on the lever allows the steering column to
be telescoped in and out.
Cab Dome Light
Horn Button The Cab Dome Light (44) is located in the center of the cab
roof directly over the seat. It is controlled by a switch on the
The Horn Button (46) is located in the center of the steering
light and by a door switch that powers the light when the cab
wheel (45). Depressing the horn button energizes the circuit
door is opened.
sounding the horn.
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Fire Extinguisher Air Horn (Not Shown)
A set of air horns are mounted on top of the cab and are
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The Fire Extinguisher (43) is mounted on the inside rear of
controlled by a valve manually actuated by a cable inside the
the cab.
cab.
Cab Circulating Fan Fuse and Relay Panel
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The Cab Circulating Fan (50) is mounted on the left front of
The fuse and relay panel (54) is located on the rear of the
the cab and is controlled by a two speed switch on the base
cab under a removable cover. It contains fuses and relays
of the fan.
that protect and control the various electrical components of
the carrier.
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Seat Adjustment Lever
The Seat Adjustment Lever (60) works by lifting on the bar at Additional Carrier Controls and Indicators
the front center of the seat. NOTE: The following paragraphs describe the additional
controls and indicators located on the carrier to
Seat Tilt Lever
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operate the outriggers. The numbers in

The Seat Tilt Lever (61) operates by lifting the handle to tilt parentheses ( ) represent the index number from
the backrest forward or backward. Figure 3-2.
Tire Inflator Switch Outrigger Control Summary

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The Tire Inflation Switch (TIRE INFLATOR) (18) is located on There is an outrigger control box located on each side of the
the left side of the front console. It is a guarded two position crane carrier. Each box contains an outrigger control panel
toggle air valve that activates the tire inflation system. with switches for extending and retracting the outrigger
beams and for raising and lowering the outrigger jack
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Tire Inflator On Indicator cylinders on that side of the crane. Each control panel also
contains a control switch for raising and lowering the center
The Tire Inflator On Indicator (31) is located at the top of the front jack cylinder. A level is installed at the bottom of the
front console. It is an amber light that is lit when the pressure outrigger box. The following paragraphs explain these
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switch in the tire inflation system is activated. In addition to controls.

illuminating the Tire Inflator On Indicator, the pressure switch
also energizes a warning buzzer.

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6776-4 5
1
Item Description
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1 Outrigger Control Panel
6 2 Outrigger Beam Selector Switch
3 Extend/Retract Switch
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4 Center Front Jack Cylinder Switch
5 Jack Cylinder Selector Switch
6 Level Indicator
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6776-5 FIGURE 3-2
Outrigger Control Panel to either position, a signal is sent to the engine ECM to
increase engine speed above idle for operation of the
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There is one Outrigger Control Panel (1) on each side of the outriggers.
unit’s frame. The panel on the right side operates the
outrigger beams for that side only. The panel on the left side Center Front Jack Cylinder Switch
operates the outrigger beams for that side only. The jack
cylinders may be operated from the left or right side of the The Center Front Jack Cylinder Switch (4) is located in the
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crane. center of the outrigger control panel. It must be used in

conjunction with the Extend/Retract Switch to control the
Outrigger Beam Selector Switch operation of the center front jack cylinder. The center front
jack cylinder will retract automatically when any of the other
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The Outrigger Beam Selector Switch (2) is used to indicate four jack cylinders are retracted, therefore it must be reset if
desired operation of the front or rear outrigger beam for the lifting is to be continued.
side of the crane the control panel is on.
Jack Cylinder Selector Switch
Extend/Retract Switch
The Jack Cylinder Selector Switch (5) is used to choose
The Extend/Retract Switch (3) will operate both the outrigger which jack cylinder to operate.
beams or the jack cylinders. After positioning the desired
selector switch, positioning the Extend/Retract Switch Level Indicator
energizes the control solenoid to allow hydraulic fluid to flow
through the control solenoid valve and the individual The Level Indicator (6) is used to indicate when the crane is
solenoid valve and move the selected component in the level during the positioning of the jack cylinders.
desired direction. In addition, when the switch is positioned

Daytime Running Lights Voltmeter

The Daytime Running Lights are powered by the carrier The Voltmeter (VOLTS) is located on the lower right of the
ignition switch (14) accessory circuit (Figure 3-1). When the gauge cluster. With the ignition switch in the RUN (1) position
park brake control (29) is pulled to apply the park brake, the and before starting the engine, the voltmeter indicates the
daytime running lights lose power and turn off. This feature condition of the batteries. With the engine running, the
allows the low beam of the headlights to automatically be on voltmeter indicates output voltage of the alternator. The
any time the crane is roading. voltmeter scale is from 10 to 16 volts.
Engine Oil Pressure Gauge
SUPERSTRUCTURE CAB
The Engine Oil Pressure Gauge (OIL) is located on the
The front console is laid out vertically and is located in the upper right of the gauge cluster. The gauge indicates the
right front of the superstructure cab. This location provides engine oil pressure on a scale calibrated from zero (0) to 100
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the operator with a clear view out of the front of the cab. psi. It receives a signal from an oil pressure sending unit on
Additional indicators and switches are on the overhead the engine.
console above the right side cab window. The outrigger
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controls are located on a hand held control box that is stored Water Temperature Gauge
in a pocket on the left front of the superstructure cab. The Engine Coolant Temperature Gauge (TEMP) is located
NOTE: The following paragraphs describe all the available on the lower left of the gauge cluster. The gauge indicates
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(standard and optional; some cranes may not be the engine coolant temperature on a scale calibrated from
equipped with the optional controls shown) controls 1 0 0 t o 2 4 0 ° F. T h e g a u g e r e c e i v e s a s i g n a l f r om a
and indicators located in the cab. The numbers in temperature sending unit in the engine cooling system.
( ) represent the index number from Figure 3-3. Fuel Quantity Gauge
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All rocker switches contain one or two LED lighted The Fuel Quantity Gauge (FUEL) is located on the upper left
slots in the switch for illumination. In addition, all of the gauge cluster. The gauge indicates the quantity of fuel
but the throttle mode switch contains a LED lighted in the tank and has a scale calibrated from empty (E) to full
square to indicate when the switch/function is (F). The Fuel Quantity Gauge receives a signal from a
activated. sending unit in the fuel tank.
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Engine Controls and Indicators Ignition Switch

Hand Throttle Switch (Engine Increment/ The Ignition Switch (32) is located on the front console. It is a
Decrement Switch) key operated switch with four positions; 3 (accessory), 0
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(off), 1 (run), and 2 (start). The switch is spring returned from

This switch (31), located on the front console, is used to set the 2 position to the 1 position. In the 0 position, all electrical
the engine operating speed. It is a two position (+/-) power in the superstructure is off except for the boom work
momentary switch. lights, cab work lights, panel lights, dome light, swing horn,
and accessory outlet. In the 3 position, all electrical
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Pushing the top of the switch quickly increases (+) engine

components are energized except the starter circuit
RPM to the maximum allowed operating speed. Pushing the
components. Placing the switch in the 2 position energizes
bottom of the switch quickly decreases (-) engine RPM to
the starter motor relay and solenoid for starting the engine.
idle speed (ISX engine only). Pushing and holding either side
Releasing the switch will allow it to spring return to the 1
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of the switch will increase or decrease engine speed.

position. To shut down the engine, turn the switch to the 0
Releasing the switch will hold the engine at the current
position.
speed. Pressing the foot pedal will increase engine speed
above the “hold” speed. Releasing the foot pedal causes the
engine to return to the “hold” speed.
Tachometer
The Tachometer (TACH) (27) is located at the top of the front
Gauge Cluster console and registers engine RPM. The Tachometer is
calibrated in RPM x 100 with a range of zero (0) to 35. The
The Gauge Cluster (29) is located in the center of the front
Tachometer receives an electrical signal from a sending unit
console above the RCL panel and contains a Voltmeter, Oil
on the engine that does not use the machine’s electrical
Pressure Gauge, Water Temperature Gauge, and a Fuel
system.
Quantity Gauge.

Hourmeter Foot Throttle Pedal

The Hourmeter (28) is located at the bottom of the The Foot Throttle Pedal (4) is located on the right side of the
Tachometer and registers the total hours that the engine has cab floor. The pedal sends an electronic signal to control
run. The Hourmeter receives an electrical signal from the engine speed.
Tachometer.
Engine Warning Indicator
Engine Stop Indicator
The Engine Warning Indicator (48) will light to alert the
The Engine Stop Indicator (25) is located on the alert panel operator of a temperature high, a pressure low, or a coolant
at the top of the right hand console. It is a red light that lights level low condition.
when energized by a signal from the engine ECM. When the
light lights a buzzer also sounds.
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1
2 3
Outrigger
Control Box
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Front
23 Console
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22 5
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21
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7
9
20
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Overhead
Console
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15
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FIGURE 3-3
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WILL COME ON. For the other conditions (2 to 6 hours or 1

Item Description to 2 hours), regenerate the exhaust system while parked, or
change to a more challenging duty cycle, like highway
1 Work Lights driving, for about 20 minutes to get the exhaust system hot
2 Windshield Wiper/Washer enough to regenerate properly. (Use the Engine Regen
Initiate/Inhibit Switch for regeneration.)
3 Boom Telescope Control Pedal (Optional)
If successful regeneration still does not occur, the engine
4 Throttle Pedal
stop light will replace the previous lamps and the filter unit
5 Bubble Level Indicator will need to be removed and serviced by an authorized
6 Swing Pin Lock Control Lever facility.
7 Seat Adjustment Lever Crane Controls and Indicators
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8 Boom Lift Control Lever
Telescope or Auxiliary Hoist Control Lever
9 Main Hoist Control Lever
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The Telescope or Auxiliary Hoist Control Lever (18) is
10 Main Hoist Speed Selector Switch
located on the left armrest. The lever controls the telescope
11 Hydraulic Boost Switch functions when the crane is not equipped with an auxiliary
12 Cab Dome Light hoist. Positioning the lever forward actuates the control valve
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to telescope the boom out and pulling the lever back
13 Fuse Panel actuates the boom to telescope in.
14 Beacon Light (Optional) When equipped with an auxiliary hoist, the lever controls
15 Fire Extinguisher auxiliary hoist functions and telescope functions are
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controlled through a foot pedal (3). Positioning the lever
16 Auxiliary Hoist Speed Selector Switch (Optional) forward actuates the control valve to let out the hoist cable
17 Swing Brake Control Switch and pulling the lever back reels the cable in.
18 Telescope or Auxiliary Hoist Control Lever
Swing Control Lever
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19 Swing Control Lever

The Swing Control Lever (19), located on the left armrest,
20 Swing Horn Button controls the swing function. The lever, when positioned
21 Skylight Wiper forward (rotates the turntable clockwise) or back (rotates the
turntable counterclockwise), actuates a control valve through
22 Swing Brake Pedal hydraulic pilot pressure to provide 360 degree continuous
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23 Cab Circulating Fan rotation in the desired direction.

24 Positive Swing Lock Control Pedal
Boom Lift Control Lever
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Regeneration Exhaust/Inhibit Indicator The Boom Lift Control Lever (8) is located on the right
armrest. The lever, when positioned forward (lowers the
The Regeneration Exhaust/Inhibit Indicator (49) lights when
boom) or back (raises the boom), actuates the control valve
the exhaust system has not been able to regenerate under
through hydraulic pilot pressure to raise or lower the boom.
normal operating conditions and is in need of assistance in
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order to perform an active regeneration. There are three

progressive stages of need for regeneration indicated by this
Main Hoist Control Lever
light: A) On solid: Regeneration should be done within two to The Main Hoist Control Lever (9) is located on the right
six hours of operation. B) Flashing: Regeneration needs to armrest. The lever, when positioned forward (lowers the
be done in the next one to two hours. C): Flashing w/Engine cable) or back (raises the cable), actuates the control valve
Warning Light illuminated: Regenerate immediately. through hydraulic pilot pressure to raise or lower the main
If regeneration (active or stationary) is not desired, press the hoist cable.
indicator should illuminate. When the switch is in the center Swing Horn Switch
position, the engine will perform an active regeneration as it The Swing Horn Switch (20) is located on top of the swing
requires and is able. controller and is used by the operator to provide a warning
An immediate regeneration must be done while the crane is that the superstructure is rotating. Press down on the switch
parked. IF IGNORED, THE ENGINE STOP INDICATOR to sound the swing horn.

Telescope Control Pedal (Optional) indicator should illuminate. When the switch is in the center
position, the engine will perform an active regeneration as it
The Telescope Control Foot Pedal (3), supplied when the requires and is able.
crane is equipped with an auxiliary hoist, is located at the
center of the cab floor. Pushing forward on the top of the High Exhaust Temp Indicator
pedal will extend the boom and pushing down on the bottom
of the pedal will retract the boom. The High Exhaust Temp Indicator (51) lights when an active
exhaust regeneration has been initiated and the exhaust
Main Hoist Speed Selector Switch temperatures will be elevated above normal levels for the
vehicle operating conditions This can occur while driving or
The Main Hoist Speed Selector Switch (10) is located on the during a manually initiated “stationary regeneration”.
right armrest. It is a two position switch placarded HIGH and
LOW. Positioning the switch to HIGH energizes a solenoid
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controlled valve on the main hoist to direct the flow of
hydraulic oil to the hoist motors. When the switch is in the WARNING
HIGH position, the amber LED square in the switch will light. While regenerating, ensure the exhaust is not aimed at
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any surface or material that will melt, burn, or explode.
Auxiliary Hoist Speed Selector On/Off Switch
(Optional) Diesel Exhaust Fluid (DEF) Level Gauge
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The Auxiliary Hoist Speed Selector Switch (16) is located on This gauge (52), located on the right center of the front
the left armrest. It is a three position switch placarded HIGH- control panel indicates the amount of fluid in the DEF tank.
OFF-LOW. Positioning the switch to HIGH energizes a
Engine performance will be derated per the following
solenoid controlled valve on the auxiliary hoist to direct the
conditions:
flow of hydraulic oil to the hoist motors. When the switch is in
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either the HIGH or LOW position, the amber LED square in • 3% derated during inducement
the switch will light. The switch must be in the HIGH or LOW
• 5% derated during the warning level of the fluid
position before the auxiliary hoist can be operated.
Positioning the switch to OFF prevents the operator from • 10% derated when the fluid level is low.
accidentally activating the auxiliary hoist.
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Malfunction Indicator Lamp

Regen Initiate/Inhibit Switch
The Malfunction Indicator Lamp (MIL) (53) illuminates amber
This switch (50), located on the right side of the console in when there is an emission related system error. When this
the superstructure cab, is used to initiate or inhibit a indicator illuminates have the crane serviced as soon as
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stationary exhaust regeneration. The switch must be cycled possible.

on and off to initiate regeneration. The Regen Inhibit Switch
is a maintained ON switch, when selected to manually Hydraulic Oil Temperature Lamp
override the regen process.
The Hydraulic Oil Temperature Lamp (54) illuminates red
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The clutch and brake pedals must also be released. The when the hydraulic oil temperature reaches 210 degrees. is
engine will automatically change speed as needed. The an emission related system error. When this indicator
cycle will take approximately 20 minutes. illuminates, discontinue operations and have the crane
serviced as soon as possible.
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If regeneration (active or stationary) is not desired, press the


54 26
48 47
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27
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37 38 40
39 41
36 34 33

Item Description
25 Engine Stop Indicator
26 Front Jack Cylinder Overloaded Indicator
27 Tachometer
28 Hourmeter
29 Gauge Cluster (Fuel, Temperature, Oil, Volts)
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30 RCL Panel
31 Hand Throttle Switch
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32 Ignition Switch
46 33 Air Conditioning Control Switch (Optional)
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44
34 Heat Control Knob
35 12 VDC Accessory Outlet
36 Fan Switch
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37 Crane Function Power Switch
38 Windshield Wiper/Washer Switch
39 Panel Light Control Dimmer
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40 Work Lights Switch
FIGURE 3-3 continued 41 Boom Lights Switch (Optional)
42 Positive Swing Lock Release Lever
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43 Positive Swing Lock Foot Pedal

44 Outrigger Extension/Retraction Switch
45 Center Front Jack Cylinder Control Switch
46 Outrigger Selector Switches
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47 Wait to Start Indicator

48 Engine Warning Indicator
49 Regen Exhaust/Inhibit Indicator
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50 Initiate/Inhibit Exhaust Switch

51 High Engine Temperature Indicator
52 Diesel Exhaust Fluid (DEF) Level Gauge
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53 Malfunction Indicator Lamp

54 Hydraulic Oil Temperature Lamp

Hoist Rotation Indicators (HRI) The Hydraulic Boost Switch (11) is located on the right arm
rest. This two position switch is used to control the high
The Hoist Rotation Indicators (“thumb thumpers”) are located speed boost selector valve. With the switch in the HI
on top of each hoist control lever. The HRI indicators are position, the solenoid valve is energized. The solenoid valve
electronically driven by a signal from an electronic stops flow of oil from Pump No. 1 (Section 2) to the
transmitter and sensor attached to each hoist. A pulsating integrated outrigger selector valve. The poppet check valve
signal is sensed by the operator’s thumb during hoist opens to combine this flow of oil with the output from Pump
operation. No. 1 (Section 1). Hydraulic boost will not function unless the
crane function switch is in the ON position. With the switch in
HRI Display the HI position, the amber LED square in the switch will light.
The HRI display is located in the front overhead panel
(Figure 3-4). The LED display illuminates to indicate the Outrigger Control Box
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current hoist in operation and which direction the hoist is NOTE: The park brake in the carrier cab must be set
rotating. before the outrigger controls will operate.
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The Outrigger Control Box contains the switches that are
used to control the outrigger beams, jack cylinders, and
center front jack cylinder. The box is a hand held unit that is
stored in a pocket at the left front of the superstructure cab.
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The parking brake must be set before the outrigger controls
can be operated.
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3 There are four outrigger selector switches on the top of the
control box and one extend/retract switch on the side of the
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2 4 control box. To extend or retract an outrigger component,
first select the component with the outrigger selector switch,
then select EXTEND or RETRACT with the appropriate
outrigger extend/retract switch.
A center front jack cylinder switch is also located on the top
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of the outrigger control box. To extend or retract the center
front jack cylinder, press the center front jack cylinder switch
Item Description and then energize the related extend/retract switch.
1 Main Hoist UP (Clockwise) NOTE: The center front jack cylinder will retract any time
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2 Main Hoist DOWN (Counterclockwise) any one of the main jack cylinders are retracted.
3 Auxiliary Hoist UP (Clockwise) Front Jack Cylinder Overloaded Indicator
4 Auxiliary Hoist DOWN (Counterclockwise)
The Front Jack Cylinder Overloaded Indicator (26) (FRONT
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FIGURE 3-4 STABIL OVER LOAD) is located on the LED alert panel at
the top of the front console. The indicator is a red light that
Crane Function Power Switch will light when the pressure switch in the front jack cylinder
circuit senses over-pressurization indicating an overload
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The Crane Function Power Switch (37) is located on the right

condition. In addition to the indicator light, a buzzer will
overhead console. This two-position (ON/OFF) rocker switch
sound.
permits the operator to disconnect power from the crane
functions controlled by the hydraulic remote controllers on
the armrests. Positioning the switch to OFF prevents Bubble Level Indicator
inadvertent operation of functions due to bumping the The Bubble Level Indicator (5) is located at the bottom of the
controllers while roading or any other operation. With the front console. The indicator provides the operator with a
switch in the OFF position, operation of hydraulic boost and visual indication for determining the levelness of the
high speed hoist is also prevented. When the switch is in the machine. Refer to Bubble Level Adjustment, page 3-28 for
ON position, the red LED square in the switch will light. more information.
Hydraulic Boost Switch Swing Brake Control Switch

NOTE: The Hydraulic Boost Switch must be positioned to The Swing Brake Control Switch (17) is located on the left
LOW to function the outrigger circuits armrest. This two-position rocker switch (ON/OFF) is used to

control a hydraulic valve that directs a regulated flow of Boom Lights Switch (Optional)
pressure to and from the swing brake. Positioning the switch
to ON will apply the swing brake and positioning the switch to The Boom Lights Switch (41) is a two position ON/OFF
OFF will release the swing brake. When the switch is in the rocker switch located on the overhead panel. The switch
ON position, the square amber LED in the switch is lit. controls the flood lights located on the boom base section.
When the switch is in the ON position, the square amber
Swing Brake Pedal LED in the switch is lit.
The Swing Brake Pedal (22) is located on the left side of the Cab Circulating Fan
cab floor. The Swing Brake Pedal is used to actuate the
swing brake to slow or stop swing motion. Braking is The Cab Circulating Fan (23) is located on a mounting
proportional to pedal depression. With the pedal not bracket above the left window frame. A swivel allows the fan
depressed and the swing brake control valve disengaged, to be positioned in any direction and a high-off-low switch on
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hydraulic pressure is applied to the brake release circuit, the base controls the fan.
overcoming spring pressure and releasing the brake.
Depressing the pedal actuates a swing power brake valve to Cab Dome Light
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apply pressure to the brake assembly. This pressure aids the The Cab Dome Light (12) is located on the right rear corner
spring pressure to overcome the hydraulic pressure being of the cab roof and provides illumination of the cab. The light
applied to the brake release circuit and applies the spring is controlled by an on/off switch on the light.
brake according to the pressure from the swing power brake
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valve. Fire Extinguisher
Pin Swing Lock Control (Pin Type) The Fire Extinguisher (15) is located at the left rear side of
the cab. The fire extinguisher is a BC rated dry type fire
The Pin Swing Lock Control handle (6) is located on the right
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extinguisher for emergency use.
side of the cab. The purpose of the pin swing lock is to lock
the superstructure in position directly over the front or over Windshield Wiper/Washer Switch
the rear. When the control handle is pushed down and the
superstructure is directly over the front or rear, the swing lock The Windshield Wiper/Washer Switch (38) is located on the
overhead console. The switch is a three position rotary
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pin drops into a socket on the carrier frame, locking the

superstructure in place. When the control handle is pulled switch (off-low-high) that controls the windshield wiper. The
up, the pin is pulled out of the socket, unlocking the low and high positions run the wiper at low and high speeds
superstructure. and the off positions turns off the wiper and parks the wiper
blade. Pushing the switch sprays washer fluid on the
Swing Lock Control (Positive Lock Type) windshield.
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The Swing Lock Control Pedal (24) is located on the left side Skylight Wiper
of the cab floor. The purpose of the swing lock is to secure
the superstructure in any position. When the control pedal is The electrically-operated Skylight Wiper (21) is installed to
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up, the swing lock is disengaged and swing can be remove moisture from the skylight. The wiper is located on
accomplished. Pushing down on the control pedal engages the left side of the skylight frame.The skylight wiper is
the swing lock. Pulling up on the lever releases the swing controlled by an on/off switch on the wiper motor.
lock.
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Heat Control Knob

Accessory Controls and Indicators
The Heat Control Knob (34) is located on the front console.
The knob is a push-pull control that positions a flow diverter
Panel Light Control
valve in the hot water heater supply line. Pull out on the knob
The panel light (PANEL DIM) control (39) is located on the (PULL ON) to allow hot water to flow through the heater coil
right overhead console. Rotate the control knob to turn the and push in on the knob (PUSH OFF) to shut off the flow of
lights on and control the brightness of the gauge lights. hot water to the coil.
Work Lights Switch Fan Switch

The Work Lights Switch (40) is a two position ON/OFF rocker The Fan Switch (36) is located on the left side of the front
switch which is located on the right overhead console and console. The switch is a four-position rotary switch (OFF,
controls the crane’s work lights mounted on the top front of LOW, MED, HI) that controls operation of the blower to
the superstructure cab. When the switch is in the ON circulate heated or cool air throughout the cab.
position, the square amber LED in the switch is lit.

Air Conditioner Control Switch (Optional) 12 VDC Accessory Outlet

The Air Conditioner (AIR COND) Control Switch (33) is The 12 VOLT Accessory Outlet (35) is located at the bottom
located on the right side of the front console. The switch is a of the front console. It provides an outlet for the operator to
two-position rocker switch (OFF, ON) that controls the plug in a 12 VDC accessory. It is protected by a 10 amp fuse.
operation of the optional air conditioning system in
conjunction with the FAN switch. When the switch is in the Fuse Panel
ON position, the square amber LED on the switch is lit.
The Fuse Panel (13) is located under the cover panel on the
Beacon Light (Optional) back wall of the cab behind the seat. It contains fuses that
protect the various electrical components of the
The Beacon Light (14) is located on the left rear corner of the superstructure.
cab roof. It is operational anytime the ignition switch is in the
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ACC or RUN position.
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OPERATING PROCEDURES Engine Coolant

Breaking in a New Carrier Check the coolant level in the radiator and fill to the proper
level. Do not overfill and ensure the radiator cap is secure.
Your new Grove Manitowoc carrier has been thoroughly
tested, adjusted, lubricated, and inspected prior to delivery.
For detailed engine break-in, refer to the applicable engine
manual.
WARNING
The guidelines below will aid in getting a long service life out Do not loosen radiator cap on a hot engine. Steam or hot
of the crane. coolant will cause severe burns.
• Operate as much as possible in the half to three-
quarters throttle or load range. Batteries
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• Avoid long periods of operation with the engine at idle or Check the state-of-charge indicator if applicable with
continuous maximum horsepower levels. maintenance free batteries or check each cell for the correct
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fluid level if equipped with standard or low maintenance
• Observe instruments often and shut down at the first batteries. Use only clean distilled water and do not overfill.
indication of an abnormal reading. On all types of batteries, make sure the cables and clamps
• Operate to a power requirement that allows acceleration are tight and not corroded.
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to governed speed when conditions require more power.
Hydraulic Reservoir and Filter
• Check all components frequently for proper operation,
unusual noises, and excessive heating. Check the hydraulic level sight gauge and filter condition
indicator on the hydraulic tank. Hydraulic fluid should be at
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• Check the engine oil and coolant levels frequently.
normal operating temperature and the boom and outriggers
These guidelines should not be considered limitations but in a retracted position.
rather a guide for familiarization of the machine and
Check breather for cleanliness and security.
development of good operating habits.
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Pre-Starting Checks Wire Rope

Inspect the wire rope in accordance with applicable Federal
A complete walk-around visual inspection of the crane
Regulations. Sheaves, guards, guides, drums, flanges, and
should always be made with special attention to structural
any other surfaces that come in contact with the rope should
damage, loose equipment, leaks, or other conditions that
be inspected for any condition that could cause possible
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would require immediate correction for safe operation. Refer

damage to the rope.
to Maintenance Checklist, page 6-1. The following checklist
items are suggested to ensure the crane is prepared for
starting the day’s work.
Hook Block and Headache Ball
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Inspect for nicks, gouges, cracks, and evidence of any other

Fuel Supply damage. Replace a hook that has cracks or shows evidence
of excessive deformation of the hook opening (including
Fill the fuel tank and ensure the cap is on tight.
twist). Be sure the safety latch is free and aligned.
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Diesel Exhaust Fluid (DEF) Supply Swingaway Extension

Check the level of the fluid; engine derates occur when tank
is below 10% capacity.
Engine Oil DANGER

Engage boom extension stop block to keep swingaway
and boom nose attach fittings from hitting each other
CAUTION when boom is retracted. Failure to do so can result in
Do not overfill. damage to the boom and possible injury or death to
personnel.
Check the oil level in the crankcase and fill to the FULL mark
on the dipstick. Do not overfill. The boom extension stop block must be engaged to keep the
swingaway and boom nose attach fittings from hitting each

other, when the boom is fully retracted and the swingaway is Daily Lubrication
properly stowed.
Ensure all components requiring daily lubrication have been
Seats and Mirrors serviced. (Refer to Lubrication, page 5-1).
Adjust seat and mirrors for clear vision and safe driving. Cold Weather Operation
Seat Belts The following recommendations are for operating Grove
cranes in very low (i.e. freezing) temperatures.
Seat Belt Maintenance
Use particular care to ensure that cranes being operated in
Seat belt assemblies are maintenance-free; however, they very cold temperatures are operated and maintained in
should be periodically inspected to ensure that they are not accordance with the procedures as provided by Grove
damaged and are in proper operating condition, especially if Manitowoc Crane Group. Cranes should have appropriate
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they have been subjected to severe stress. hydraulic oil, lubricants, and other auxiliary items required for
operation in sub-zero temperatures. Individual crane
Cleaning Seat Belt Webbing
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functions should be operated to ensure they are sufficiently
Wash the seat belt webbing with any mild soap or detergent. warmed prior to performing a lift.
Do not use commercial solvents. Also, bleaching or re-
Operation of cranes at full rated capacities in temperatures
dyeing the webbing is not recommended because of
between 0°C and -40°C (+32°F and -40°F) or lower shall be
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possible loss of webbing strength.
accomplished only by competent operators who possess the
skill, experience, and dexterity to ensure smooth operation.
Signal and Running Lights Shock loading shall be avoided.
Check all signal and running lights for proper operation.
Operation Below -40°C
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Replace burned out lamps with those of the same number, or
equivalent.
For crane operation below -40°C, capacities shall be derated
3.67% of the capacities shown on the load chart for each
Service and Parking Brakes degree (1°C) below -40°C.
Check for proper operation.
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Operation Below -40°F

Tires For crane operation below -40°F, capacities shall be derated
Check the pressure and condition of all tires before traveling. 2.0% of the capacities shown on the load chart for each
degree (1°F) below -40°F.
NOTE: For tire inflation pressures, refer to the Tire Inflation
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Decal on the crane. Crane Warm-up Procedures

Wheels The following procedures detail the actions that must be
taken to properly warm the different crane components
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Maintain proper torque on wheel lugs and check for proper before operating the crane.
wheel mounting. If equipped with steel or aluminum wheels,
the wheels should be retorqued 80 to 160 km (50 to 100 NOTE: For temperatures below -9°C (15°F) refer to arctic
miles) after initial installation or after any time the tires and lubricants and conditions in the Operator and
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wheels are removed. Doing this will reseat the lug nuts. Service Manuals.
Recheck the lug nuts for proper torque every 800 km (500 Before starting the crane, ensure the appropriate lubricants
miles) thereafter. are used to provide lubrication for the prevailing ambient
temperatures in which the crane will operate in (a list of
Safety Equipment lubricants and their temperature ranges can be found in the
Check all lights, windshield wipers, washers, washer liquid Lubrication section of your crane’s Operator Manual, by
supply, horn, instruments, signaling devices, etc. contacting your local Manitowoc distributor, or by contacting
Manitowoc Crane Care directly).

Swing Drive and Turntable Bearing

CAUTION Warm-up Procedures for Temperatures Above -7°C
(20°F):
Crane Damage Hazard!
Operating the crane with the incorrect lubricants and 1. Setup the crane on fully extended outriggers, with the
fluids for the prevailing ambient temperature and/or failing boom fully retracted and near maximum lift angle with no
to adequately warm the crane prior to cold weather load applied.
operation can lead to a failure of a crane component or 2. Rotate the superstructure at a speed of less than one
system. RPM for at least one complete revolution in one
Always use Manitowoc recommended lubricants and direction, then rotate the superstructure at a speed of
fluids for the prevailing ambient temperature and properly less than one RPM for at least one complete revolution
start and warm the crane using the cold weather in the opposite direction.
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procedures found in this Operator ’s Manual and
Warm-up Procedures for Temperatures Below -7°C
supplement before operating the crane at full load.
(20°F):
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Engine 1. Ensure the boom is fully retracted and near maximum lift
angle with no load applied.
Warm-up Procedures for All Temperature Ranges:
2. Rotate the superstructure at a speed of less than one-
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1. Upon startup, allow the engine to idle for 3 to 5 minutes half RPM for at least two complete revolutions in one
before operating with a load. direction, then rotate the superstructure at a speed of
2. Cold Engine Startup: After allowing the engine to warm less than one-half RPM for at least two complete
by idling it for 3 to 5 minutes, slowly increase the engine revolutions in the opposite direction.
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speed to provide adequate lubrication to the bearings
and to allow the oil pressure to stabilize. Axles
Warm-up Procedures for Temperatures Below -35°C
Transmission (-30°F):
Operating the transmission with a sump temperature below
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1. Setup the crane on outriggers.

normal operating temperature is limited to:
2. Engage the transmission (see Crane Transmission,
• operating in the neutral gear or page 3-35) with 4-wheel drive selected (if equipped) and
• driving with an unloaded crane while not exceeding allow crane to run at idle until the temperature of the
1500 engine RPM and not exceeding half throttle. transmission sump reaches normal operating
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temperature.
Warm-up Procedures for Truck Mount (TM/TMS) Cranes:
NOTE: Warm-up operation of 4-wheel drive transmission
1. Setup the crane on outriggers. engaged in 2-wheel drive only could cause
transmission damage.
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2. Engage the transmission and allow crane to run at idle

until the temperature of the transmission sump reaches
normal operating temperature. Hydraulic Oil System
Operating Limits and Warm-up Procedures:
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Hoist
• From 4°C to -10°C (40°F to 15°F): Crane operation
Performing a warm-up procedure is recommended at every without a load is allowed with medium engine RPM and
startup and is required at ambient temperatures below 4°C medium function speed (joystick position) until the fluid
(40°F). reaches at least 10°C (50°F). It is then recommended
Warm-up Procedures: that all crane functions be cycled to remove cold fluid
from all components and cylinders of the hydraulic
1. Without operating the hoist function, warm the hydraulic system. If there is any unusual sound coming from the
oil (see Hydraulic Oil System, page 3-23). crane’s hydraulic pumps or motors, stop the operation
2. Once the hydraulic system is warm, operate the and engine immediately and contact a Manitowoc
unloaded hoist, in both directions, at low speeds several distributor.
times to prime all hydraulic lines with warm hydraulic oil • From 10°C to 4°C (50°F to 40°F): Crane operation with
and to circulate gear lubricant through the planetary a load is allowed with medium engine RPM and medium
gear sets. function speed (joystick position) until the fluid reaches
at least 10°C (50°F).

• From 95°C to 10°C (200°F to 50°F): Crane operation expected temperature. In case of an emergency, white
with a load is allowed with no restrictions. kerosene can be added to the fuel to bring the pour point
down to the required temperature. This will prevent clogging
• Above 95°C (200°F): No crane operation is allowed. Let
of filters and small passages by wax crystals. The addition of
the crane’s hydraulic oil cool by running the engine at
kerosene is NOT recommended for general use.
idle with no functions actuated.
Warm Engine
Engine Operation
The ENGINE WARNING and ENGINE STOP indicators will
Start-up and shutdown procedures for most diesel engines light and go off in sequence after about two seconds (as a
are generally the same. Therefore, the following procedures check) when the key is first turned on. If an indicator comes
can be applied, except where specific differences are noted. on after initial start-up, there is a problem that needs to be
(Refer to the applicable engine manufacturer’s manual for corrected. With the ignition key on, but engine not running,
detailed procedures). place the engine diagnostics test switch at ON for code
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retrieval and check the engine manufacture’s service manual
Start-Up Procedure for code identification.
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Make an under-the-hood inspection for fuel, oil, and coolant 1. Place the hydraulic pump switch at DISENGAGE.
leaks, worn drive belts, and trash build-up.
2. Ensure the parking brake is set and position the
transmission in neutral. Depress the brake pedal.
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NOTE: The engine will not crank unless the transmission
CAUTION shift lever is in neutral and the brake pedal is
depressed.
Diesel engine exhaust can be harmful to your health. Only
operate the engine in a well ventilated area or vent 3. Turn the ignition switch to start (2) and release
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exhaust outside. immediately when the engine starts. Do not push or hold
the throttle down. The ECM will automatically provide
the proper amount of fuel to start the engine.
4. Immediately check the engine instruments for proper
CAUTION
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indication after starting. Shut down the engine if the oil

Never crank engine for more than 30 seconds during an pressure gauge does not reach the proper reading
attempted start. If engine does not start after 30 seconds, within 15 seconds.
allow starter motor to cool for about two minutes before
attempting another start.
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NOTE: The engine control system will allow only 30

seconds of cranking every two minutes, this
CAUTION
system will automatically reset. Both air system pressures must be in the normal
operating range prior to disengaging the park brake.
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This c rane is equ ipp ed wit h an ov er-cra nk

protected starter that will automatically cut out
when the starter gets too hot.
CAUTION
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If oil pressure and/or temperature indicator(s) do not

CAUTION display the proper readings, shut down engine and
If engine does not start after four attempts, correct correct malfunction.
malfunction before attempting another start.
5. Allow the engine to warm up for about five minutes
Use the correct grade of oil for the prevailing temperature in before applying a load. Do not race the engine for a
the crankcase to prevent hard cranking. Diesel fuel should faster warm up.
have a pour point of 5°C (10°F) less than the lowest

Cold Engine pressure gauge does not reach the proper reading
within 15 seconds.
CAUTION
Wear proper eye protection when replacing starting fluid CAUTION
containers. Starting fluid can cause blindness or severe
Both air system pressures must be in the normal
eye damage and breathing problems.
operating range prior to disengaging the park brake.
CAUTION
Always start a cold engine from the carrier cab (with pump
disconnected). CAUTION
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If oil pressure and/or temperature indicator(s) do not
The ENGINE WARNING and ENGINE STOP indicators will display the proper readings, shut down engine and
correct malfunction.
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light and go off in sequence after about two seconds (as a
check) when the key is first turned on. If an indicator comes
on after initial start-up, there is a problem that needs to be 5. Allow the engine to warm up for about five minutes
corrected. With the ignition key on, but engine not running, before applying a load. Do not race the engine for a
faster warm up.
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place the engine diagnostics test switch at ON for code
retrieval and check the engine manufacture’s service manual
for code identification. Idling the Engine
The engine is equipped with an automatic cold starting Idling the engine unnecessarily for long periods of time
wastes fuel and fouls injector nozzles. Unburned fuel causes
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system that provides a metered flow of starting fluid to the
engine when the engine ECM determines this is necessary. carbon formation; oil dilution; formation of lacquer or gummy
An engine block heater is also provided. It is recommended deposits on the valves, pistons and rings; and rapid
that no other type of cold starting aid be used with this accumulation of sludge in the engine.
engine. NOTE: When prolonged engine idling is necessary,
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If starting fluid runs out, replace the empty starting fluid maintain at least 800 rpm.
container with a full container. Particulate Filter Maintenance at Idle — Unexpected
Idle Speed Increase
CAUTION If the engine is left at idle for significant periods of time

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The engine cold start system operates automatically without reaching the minimum exhaust operating
when the engine temperature is at or below a preset temperatures, the engine will automatically increase the
temperature. If the engine does not start immediately, engine idle speed to 760 rpm for 10 minutes to maintain the
avoid overloading the air box with highly volatile fluid condition of the particulate filter. Unexpected idle speed
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which could result in a minor explosion. increase will occur if the crane’s speed is zero, the clutch and
brake pedals are released, the transmission is out of gear
1. Place the hydraulic pump switch at DISENGAGE. a n d a ft e r f o u r c o n t i n u o u s i d l e h o u r s w i t h e x h a u s t
temperature less than 120°C (248°F) or after eight
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2. Ensure the parking brake is set and position the continuous idle hours with exhaust temperature less than
transmission in neutral. Depress the brake pedal. 250°C (482°F).
NOTE: The engine will not crank unless the transmission NOTE: The standard idle speed is 800 rpm, so unexpected
shift lever is in neutral and the brake pedal is idle speed increase is only an issue if the operator
depressed. intentionally lowered the idle speed to a setting
3. Turn the ignition switch to start (2) and release below 760 rpm.
immediately when the engine starts. Do not push or hold
the throttle down. The ECM will automatically provide Racing the Engine
the proper amount of fuel to start the engine. DO NOT race the engine during the warm-up period or
4. Immediately check the engine instruments for proper operate the engine beyond governed speed (as might occur
indication after starting. Shut down the engine if the oil in downhill operation or downshifting). Engine bearings,
pistons, and valves may be damaged if these precautions
are not taken.

Shutdown Procedure
1. Allow the engine to run at fast idle speed for about five CAUTION
minutes to avoid high internal heat rise and allow for Run the engine at or near the governed RPM during
heat dissipation. operation of all crane functions.
2. Position the ignition switch to OFF.
NOTE: Carefully read and become familiar with all crane
3. Drain the fuel filter-water separator. operating instructions before operating the crane.
General Crane Operation Using Your Load Chart
Pump Drive NOTE: One of the most important tools of every Grove
crane is the Load Chart found in the crane
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The main three section hydraulic pump is driven by an operator's cab.
engine driven pump drive with disconnect. The two single
section hydraulic pumps are direct engine driven. The Load Chart contains the lifting capacities of the crane in
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all allowable lifting configurations, and must be thoroughly
Control Lever Operation understood by the operator.
The control lever operation for crane functions is standard, The Load Chart is divided into capabilities limited by crane
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i.e., the closer the lever is to neutral (center), the slower the structural strength and stability which is shown by a bold line
system responds. Return the control lever to neutral to hold across the chart. Structural strength limits are above the line
the load. Do not feather the hoist control to hold the load. and stability limits are below the line.
NOTE: Always operate the control levers with slow, even The left column is the load radius, which is the distance from
the axis of the crane rotation to the load center of gravity. The
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pressure.
top row lists various boom lengths from fully retracted to fully
Preload Check extended with swingaway extension. The number at the
intersection of the left column and top row is the total load
After the crane has been readied for service, an operational limit for that load radius and boom length. The number in
check of all crane functions (with no load applied) should be parentheses below the total load limit is the required boom
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performed. Preload check is as follows: angle (in degrees) for that load. Boom lengths between
increments should always be treated as if it were the next
• Extend and set the outriggers and level the crane.
longer length. For example, if the actual boom length is 15.2
• Raise, lower, and swing the boom right and left at least m (50 ft) and the chart shows boom lengths of 14.6 - 16.4 m
45 degrees. (48 - 54 ft), use the load capacity shown in the 16.4 m (54 ft)
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column.
• Telescope the boom out and back in, ensuring all
sections extend and retract properly. Another important section is the range diagram. The range
diagram shows the operating radius and tip height that can
• Raise and lower the cable a few times at various boom
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be achieved at a given boom length and angle. If the

lengths. Make sure there are no kinks and that the cable
operator knows the radius and tip height required for a
is spooling on the hoist properly.
specific lift, the angle and boom length can quickly be
determined from the range diagram. Or if he knows the boom
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length and angle, he can quickly determine the tip height and
operating radius.

MA
IN
BO
OM
LE
NG AXIS OF ROTATION
TH
BOOM ANGLE
3
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HORIZONTAL
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4605
OPERATING RADIUS
TERMS TO KNOW
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FIGURE 3-5
A lifting diagram is included for over-side, over-rear, and 172 lb (78 kg) for a total of 282 lb (128 kg). The lift requires
over-front lifting areas. The lifting area diagram shows that slings and spreader bars weighing 350 lb (159 kg) which
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the locations of the outrigger jack cylinders in the full makes the total weight for the load handling devices 632 lb
extended position are used to mark the boundaries of the (286 kg).
lifting areas.
A check of the load chart for a 50 ft (15.2 m) radius and 64 ft
Another section contains notes for lifting capacities. Be sure (19.5 m) of boom length shows a capacity of 7940 lb (3601
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to read and understand all notes concerning lifting kg) on outriggers over-front and 4970 lbs on outriggers 360
capacities. degrees. We subtract the load handling weight of 632 lbs
from the load capacity of 7940 lb (3601 kg) and 4970 lb
The load chart also gives weight reductions for Grove load
(2254 kg). The result is a weight capacity of 7308 lb (3315
handling devices such as hookblocks, headache balls, boom
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kg) over-the-front and 4338 lb (1968 kg) for 360 degrees. We

extension sections, etc, which must be considered as part of
are constricted in making the lift over-front only and the
the load. The weight of any other load handling devices such
boom angle will be about 29 degrees.
as chains, slings, or spreader bars must also be added to the
weight of the load.
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Proper Leveling of the Crane

NOTE: The information in the following paragraph is an
ASME B30.5 specifies that if a crane is not level within 1% of
example of how to compute a lift. The numbers
grade, the allowable capacities must be reduced. Therefore,
used in the example may not coincide with the load
whether lifting on rubber or outriggers, it is essential that the
chart in the crane cab.
crane is level to within 1% of grade. The bubble level that is
Problem: A concrete beam weighing 5000 lb (2268 kg) provided on the crane is calibrated to be accurate within 1%
needs to be lifted to a height of 30 ft (9.1 m) at a radius of 50 of grade.
ft (15.2 m) (maximum). The range diagram indicates the
To properly level the crane, the boom must be positioned
boom must be extended to 62 ft (18.9 m) in order to reach a
over the front of the crane, fully lowered to horizontal and
height of 30 ft (9.1 m) at a radius of 50 ft (15.2 m).
fully retracted (for cranes fitted with a boom rest, the boom
First we need to check the crane for load handling devices. shall be stowed onto the rest). Raise and level the crane
In our example, the crane is equipped with an auxiliary boom using the outriggers; refer to Setting the Outriggers, page 3-
nose (rooster sheave) and a five ton headache ball. The 28.
rooster sheave is 110 lb (50 kg), and the headache ball is

A working crane may settle during lifting operations. The air suspension system must be deflated when
Frequently check the crane for level. When rechecking the on outriggers.
crane for level, the boom must be positioned over the front of
The outrigger control switches are located on the outrigger
the crane, fully lowered to horizontal and fully retracted (for
control box located in a pocket at the front of the
cranes fitted with a boom rest, the boom shall be stowed
superstructure cab. In addition, the outriggers may be
onto the rest). If necessary, relevel the crane using the
operated from optional control boxes mounted on both sides
procedures under Setting the Outriggers, page 3-28.
of the carrier just forward of the front outriggers. When using
the optional control boxes, the engine speed is increased
Bubble Level Adjustment due to a signal to the engine ECM when the EXTEND/
The bubble level adjustment should be checked periodically; RETRACT switch is placed in either position.
if it is suspected that the bubble level indicator is out of
adjustment, verify and adjust the bubble level as follows:
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1. Position the crane on a firm, level surface.
CAUTION
Depress outrigger selector switch before the outrigger
2. Extend and set the outriggers. Level the crane, as
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extension/retraction switch. Failure to do so may cause a
indicated by the bubble level indicator, using the hydraulic lock against the individual solenoid valves, and
outriggers. keep them from opening.
3. Place a miracle pointer level, carpenter level, or similar
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type device on a machined surface such as the turntable 1. If outrigger floats are not already installed, remove them
bearing or bearing mounting surfaces. from float stowage locations on left, right, and rear of
carrier frame. Secure the floats to the rods of the
4. Using the outriggers, level the crane as indicated on the outrigger jack cylinders using the levers on each float.
leveling device used in step 3.
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2. Depress the appropriate outrigger selector switch to
5. Using the bubble level indicator mounting screws, adjust EXTENSION and then position the outrigger extension/
the bubble level indicator to show level. retraction switch to EXTEND. The outrigger beam
should begin to extend. Refer to Engaging the Mid
Crane Functions Extension Lock Pin, page 3-29 if the crane is to be
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operated at the mid-extend position.
DANGER
Death or serious injury could result from improper crane WARNING
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setup on outriggers. All four outrigger beams must be equally extended to the
mid position vertical stripe or fully extended position
before beginning operation. Failure to properly deploy the
outriggers may cause death or serious injury.
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WARNING NOTE: More than one outrigger may be extended at one

The outriggers and the center front jack cylinder must be time. However, each outrigger selector switch
properly extended and set and the crane level before any should be depressed individually and the outrigger
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other operation of the crane on outriggers is attempted. extension/retraction switch momentarily positioned
to EXTEND to ensure that each outrigger is fully
When operating the crane on outriggers, the outriggers extended.
should always be fully extended or locked in the mid-
extend position, depending on the Load Chart being used. 3. After all four outrigger beams have been extended,
The center front jack cylinder will retract when any main depress the appropriate outrigger selector switch to
outrigger jack cylinder is retracted. Reset center front jack STABILIZER and position the outrigger extension/
cylinder if any main outrigger jack cylinder is retracted or retraction switch to EXTEND.
extended after initial set-up. 4. Extend each jack cylinder, until the floats touch the
ground.
Setting the Outriggers NOTE: More than one jack cylinder may be extended at
NOTE: The park brake must be set and the hydraulic boost one time.
switch must be in the LOW position before the
5. After all floats are on the ground, extend the front jack
outriggers will operate.
cylinders about 3 to 4 in (8 to 10 cm) and then extend the

back jack cylinders the same distance. Repeat until all retraction switch to RETRACT until the front jack
tires are off the ground. cylinders have retracted several inches.
3. Repeat steps 1 and 2 until the crane is resting on all four
wheels and the jack cylinder floats are several inches off
the ground.
DANGER
All four outrigger beam lock pins must be engaged before
operating from the mid-extend position.
Operator must select proper Load Chart and RCL DANGER
program for the outrigger position selected. Keep feet and hands clear of floats when unlocking the
Improper setup on outriggers may cause death or serious floats from the jack cylinders.
injury.
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4. Release the locking levers and allow the floats to drop to
6. Repeat step 5 until all wheels are clear of the ground the ground.
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and the crane is level as indicated by the sight bubble
5. Continue to retract the jack cylinders until they are fully
level located on the right side of the cab. If it is
retracted.
suspected that the bubble level indicator is out of
adjustment, verify and adjust the bubble level as 6. Position the desired outrigger selector switch to
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described in Bubble Level Adjustment, page 3-28. EXTENSION and hold the outrigger extension/retraction
switch to RETRACT. The appropriate outrigger beam
Outrigger Monitoring System (OMS) (Optional—
should begin to retract.
Standard in North America)
NOTE: More than one outrigger beam may be retracted at
The Outrigger Monitoring System (OMS) aids the operator in
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one time.
accurately programming the Rated Capacity Limiter (RCL)
by automatically identifying the horizontal position of each 7. After all outriggers have been fully retracted, stow the
outrigger beam. The OMS uses four sensors, one per outrigger floats. Secure the floats with quick pins and
outrigger beam, to identify when an outrigger beam is spring clips.
positioned to one of three pre-defined locations, including
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Stowing the Mid-Extend Lock Pin

fully retracted, mid-extend, and fully extended.
1. Retract the outrigger extension/retraction cylinder.
Set up of the outriggers is the same for cranes equipped with
OMS; refer to Setting the Outriggers, page 3-28. The RCL NOTE: If the lock pin is wedged in the hole in the outrigger
only indicates the horizontal position of the outrigger beam beam, it may be necessary to jog the outrigger
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and should not be used to deploy the beam. extension/retraction switch slightly while pulling
upward on the pin.
Engaging the Mid Extension Lock Pin
2. Lift the lock pin and turn it 90° to its stowed position.
1. Turn the locking pin 90° from its stowed position and
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allow the pin to rest on top of the outrigger beam.

Setting the Center Front Jack Cylinder
NOTE: It may be necessary to jog the outrigger extension/
retraction switch slightly to ensure proper pin
engagement. CAUTION
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2. Slowly extend or retract the outrigger beam, allowing the Never operate center front jack cylinder unless boom is
locking pin to drop into the hole in the top of the outrigger retracted and in boom rest, and outriggers and jack
beam, engaging the outrigger beam at the desired cylinders are extended and set. Retract center front jack
length. cylinder before jack cylinders and outriggers.
Stowing the Outriggers 1. Position the CENTER FRONT jack cylinder control
switch to ACTIVATE and position the outrigger
1. Position the rear outrigger selector switches to extension/retraction switch to EXTEND.
STABILIZER and position the outrigger extension/
retraction switch to RETRACT until the rear jack
cylinders have retracted several inches. CAUTION
2. Position the front outrigger selector switches to Do not try to lift or level the crane with the center front jack
STABILIZER and position the outrigger extension/ cylinder.

2. Continue to extend the jack cylinder until the float is the control lever with a slow, even pressure. Rotation is
firmly set on the ground. stopped utilizing the swing brake foot pedal. When rotation is
stopped, put the SWING BRAKE switch in the ON position to
Stowing the Center Front Jack Cylinder prevent further rotation.
Elevating and Lowering the Boom
WARNING
Center front jack cylinder will retract when any main
outrigger jack cylinder is retracted. Reset center front jack DANGER
cylinder if any main outrigger jack cylinder is retracted or Clear area above and beneath boom of obstructions and
extended after initial set-up. personnel before elevating or lowering boom.
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Elevating the Boom
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CAUTION To elevate the boom, pull the BOOM control lever back, and
hold until the boom rises to the desired elevation.
Only operate center front jack cylinder when outriggers
are extended and set, and boom is retracted and in boom Lowering the Boom
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rest.
To lower the boom, push the BOOM control lever forward
and hold until the boom is lowered to the desired position.
1. Position the CENTER FRONT jack cylinder control
switch to ACTIVATE and the extension/retraction switch
to RETRACT.
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2. Fully retract the center front jack cylinder. WARNING
Long cantilever booms can create a tipping condition
Swinging the Boom even when unloaded and in an extended and lowered
position. Death or serious injury may result from the crane
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overturning.
Lower boom and let out cable simultaneously to prevent
DANGER two-blocking.
Death or serious injury could result from being crushed by
moving machinery. Sound swing horn and clear all
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personnel from moving parts.

Do not elevate or swing boom over side unless outriggers CAUTION
are properly extended and crane is level. The closer the load is to the boom nose, the more
Clear boom and tail swing path of all obstructions and important it becomes to let out cable as the boom is
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personnel. lowered.
When swinging from over-the-front to over-the-side, refer
to over-the side Load Chart and make certain the capacity Telescoping the Boom
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is not exceeded. Traveling with any load over-the-side is NOTE: When the crane is equipped with an auxiliary hoist
prohibited. the telescope function is controlled by a foot pedal.
Extending the Boom
CAUTION
Disengage 360° swing lock, pin swing lock, and swing
brake before swinging. DANGER
Never push or pull swing control lever through neutral to Check the Load Chart for maximum load at given radius,
the opposite direction to stop swing motion. boom angle, and length before extending boom with a
load. Death or serious injury may result from the load
To swing the boom, push the SWING control lever to forward falling.
for right swing and pull back for left swing. Always operate

Lowering the Cable

Push the MAIN or AUX hoist control lever forward, away
from the operator, and hold until the hook or load is lowered
WARNING to the desired height.
When extending the boom, simultaneously let out the
cable to prevent two-blocking the boom nose and hook Raising the Cable
block. Death or serious injury may result from the load
falling. Pull the MAIN or AUX hoist control lever back, toward the
operator, and hold until the hook or load is raised to the
desired height.
CAUTION Hoist Speed Range Selection
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Before extending the boom, ensure the large access
covers on each side of the boom base section are
installed.
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WARNING
Push the TELESCOPE control lever forward away from the Do not change the hoist speed range with the hoist
operator and hold until the boom extends to the desired rotating.
length.
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Retracting the Boom To change the speed range of the hoist(s), position the
applicable switch (MAIN HOIST SPEED or AUX HOIST
SPEED) to HIGH or LOW as applicable.
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Operational Aids
CAUTION
When retracting the boom, the load will lower unless the
cable is taken in at the same time.
WARNING
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To retract the boom, pull the TELESCOPE control lever

back, toward the operator, and hold until the boom retracts to Electronic equipment on this crane is intended as an aid
the desired length. to the operator. Under no condition should it be relied
upon to replace the use of capacity charts and operating
Telescope Control Pedal instructions. Sole reliance upon these electronic aids in
place of good operating practices can cause an accident.
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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 Rated Capacity Limiter (RCL) System
boom. The Rated Capacity Limiter (RCL) is an electro-mechanical
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sensing system designed to alert the crane operator of

Lowering and Raising the Hoist Cable impending capacity when the system has been properly
preset by the operator. The control panel is mounted in the
front console of the operator’s cab. When an overload
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condition is sensed, the system provides the operator with a

WARNING visual and audible warning, and locks out the control levers
Keep the area beneath the load clear of all obstructions to prevent lowering the boom, extending the boom, or raising
and personnel when lowering or raising the cable (load). the main or auxiliary hoist cables.
Death or serious injury may result from the load falling. Three additional features are included within the RCL
Do not jerk control lever when starting or stopping hoist. system:
Jerking causes load to bounce, which could result in
• Swing Angle Set Limitation
possible damage to the crane.
• Work Area Definition
NOTE: When the load is stopped at the desired height, the • Anti-two Block Device
automatic brake will engage and hold the load as
long as the control lever remains in neutral. Swing Angle Set Limitation allows left and right swing
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
virtual wall.
CAUTION FIGURE 3-6
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When defining virtual walls (s), always allow a safe
working distance to any obstacles. Never work outside a For greater restraint and comfort:
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safe working area as defined by common practice, 1. Be sure the belt is snugly fitted around the hips - not the
standards, and manuals. waist - and not twisted. Failure to properly fit belts may
result in unnecessary injury in the event of a collision.
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WARNING Pull this portion of the strap to shorten
There are no cut-outs associated with the swing angle set
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limitation or the work area definition features.
An Anti-two Block Device is also incorporated into the

system to prevent the hook block or headache ball from
coming into contact with the boom nose or boom extension.
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This condition will also cause a lockout of hoist up, boom With buckle positioned as shown.
down, and telescope out, and also provide a visual and an Pull buckle to lengthen.
audible alarm.
Refer to the RCL Operator’s Handbook for more detailed
information on the function of the RCL system.
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Control Lever Lockout System Push button in to release
The control lever lockout system consists of hydraulic

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solenoid valves (located in the directional control valves)

which are in series between the hydraulic remote control
valves in the cab and the pilot-operated directional control
valves. When the valves are actuated, they prevent pilot flow Snap into buckle to connect
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between the hydraulic remote control valve in the cab and

the appropriate directional control valve. The valves are FIGURE 3-7
activated in such a manner as to prevent worsening the
condition, i.e. boom down, telescope out, or hoist up. The 2. Only one person should be strapped in each seat belt.
control lever lockout system is used with the anti-two-block To lengthen the belt, tip the buckle end downward, as shown,
system or the rated capacity limiter (RCL) system. and pull the buckle until the belt ends can be joined. Insert
the belt into the open end of the buckle until a snap is heard
Crane Travel Operation and check for latch engagement. The belt can be shortened,
after connection, by pulling on the loose end until the belt is
Active Restraints snug. Press the buckle release to remove the belt.
Seat Belts
Before fastening a seat belt, always adjust the driver’s seat
to the position in which you will drive.

Traveling - General Traveling with Boom Extension and/or Inserts

Erected
CAUTION 10.1 m (33 ft)/17.1 m (56 ft) Extension
Disengage the hydraulic pumps for extended traveling, Travel is permissible under the following conditions.
cold weather starting, or engine checks.
1. The 33 ft (10.1 m) or 56 ft (17.1 m) boom extension shall
Check cold tire pressure prior to extended travel. Refer to be erected at minimum offset. If traveling with just the
tire inflation decal on crane. 10.1 m (33 ft) extension, the stinger section must be
Job site travel with deflated suspension must be limited to stowed on the boom base section, not on the extension
8 kM/H (5 MPH). Attempting to travel at higher speeds base section.
may cause drive train component failure.
2. Jobsite travel only on firm, level surface.
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Do not move the crane until the superstructure has been 3. Main boom shall be fully retracted.
secured as outlined below.
4. Main boom angle: 0 degrees minimum, 20 degrees
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1. To ensure the axles and/or suspension are not maximum.
overloaded, adhere to the following.
5. Maximum travel speed: 2.5 mph (4 km/h).
a. For highway travel with 16,500 lb (7484 kg) of
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6. Main counterweight (as applicable) shall be installed.
c o u n t e r w e i g h t , i n s ta l l 5 5 0 0 l b ( 2 4 9 5 k g ) o f
counterweight on the carrier. Check that front axle a. With the 33 ft (10.1 m) extension and any
load does not exceed 49,200 lb (22,318 kg) and rear counterweight, the boom shall be over the front or
axle load does not exceed 60,000 lb (27,216 kg). rear.
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b. GVW should never exceed 109,200 lb (49,532 kg). b. With the 56 ft (17.1 m) extension and 16,500 lb
Also refer to certification label on inside of cab door (7484 kg) counterweight only, the boom shall be
for Gross Axle Weight Ratio (GAWR). over the front or rear.
2. Ensure all boom sections are fully retracted or set to c. With the 56 ft (17.1 m) extension and less than
whatever extension is necessary for balance load on the
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16,500 lb (7484 kg) counterweight, the boom shall

axles. be over the front only.
3. Ensure the boom is fully lowered into the boom rest. 7. Swing lock and pin shall be engaged.
4. Engage the swing brake. 8. Hookblock must be removed from main boom nose.
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5. Engage the swing lock. 9. Headache ball may be reeved over boom extension,
hanging 3 ft (0.9 m) below sheave.
6. Ensure the swingaway, if so equipped, is properly
stowed and secured. 10. Suspension air bags shall be inflated.
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7. Remove the hookblock and/or headache ball from the 11. The tires shall be properly inflated.
hoist cable(s) and stow securely before traveling or
ensure headache ball is properly secured to the tie down 33 ft (10.1 m)/56 ft (17.1 m) Extension Plus 20 ft (6.1 m)
provided for that purpose. Insert
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8. Ensure the outrigger jack cylinders and outrigger beams Travel is permissible under the following conditions.
are fully retracted and the floats are removed. 1. The 33 ft (10.1 m) or 56 ft (17.1 m) boom extension plus
9. Ensure the center front jack cylinder is fully retracted. 20 ft (6.1 m) insert shall be erected at minimum offset. If
Float remains installed. traveling with just the 33 ft (10.1 m) extension and insert,
the stinger section must be stowed on the boom base
10. Ensure the jack cylinder floats are properly stowed in section, not on the extension base section.
their holding racks.
2. Jobsite travel only on firm, level surface.
11. Ensure the cover doors on the battery box and sling box
are closed. 3. Main boom shall be fully retracted.
12. Close and/or install all superstructure cab windows and 4. Main boom angle: 0 degrees minimum, 20 degrees
door. maximum.
5. Maximum travel speed: 2.5 mph (4 km/h).

a. With the 33 ft (10.1 m) or 56 ft (17.1 m) extension Clutch Operation

plus insert and 16,500 lb (7484 kg) counterweight
only, the boom shall be over the front or rear.
Free Travel
b. With the 33 ft (10.1 m) or 56 ft (17.1 m) extension 1.5 inch
plus insert and less than 16,500 lb (7484 kg) Pedal Travel
counterweight, the boom shall be over the front only.
7. Swing lock and pin shall be engaged.
8. Hookblock must be removed from main boom nose.
9. Headache ball may be reeved over boom extension,
hanging 3 ft (0.9 m) below sheave.
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10. Suspension air bags shall be inflated.
4664
Depress Pedal
11. The tires shall be properly inflated. Last One Inch To Engage
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Clutch Brake
33 ft (10.1 m) Extension Plus 40 ft (12.2 m) Insert FIGURE 3-8
NOTE: Travel with the 56 ft (17.1 m) extension plus 40 ft
(12.2 m) insert is not permissible. Clutch pedal adjustment provides for approximately 1.5 in
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(3.8 cm) for free travel movement of the pedal after the first
Travel is permissible under the following conditions. free travel of 0.5 in (1.27 cm) is passed before engaging the
release bearing fully. It is important that this free travel be
1. The 33 ft (10.1 m) boom extension plus 40 ft (12.2 m)
maintained to avoid possible excessive wear on the bearing
insert shall be erected at minimum offset. The stinger
and/or clutch slippage. Approximately the last one inch of
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section must be stowed on the boom base section, not
downward clutch pedal travel engages the clutch brake
on the extension base section.
which overcomes the tendency of the clutch to rotate at high
2. Jobsite travel only on firm, level surface. speed when the clutch is disengaged. A slight but definite
resistance to clutch pedal downward movement will be felt at
3. Main boom shall be fully retracted.
the last one inch of travel.
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4. Main boom angle: 0 degrees minimum, 20 degrees

The clutch brake is particularly useful for initial gear
maximum.
engagement in the lower gears when going uphill, when the
5. Maximum travel speed: 2.5 mph (4 km/h). road speed drops off more quickly than the engine RPM
requiring rapid shifts. The clutch brake MUST NOT BE
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USED when making a downshift.

a. With the 33 ft (10.1 m) extension plus insert and
Clutch engagement should always be made smoothly while
16,500 lb (7484 kg) counterweight only, the boom
synchronizing accelerator movement necessary to move the
shall be over the front or rear.
crane.
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b. With the 33 ft (10.1 m) extension plus insert and less

than 16,500 lb (7484 kg) counterweight, the boom
shall be over the front only. CAUTION
Never fully depress the clutch pedal before the
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7. Swing lock and pin shall be engaged.

transmission is put in neutral. If the clutch brake is applied
8. Hookblock must be removed from main boom nose. with the transmission still in gear, a reverse load will be
9. Headache ball may be reeved over boom extension, put on the gears making it difficult to get the transmission
hanging 3 ft (0.9 m) below sheave. out of gear. At the same time, it will have the effect of
trying to stop or decelerate the crane with the clutch
10. Suspension air bags shall be inflated. brake, with resultant rapid wear and generation of
11. The tires shall be properly inflated. excessive heat necessitating frequent replacement of the
brake friction discs.
Double clutching is a means of bringing the speed of the

transmission gears into synchronization so the shift can be
made without clash. The engine is used to speed up the
countershaft for a downshift and to slow it down for an

upshift. Double clutching operation is accomplished as On downhill operation, the engine provides most efficient
follows. braking when run at or near top RPM in the operating range
BUT REMEMBER the governor has no control over the
1. Depress the clutch (do not engage clutch brake) and
engine speed when it is being pushed by a heavy crane.
shift into neutral.
When the engine exceeds the rated governed RPM while
2. Release clutch pedal and accelerate the engine (when descending a grade or downshifting at the high end of the
making downshift) or allow engine to slow down (when operating range, engine overspeed can result in serious
upshifting) until engine speed approximately damage. On downhill operation, use the vehicle brakes and
corresponds to road speed of the gear ratio selected. gears in combination to keep crane speed under control and
the engine below rated governed RPM.
3. Depress the clutch pedal (do not engage clutch brake)
and shift into gear. The transmission has 11 forward speeds and three reverse,
consisting of a five speed front section and a three speed
4. Release the clutch pedal. Always use the double
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auxiliary section. The auxiliary section contains low and high
clutching technique.
range ratios, plus three deep reduction gears. The three
NOTE: Never allow your foot to ride the clutch pedal when lowest (LL1, LO, LL2) gear sets are used for road speed
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the clutch is engaged. This causes premature control and are not intended to be used as progressive shifts.
release bearing failure and short clutch facing life. The other four ratios are used twice, once in low (LO) range
and once in high (HI) range.
Shifting Gears
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As with any transmission gearing, shifting depends on
Next to concern for safety, good shifting habits are probably proper synchronization. Adhere to the following:
the most important capability a driver can have. Knowing • Never try to force the gear lever.
how and when to shift can return savings in trip time and
operating expense. • During regular shifts, when moving the gear lever into
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the next gear position for engagement, the lever should
In the early stage of moving the crane, keep the engine be held lightly against the gear to be engaged.
speed down to the actual power requirement but anticipate
the next shift demand and do not cause the engine to labor • If gears are synchronized, engagement will be made
with the next shift. Start the crane in the lowest gear immediately.
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necessary and with the first few shifts, develop only the RPM • If not synchronized, the flat gear teeth will rotate against
needed to get rolling. Then as you upshift, increase crane each other until synchronization is reached.
speed in each gear with a progressive increase in engine
speed. It should seldom be necessary to go to governed • Do not jerk the shift lever into the next gear position or
engine speed in the lower gears except in a peak load try to force gear engagement.
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situation such as starting up a grade.

• If gears are out of synchronization, no amount of force is
The biggest task when climbing a grade generally will be going to make the engagement before synchronization.
maintaining a reasonable rate of speed. When possible,
All shifts are made with one lever and a range control switch
preplan the climb and probable shift requirements according
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which is used only once during an upshift sequence, and

to traffic conditions and grade to be climbed.
only once during a downshift sequence.
When approaching a hill, gradually move the throttle all the
In the following instructions, it is assumed that the driver is
way down if necessary to maintain governed RPM and
familiar with motor trucks and tractors, and that he can
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remain at full throttle as the crane starts up the grade. If there

coordinate the necessary movements of the shift lever and
is sufficient power to maintain satisfactory road speed
clutch pedal to make progressive and selective gear
without engine laboring, remain in that gear for the entire
engagements in either direction, up or down.
grade. Whenever a grade proves too great for the gear that
you are in and the engine begins to labor, ease off the throttle
Crane Transmission
as necessary and allow speed to drop off to the next lower
shift point before downshifting to the next gear. Speed Initial Start-Up
usually drops off quickly while shifting so the shift should be
made rapidly. Additional downshifting should be performed in
the same way, as necessary. By riding each gear down to the CAUTION
next shift point, you will get over your grades in the best Before moving the crane, make sure you understand the
possible time with minimum shifts. shift pattern configuration (see Figure 3-9), or see the
decal in the cab.

1. Ensure the shift lever is in neutral and the parking brake a. When in the last gear position for low range and
is set. ready for the next upshift, pull the range control
switch up to high and move the shift lever, double
2. Start the engine.
clutching, to the next higher gear position. As the
3. Allow air pressure to build up. shift lever passes through neutral, the transmission
will automatically shift from low to high range.
4. Apply the service brakes.
5. Ensure the range control switch is down in the low
position. CAUTION
Never move the shift lever to the low speed gear position
6. If the crane is to be started in deep reduction (LL2 or
after high range preselection, or anytime the transmission
LL1), move the deep reduction switch forward to IN.
is in high range.
7. Depress the clutch pedal to the floor.
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8. Move the shift lever to the desired initial gear.
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9. Release the parking brakes. OFF HIGHWAY RATIOS
10. Slowly release the clutch pedal and depress the foot
throttle pedal.
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Upshifting
These ratios are not

progressively shifted.
CAUTION
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Never move the deep reduction switch or the range
control switch with the shift lever in neutral while the crane
is moving.
1. To make a deep reduction switch shift from LL2 to 1st,

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proceed as follows.
ON HIGHWAY RATIOS
a. Just before making the upshift, move the deep
reduction switch rearward to OUT while maintaining
foot throttle position. These ratios are
progressively shifted.
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b. Immediately release the foot throttle pedal, depress

the clutch pedal once to break torque, release the
pedal to engage the clutch, allow the engine to
decelerate until the shift is complete. Continue Do not change range while
moving in reverse
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driving or upshifting. The transmission shifts from

LL2 to 1st when synchronous is reached.
2. To shift in low range, proceed as follows.
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a. Move the shift lever, double clutching, to the next

desired gear position in low range (1st to 2nd to 3rd FIGURE 3-9
to 4th).
3. To shift from low (4th) to high (5th) range, proceed as
follows.

4. To make a deep reduction switch shift from low range

(1st) to low-low range (LL2), proceed as follows.
Deep Reduction a. Just before making the downshift, move the deep
Switch reduction switch forward to IN while maintaining foot
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
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CAUTION
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Never make a range shift or deep reduction shift while
moving in reverse.
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1. With the transmission in neutral, determine which
Range Control reverse range is to be used. Move the range control
Switch switch up for high reverse or down for low reverse.
FIGURE 3-10 2. Move the shift lever to the reverse position.
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3. To engage deep low reverse, put the range control
4. To shift in high range, proceed as follows.
switch in the down (low) position. Move the deep
a. Move the shift lever, double clutching, to the next reduction switch to the forward (IN) position.
desired gear position in high range (5th to 6th to 7th
4. Carefully release the clutch, making sure deep reverse
to 8th).
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is fully engaged.
Downshifting
Driving Tips
• For a smooth start, always select an initial starting gear
CAUTION that will provide sufficient reduction for the load and
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Never move the deep reduction switch or range control terrain.

switch with the shift lever in neutral while crane is moving. • On later model cranes, progressively shift the road
control ratios.
1. To shift in high range, proceed as follows.
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• Always use normal double clutching procedures when

a. Move the shift lever, double clutching, to the next making lever shifts.
desired gear position in high range (8th to 7th to 6th
to 5th). • Never slam or jerk the shift lever to complete gear
engagement.
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2. To shift from high (5th) to low (4th) range, proceed as

follows. • Never coast with the gear shift lever in the neutral
position.
a. When in the 5th gear position for high range and
ready for the next downshift, push the range control • Never move the deep reduction switch or the range
switch down to low range and move the shift lever, control switch with the gear shift lever in the neutral
double clutching, to the next lower gear position. As position while the vehicle is moving.
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 • Never make a range shift while operating in reverse.
transmission will automatically shift from high range
to low range. • Never downshift at too high of a road speed.
3. To shift in low range, proceed as follows. • When slowing down, the proficient operator can
downshift through all the individual gear speeds to
a. Move the shift lever, double clutching, to the next prolong the life of the brakes.
desired gear position (4th to 3rd to 2nd to 1st).

• 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
Stop immediately if low air pressure warning sounds and
CAUTION 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
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road conditions, do the following: NOTE: If the pressure drops below 2 psi (14 kPa) per
minute with the engine stopped, have the air
system checked for leaks.
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CAUTION • Regularly check the air pressure gauge. System air
Do not engage or disengage differential locks while pressure should never drop below 45 psi (310 kPa). If
wheels are spinning or at speeds over approximately 10 both systems drop below 45 psi (310 kPa), the
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mph (16 km/h). automatic spring brakes will actuate. Normal operating
pressure is 105 to 120 psi (725 to 825 kPa).
1. Stop the crane and position the control lever to the
LOCK position.
2. Proceed over the poor road conditions cautiously.
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WARNING
When adverse conditions have passed, do the following:
Do not use parking brake for stopping crane except in
1. Stop the crane and position the control lever to the case of an emergency, as a severe sudden stop will occur.
UNLOCK position.
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2. Resume driving at a safe speed.

CAUTION
Service/Parking Brakes
Release brakes before moving crane, or drive train
For the most effective braking and maximum life from the damage will result.
brake system components, the following suggestions are
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made. NOTE: Park brake must be set before outrigger controls

can be operated.
• Air brakes have light pedal operation and the driver is
cautioned to use extreme care in application until a good • The parking brakes are controlled by a push-pull knob
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feel is achieved. on the front console. Pull the knob out to apply and push
the knob in to release the parking brake.
• Use the engine as a brake when approaching a stop or
going down a long grade. On a downgrade, use the Engine Braking
same transmission gear as would be needed to go up
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the same grade. NOTE: Do not keep a foot lightly on the clutch pedal or the
throttle pedal. This will cause the engine brake not
• When necessary to use brakes to reduce crane speed
to come on.
on downgrades, use an on-and-off application to
minimize heat and wear. Do not hold a continuous brake By energizing the engine brake, the power producing diesel
application or slide the wheels. 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
compressor. To retard a crane on a downgrade using the
• When driving on slippery pavement or under icy
Engine Brake, the operator selects a gear which will provide
conditions, alternately and smoothly apply and release
a balance between engine speed and road speed, then
the brakes to prevent skidding.
engages the engine brake. If the engine speed exceeds
• Keep the tires properly inflated. Improperly inflated tires maximum rated RPM for a desired speed, a lower gear can
can reduce the efficiency of the brakes. be selected or intermittent use of the service brakes can be
made. This selection of a lower gear will generally allow
• After driving through water, dry the brakes by applying
complete control of the crane by the engine brake leaving the
them lightly while maintaining a slow forward speed with
service brakes in reserve to be used for emergency stops.

With the engine brake turned on, the engine brake will not be 4. Align the support pins with the boom attachment lugs.
energized until the momentum is driving the engine.
5. Connect the control connector (blue) (1, (Figure 3-12))
1. Position the Engine Brake On/Off switch to ON. to the rear of the crane.
2. Position the Engine Brake High/Low switch to either 6. Connect the brake supply (red) connector (2) to the rear
position, depending on the amount of braking desired. of the crane.
3. Let off the throttle to activate the engine braking system 7. Connect the electrical cable (3) to the crane.
and slow the crane.
NOTE: The engine braking system will automatically 3
deactivate when the throttle is depressed.
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CAUTION
Before engaging engine brake on slippery roads, be sure
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crane is maintaining traction.
TRAILING BOOM (OPTIONAL)
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The trailing boom option allows the crane to be driven on
roads or surfaces that normally cannot support the axle
loads by allowing a portion of the boom weight to be carried
on the boom trailer.
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In order to use the trailer the boom lift circuit and swing brake
circuit must be opened to allow the boom to freely move.
After transporting and before using the crane the lift circuit
and swing circuit valves ((Figure 3-14)) must be fully closed
by turning clockwise.
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1 2 FIGURE 3-12
Travel Configuration
8. Turn the handle of the support pin control (1,
1. Swing the boom to over the rear of the crane. (Figure 3-13)) to ENGAGE and verify the support pins
fully engage the boom support lugs.
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For Reference Only

Actual Trailer May be Different
FIGURE 3-11
For Reference Only
2. Align the trailer to the boom supports on the bottom of Actual Control May be Different
the boom ((Figure 3-11)). FIGURE 3-13
3. Lower the boom onto the trailer supports. 9. Open the lift cylinder pressure release valve by turning
counterclockwise (1, (Figure 3-14)).

10. Open the swing brake release valve (2) by turning

counterclockwise. 2 1
11. Open and close valves FC1 and FC2 as shown in

(Figure 3-15),
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FIGURE 3-14
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2
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6144
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6144-1 FIGURE 3-15

Stowing and Parking
Item Description
1 Needle Valve FC1
2 Needle Valve FC2 DANGER
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.
When parking the crane, do the following.

1. Remove the load from the hook. 4. Position all controls to neutral or off.
2. Remove or stow boom extensions if so equipped. 5. Shut down the engine using the proper procedures as
specified by this manual and the engine manual.
3. Fully retract all boom sections.
6. Perform any other specified procedures required at the
4. Lower the boom to normal travel position.
end of the workday, i.e., drain water from the fuel filter -
5. Engage the swing brake, swing lock pin, and 360 degree water separator, refueling, etc.
house lock.
7. Close all windows.
6. Retract all jack cylinders and outrigger beams.
8. Remove the keys from the crane.
7. Turn off CRANE FUNCTION power switch.
9. Lock up the crane. Install vandal guards, if used.
8. Park the crane on a stable surface.
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9. Apply the parking brakes and if necessary, chock
wheels.
CAUTION
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10. Ensure all operating controls are in neutral position. Step 10 does not take the place of the pre-starting checks
11. Shut down engine following proper procedures specified which must be performed just prior to using the crane at
in this manual and the applicable engine manual. the next working day.
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12. Remove the keys. 10. Make a thorough walk around inspection to ensure that
13. Close and lock, if applicable, all windows, covers, and all cylinders that can be retracted are retracted. The only
doors. exceptions are those cylinders which cannot be fully
retracted, i.e., steer cylinders. Also, look for anything
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Crane Shutdown Procedures that could hinder or prevent starting the next day’s work.
The following procedures will extend serviceable life of Unattended Crane

various crane components, reduce vandalism, and accidents
during crane shutdown periods or anytime the crane is left
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unattended.
1. Perform the procedures found under Shutdown DANGER
Procedure in this manual. Tipping Hazard!
Changing weather conditions including but not limited to:
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wind, ice accumulation, precipitation, flooding, lightning,

etc. should be considered when determining the location
DANGER and configuration of a crane when it is to be left
Never park crane near holes, on rocky surfaces, or on soft unattended.
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spots. This may cause crane to overturn, resulting in Failure to comply with these instructions may cause death
injury or death to personnel. or serious injury.
2. Park the crane on a proper surface with the outrigger The configuration in which the crane should be left while
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jack cylinders and beams fully retracted. Do not park in a

unattended shall be determined by a qualified, designated
location where it may become frozen to the ground or
individual familiar with the job site, configuration, conditions,
settle unevenly and overturn.
and limitations.
3. Apply parking brakes and if necessary, chock the
wheels.

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TMS700E OPERATOR MANUAL SET-UP AND INSTALLATION PROCEDURES
SECTION 4
SET-UP AND INSTALLATION PROCEDURES
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Installing Cable on the Hoist . . . . . . . . . . . . . . . . . 4-1 Setting the Folding Swingaway Offset . . . . . . . . . 4-18
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Erecting and Stowing the Bi-Fold Boom
Extension Using the 20 ft (6.1 m) Insert . . . . . . . 4-19
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . 4-7 Erecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
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Installing Wedge and Socket . . . . . . . . . . . . . . . . 4-7
Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Erecting and Stowing the Bi-Fold Boom
Removable Counterweight . . . . . . . . . . . . . . . . . . 4-21
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Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Mounting the Counterweight . . . . . . . . . . . . . . . . 4-21
Erecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Stowing the Counterweight . . . . . . . . . . . . . . . . . 4-21
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GENERAL
2 2
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This section provides procedures for installing the hoist
cable on the hoist drum, cable reeving, and erecting and
stowing the boom extension, and removal and installation of
the counterweight.
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INSTALLING CABLE ON THE HOIST
3
CAUTION
If cable is wound from the storage drum, the reel should
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1
be rotated in the same direction as the hoist.
NOTE: The cable should preferably be straightened before

installation on the hoist drum.
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Install cable on the hoist drum in accordance with the

following procedure:
7312 FIGURE 4-1
1. Position the cable over the boom nose sheave and route
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to the hoist drum.

4. Position the anchor wedge in the drum slot; pull firmly on
2. Position the hoist drum with the cable anchor slot on top. the free end (2) of the cable to secure the wedge.
3. Insert the cable through the slot and position around the NOTE: If the wedge does not seat securely in the slot,
anchor wedge (1) (Figure 4-1). carefully tap (3) the top of the wedge with a mallet.
NOTE: The end of the cable should be even with the
bottom of the slot for the anchor wedge.
7196

SET-UP AND INSTALLATION PROCEDURES TMS700E OPERATOR MANUAL
5. Slowly rotate the drum, ensuring the first layer of cable is In order to quick reeve the hook block without removing the
evenly wound onto the drum. wedge socket on the end of the cable, refer to Figure 4-2.
6. Install the remainder of the cable, as applicable.
CABLE REEVING
NOTE: There are two types of cable (wire rope) available
on this crane; 6 x 37 and 35 x 7 (non-rotating).
The use of swivels is not allowed in conjunction
with non-rotation resistant wire ropes.
Within the limits of the load and range charts and permissible
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line pull, multi-part lines allow the operator to raise a greater
load than can be raised with a single part line. Various cable
reeving (part line) is possible with the boom nose and hook
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block. This reeving should be accomplished by a qualified
rigger using standard rigging procedures (Figure 4-3)
FIGURE 4-2
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UPPER BOOM NOSE

SHEAVES TO HOIST
BOTTOM BOOM NOSE

SHEAVES
3rd SHEAVE OPTIONAL ON TMS750E
STANDARD ON TMS760E
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4th SHEAVE ON TMS760E ONLY
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BALL
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TO HOIST
SINGLE PART LINE
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BALL 0° OFFSET
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6415-1
TO HOIST
TO HOIST
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25° OFFSET 45° OFFSET

6415-2 6415-3
SINGLE PART LINE USING BOOM EXTENSION
FIGURE 4-3

UPPER BOOM NOSE

SHEAVES
TO MAIN HOIST
TO AUX HOIST
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BOTTOM BOOM NOSE
SHEAVES
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AUX. NOSE
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BOOM NOSE
DEAD END
TO MAIN HOIST
UPPER BOOM NOSE

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SHEAVES
BALL
HOOKBLOCK
SHEAVES
FOUR PARTS LINE
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TO AUX HOIST
BOTTOM BOOM
NOSE SHEAVES
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AUX. NOSE
BOOM NOSE
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DEAD END
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BALL
HOOKBLOCK
SHEAVES
SIX PARTS LINE
3 SHEAVE HOOKBLOCK

UPPER BOOM NOSE

SHEAVES
TO MAIN HOIST
TO AUX HOIST
BOTTOM BOOM
NOSE SHEAVES
AUX. NOSE
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UPPER BOOM
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NOSE SHEAVES TO MAIN HOIST
BALL BOOM NOSE

DEAD END
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TO AUX HOIST
HOOKBLOCK
SHEAVES
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FOUR PARTS LINE
BOTTOM BOOM
NOSE SHEAVES
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BOOM NOSE
DEAD END
AUX. NOSE
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BALL
SIX PARTS LINE HOOKBLOCK

SHEAVES
TMS750E - 4 SHEAVE HOOKBLOCK

UPPER BOOM
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NOSE SHEAVES
TO MAIN HOIST
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BOTTOM BOOM
NOSE SHEAVES
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BOOM NOSE
DEAD END
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HOOKBLOCK
SHEAVES
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EIGHT PARTS LINE

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TEN PARTS LINE

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TMS760E 5 SHEAVE HOOKBLOCK

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
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.
Since state and local laws may vary, alternate attachment
methods may be necessary depending upon work
conditions. If alternate methods are selected, the user is
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responsible and should proceed in compliance with the
regulations in force. If there are any questions, contact your
local distributor or Manitowoc Crane Care. FIGURE 4-4
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Do not mix components from different manufacturers. The
selection, installation and use of a wedge socket assembly Installing Wedge and Socket
must be in accordance with the requirements of the wedge 1. Inspect the wedge and socket. Remove any rough
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socket manufacturer and the wire rope manufacturer upon edges and burrs.
whose wire rope the wedge socket assembly will be used.
2. The end of the wire rope should be seized using soft, or
Manitowoc Cranes specifies the size, type, class and line annealed wire or strand. If the end of the rope is welded,
pulls for wire rope, predominately rotation resistant wire the welded end should be cut off. Do not weld on size
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rope, and rigging accessories such as overhaul balls and 6X37 rope. This will allow the distortion of the rope
hook blocks for use with each new crane that it strands, caused by the bend around the wedge, to
manufactures. Other wire ropes and rigging accessories are adjust themselves at the end of the line. Refer to Section
available from various vendors. Different wire rope 1 - Introduction in the Service Manual for wire rope
man uf ac ture rs ha ve differ ing re qu ire men ts fo r t he procedures.
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construction, handling, cutting, seizing, installation,

termination, inspection and replacement of the wire ropes 3. Make sure the live-end (Figure 4-5) of the rope is directly
they produce. Their advice should be sought for each in line with the ears of the socket and the direction of pull
specific type of wire rope a crane user intends to install on a to which the rope will be subjected. If the rope is loaded
mobile crane. into the socket incorrectly, under a load the rope will
bend as it leaves the socket, and the edge of the socket
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When assembly is complete, raise the boom to a working will wear into the rope causing damage to the rope and
position with a load suspended to firmly seat the wedge and eventual failure.
rope into the socket before the crane is used operationally. .
Wedge Socket
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CAUTION Live
End Dead
If the socket is not positioned with the flat face toward the Dead Live End is
End
boom sections, structural damage will occur. End Entering
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Wrong Side
When anchoring the socket to the boom (Figure 4-4), ensure

the flat face of the socket is in position, as shown, toward the
boom sections.
20 x Cable Dia
Minimum
RIGHT WRONG
FIGURE 4-5
4. Insert the end of the wire rope into the socket, form a
loop in the rope, and route the rope back through the

socket allowing the dead-end (Figure 4-5) to protrude should bear against the short extra piece. Torque the U-bolts
from the socket. Ensure the dead-end of the rope is of according to the table titled Wire Rope Clip Torque Values
sufficient length to apply end treatment to the dead-end (Table 4-1).
after the 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 s ling s. I t stat es , in s ec tion 5 -1 .7 .3, “ (c) Swag ge d,
live-end. compressed, or wedge socket fittings shall be applied as
recommended by the rope, crane or fitting manufacturer.”
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.
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ROPES, it states, in pertinent part, “(a) The ropes shall be of
7. The wire rope and wedge must be properly secured a c onst ruction rec ommende d by the ro pe or crane
inside the socket before placing the crane into lifting manufacturer, or person qualified for that service.” Additional
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service. It is the wedge that secures the wire rope inside information is published by the Wire Rope Technical Board in
the socket. The dead-end treatment is used to restrain the Wire Rope Users Manual, latest revised edition.
the wedge from becoming dislodged from the socket
should the rope suddenly become unloaded due to the Table 4-1
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headache ball or hook block striking the ground, etc. Wire Rope Clip Torque Values
Sketches A through F (Figure 4-6) illustrate various ANSI Clip Sizes Torque
approved methods for treating the dead-ends of wire ropes Inches mm lb-ft Nm
which exit a wedge socket assembly. While use of the loop- 1/8 3.18 4.5 6
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back method is acceptable, care must be exercised to avoid 3/16 4.76 7.5 10
the loop becoming entangled with tree branches and other 1/4 6.35 15 20
components during crane transport and with the anti-two 5/16 7.94 30 40
block system and other components during use of the crane. 3/8 13.28 45 60
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Of the methods shown below, Manitowoc prefers that 7/16 11.11 65 90

method A or F be used, i.e., clipping a short piece of wire 1/2 12.70 65 90
rope to the dead-end or using a commercially available 9/16 14.29 95 130
specialty wedge. Typically, it is recommended that the tail 5/8 15.88 95 130
length of the dead-end should be a minimum of 6 rope 3/4 19.05 130 175
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diameters but not less than 6 in (15.2 cm) for standard 6 to 8 7/8 22.23 225 300
strand ropes and 20 rope diameters but not less than 6 in
1 25.40 225 300
(15.2 cm) for rotation resistant wire ropes.
1-1/8 28.58 225 300
When using method A, place a wire rope clip around the 1-1/4 31.75 360 490
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dead end by clamping a short extra piece of rope to the rope 1-3/8 38.68 360 490
dead end. DO NOT CLAMP THE LIVE END. The U-bolt 1-1/2 38.10 360 490
should bear against the dead end. The saddle of the clip
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Specialty Clip
Specialty Wedge
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Wedge Socket
FIGURE 4-6
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6. Pull down on the handle to disengage the spring loaded

boom stop block. Place the end of the handle in the
ERECTING AND STOWING THE BI-FOLD retainer plate. Fully retract the boom.
BOOM EXTENSION NOTE: When the boom retracts, the handle will be
released allowing the stop block to engage when
the boom is extended.
DANGER
Before attempting to erect or stow the boom extension
(Figure 4-8), read and strictly adhere to all danger decals
installed on the boom/boom nose, boom extension, and
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stowage brackets.
Lifting over the bi-fold extension base section is strictly
prohibited, when the fly extension is either erected or
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folded along side of extension base section.
Erecting
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1. Fully extend and set the outriggers.
FIGURE 4-7
2. Position the boom over the rear.
3. If extended, fully retract all the boom sections and lower 7. Remove the retainer clips from the attachment pins
stowed in the base of the boom extension and insert the
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the boom to minimum elevation to permit ease of
installation of pins and access to the boom nose. attachment pins through the attachment and anchor
fittings on the right side of the boom nose. Install the
NOTE: The auxiliary boom nose (rooster sheave) does not retainer clips in the attachment pins.
have to be removed. However, if reeved, the hoist
cable must be removed from the sheave.
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4. Rig either the main hoist or optional auxiliary hoist cable CAUTION
for single part line with nothing but the wedge socket on If the boom extension fly section (stinger) is not to be
the end of the cable. erected, it should remain on the stowage brackets on the
side of the boom.
5. Extend the boom enough to disengage the spring
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loaded boom stop block (Figure 4-7).

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1 Detail D
Fly Rear Stowage Bracket
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3
Detail B
Stinger Front Stowage Bracket
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Detail A
Front Stowage Bracket
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5
13
8
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2
6
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Detail C
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Detail E
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12
10
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6056
FIGURE 4-8
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1 Base to Fly Attachment Pins 8 Mast Assembly
2 Boom Extension Base Section Boom Nose to Boom Extension Attachment
9
Anchor Fittings
3 Boom Extension Section
10 Boom Nose to Boom Extension Attachment Pins
4 Fly Rear Stowage Bracket
11 Offset Links
5 Stinger Section Front Stowage Bracket
12 Offset Pivot Point
6 Front Stowage Bracket
13 Stinger Sheave
7 Swingaway Base Sheave

14
15
16 15
17
Item Description
14 Boom Extension Base Section
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15 Adjusting Bolt
16 Upper Hanger
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17 Main Hanger
18 Lower Support
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19 Lock Hitch Pin
18
19
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DETAIL A
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22
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21
20 22
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Item Description
20 Boom Extension Fly Section
21 Adjusting Bolt
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22 Adjusting Bolts
23 Front Mount 23
24 Hangar
24
DETAIL B
6058

25
26
Item Description
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27 Shock Wear Pad and Shim
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28 Ramp Wear Pad and Shim
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27 28
DETAIL C
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34
30
34
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31
Item Description 32
29 Boom Extension Base Section 4
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31 Fly Attachment Pin and Hitch Pin
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32 Adjusting Bolts
33 Pin Stowage Lug
29 33
34 Upper Support
35 Lower Mount Ramp
36 Wear Pad
36 35
DETAIL D

40
38
Item Description
43
38 Boom Extension Fly Section 39
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39 Fly Sheave 40
40 Cable Retainer Pins
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41 Latch Hook
42 Spring
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43 Latch Bar
37 41
42
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DETAIL E
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Item Description
44 Boom Nose Upper Sheaves
45 Mast Assembly 44
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46 Offset Links
47 Offset Pivot Points
48 Offset Link Pins Stowage Lugs 45
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49 Mast Assembly Pin

50 Boom Nose Lower Sheaves
53
51 Boom Extension Attachment Pins
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Boom Extension Attachment Pins

52
Stowage Lugs
53 Offset Link Pins
54 Zero Degree Offset Holes
51
54
51
52
50
46 48 NOTE: Offset shown at 25 degrees. To

47 obtain 45 degree offset, remove pin
FIGURE 4-8 continued 49
(item 53) and stow in lug.

WORKING POSITION
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57 59, 60
58
55 56
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Item Description
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55 Pusher Bar
56 Collar Clamp
59, 60
57 Adjustment Bar 58
58 Push Bar Assembly 57

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59 Hitch Pin 56
55 6053
60 Clip Pin
STOWED POSITION
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NOTE: If erecting the boom extension fly section with the 11. At fly section sheave end (see detail E) push in on the
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boom extension base section, skip to step 12. If not spring loaded latch hook to release latch, allowing the
erecting the boom extension fly section, perform base to separate from the fly.
steps 8 to 11 and skip step 12.
12. Remove the pin attaching the fly extension section to the
8. Remove retainer clip from base to fly attachment pin and boom base section rear storage bracket (see detail D).
remove attachment pin from base section to fly section Ensure that the latch hook at the fly section sheave end
attachment fittings. (see detail E) is latched.
9. Stow the pin in the opposite attach fitting or the stowage 13. Remove the lock hitch pin securing the extension base
lug. to the front stowage bracket (see detail A). Stow lock
hitch pin in lug provided.
10. Ensure the pin attaching the fly section to the boom base
section rear stowage bracket (see detail D) is in place. 14. Attach a length of rope to the extension base section tip
to aid in the extension of the swingaway into place
ahead of the boom nose.

21. Remove the hitch pin and clip pin securing the boom
extension alignment device in the working position.
CAUTION Push the push bar assembly back to the stowed position
If the fly section remains on the extension base, do not and secure it in place with the hitch pin and clip pin.
extend the extension assembly too far as the nose of the
extension fly section could contact the front stowage
bracket and cause damage.
DANGER
15. Raise the boom to horizontal and extend the boom just Do not attempt to erect the fly section unless it was
enough to clear the extension stowage lugs from the attached to the boom extension base section during the
guide ramps and stowage pins on the front and rear initial erection procedure.
stowage brackets.
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16. Remove the hitch pin and clip pin securing the boom 22. Erect the boom extension fly section as follows:
extension alignment device in the stowed position. Pull a. Attach a length of rope to the tip of the extension fly
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the push bar assembly out to the working position and section to aid in swinging the fly into place ahead of
secure it in place with the hitch pin and clip pin. the base section. Ensure that the right base to fly
extension attachment pin is in place.
b. Position the boom to horizontal.
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DANGER c. At the fly section sheave end (see detail E), push in
When erecting the boom extension, ensure that all on the spring loaded latch hook to release the latch
personnel and equipment are kept clear of the swing path. allowing fly to separate from the base.
The boom extension may swing around causing death or
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serious injury.
17. Slightly raise and/or lower the boom to help control the DANGER
extension. Using the rope attached to the tip of the When erecting the extension fly section, ensure that all
extension, swing the extension into place ahead of the
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personnel and equipment are kept clear of the swing path.

boom nose, engaging the anchor fittings with the
attachment fittings on the left side of the boom nose. d. Slightly raise and/or lower the boom to help control
the extension fly. Using the rope attached to the tip
of the fly section, swing the fly into place ahead of
the extension base, engaging the anchor fittings
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DANGER with the attachment fittings on the left side of the

Do not modify the attach points to permit the installation of base section.
the attach pins. Modified equipment may not assemble
e. Install the attachment pin into the anchor and
properly and allow the extension to fall, causing death or
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attachment fittings on the left side of the base

serious injury.
section.
18. Install the attachment pin into the upper anchor and f. Lower the boom and remove the rope from the tip of
attachment fitting on the left side of the boom nose. the extension.
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Install retainer clip in attachment pin.

NOTE: Refer to Setting the Folding Swingaway Offset,
NOTE: If the boom extension alignment device does not page 4-18 to obtain a 25 or 45 degree offset with
properly align the anchor and attachment fittings to the swingaway.
allow installation of the last attachment pin, refer to
23. Remove the cable retainer pins and clip pins from the tip
the Service Manual and adjust the boom extension
of the extension base section or extension fly section.
alignment device.
NOTE: For zero (0) degree offset, leave the mast
19. Fully retract the boom until the bottom extension anchor
assembly in the stowed position.
fitting is against the boom extension alignment device
and install the attachment pin in the lower anchor and 24. Remove the mast assembly clip pin and pin from the
attachment fittings on the left side of the boom nose. stowed position on the extension and raise the mast
Install the retainer clip in the attachment pin. assembly to an upright position. Install the pin and clip
pin. Remove the cable retainer pin and clip pin from the
20. Lower the boom and remove the rope from the tip of the
mast.
extension base section.

NOTE: The hoist cable is not routed over the base on the base section. Ensure the latch hook is
extension sheave when using the fly extension. properly engaged.
25. Route the hoist cable over the mast sheave, the rollers f. Lower the boom and remove the rope from the fly
on the adapter, the roller on the fly extension, and the section.
sheave on the extension tip. Install the cable retainer
6. Remove the pin and clip pin securing the boom
pins and clip pins.
extension alignment device in the stowed position. Pull
NOTE: Do not reeve hoist cable through sheaves on the the alignment device out to the working position and
main boom nose. secure it in place with the pin and clip pin.
26. Rig the hoist cable. 7. Lower the boom to minimum elevation.
Stowing 8. Attach a length of rope to the base extension tip.
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9. Raise the boom to horizontal.
NOTE: The boom extension must be set at the zero (0)
degree offset. Refer to Setting the Folding 10. Remove the retainer clips and attach pins from the
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Swingaway Offset, page 4-18. anchor and attachment fittings on the left side of the
boom nose and stow them in the base of the base
If so equipped, the folding fly section must be
extension.
stowed on the side of the base section.
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11. Extend the boom enough so that the extension base and
1. Fully retract the boom and swing it over the rear.
fly stowage lugs will line up in front of the guide ramps
2. Lower the boom to minimum elevation. and pins on the stowage brackets when the swingaway
is positioned to the side of the boom.
3. Remove the cable retainer pins and clip pins from the
swingaway tip and mast assembly. Remove the hoist
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cable from the extension sheave and or mast. Install the
cable retainer pins and clip pins.
DANGER
4. Remove the mast assembly pin and clip pin securing the When stowing the extension, ensure that all personnel
mast in the upright position. Lay the mast over to the and equipment are kept clear of the swing path.
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stowed position and install the mast assembly pin and

clip pin. 12. Raise and/or lower the boom to help control the
5. If erected, stow the extension fly section as follows: swingaway and using the rope attached to the tip of the
base extension, swing the base extension to the side of
a. Attach a length of rope to the fly extension tip. the boom.
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b. Raise the boom to horizontal. 13. Elevate the boom to approximately 30° and push in on
c. Remove the retainer clip and attachment pin from the extension to align the stowage lugs on the extension
the anchor and attach fittings on the left side of the with the guide ramps and pins on the stowage brackets
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base section and stow in the base section. and fully retract the boom. (An increased boom angle
will help the extension to slide into place for storage.)
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DANGER
When stowing the extension fly, ensure that all personnel DANGER
and equipment are kept clear of the swing path. During disengagement of the stop block, extend the boom
only enough to free the block. Extending the boom too far
d. Slightly raise and/or lower the boom to help control will cause the base extension to slide off the guide ramps
the extension fly. Using the rope attached to the tip and allow the extension to swing.
of the fly section, swing the fly to the side of the base
section. 14. Lower the boom and extend the boom only enough to
disengage the spring loaded boom stop block.
e. Elevate the boom and push in on the fly section to
engage the spring loaded latch hook (see detail E) 15. Pull down on the handle to disengage the spring loaded
boom extension stop block (Figure 4-9). Place the end
of the handle in the retainer plate. Fully retract the boom.

25. Extend the boom enough to engage the boom stop

block.
26. Rig the boom nose and hoist cable as desired and
operate the crane using normal operating procedures.
Setting the Folding Swingaway Offset
DANGER
Ensure any blocking material used is adequate to support
the weight of the extension assembly without tipping or
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falling.
FIGURE 4-9
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NOTE: When the boom retracts, the handle will be 1. Extend and set the outriggers and swing the boom to
released allowing the stop block to engage when over the rear. Position the boom to above horizontal.
the boom is extended. 2. Block up under the tip of the extension assembly
section.
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16. Ensure that all the stowage lugs on the base and fly are
fully engaged with the pins on the stowage brackets. 3. To set the offset from a lesser degree to higher degree
17. Insert lock hitch pin. Install the pin securing the perform the following procedures.
extension base to the front stowage bracket (see detail
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A). Ensure the lock hitch pin is pushed all the way in.
CAUTION
18. Install the pin attaching the fly section to the boom base Do not overload the extension anchor fittings or the
section stowage bracket (see detail D). extension base section when lowering the boom.
NOTE: If the extension fly section remained on the boom
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stowage brackets, perform steps 19 thru 22. a. Slowly lower the boom until the pressure is relieved
on the offset link pins.
19. Remove retainer clip and attachment pin from the
bushing on base section. b. Remove the offset link clip pins and attach pins
securing the offset links in the lesser degree offset
20. Insert the attachment pin into the base section to fly position. If going to maximum offset stow them in
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section attachment fittings and install the retainer pin. the stowage lugs. If going to the intermediate (25
21. Ensure the spring loaded latch hook is engaged on fly degree) offset install them in the offset links for that
section sheave end (see detail E). degree of offset.
c. Slowly elevate and telescope the boom at the same
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22. Ensure the pin attaching the fly section to the boom base
section stowage bracket (see detail D) is in place. time so that the extension does not move off of the
blocking until the offset links take the full weight of
23. Remove the retainer clips and attachment pins from the the extension.
anchor and attach fittings on the right side of the boom
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nose and stow them in the base of the swingaway. d. Reeve the hoist cable as described under normal
erecting procedures.
24. Remove the clip pin and pin securing the boom
extension alignment device. Place the boom extension 4. To set the offset from higher degree to lesser degree,
push bar assembly in the stowed position and secure it perform the following procedures.
in place with the pin and clip pin.
CAUTION
Do not overload the extension anchor fittings or the
DANGER extension base section when lowering the boom.
Failure to maintain the proper clearance between the
a. Slowly lower the boom until the pressure is relieved
base extension anchor fittings and the boom nose attach
from the offset links.
fittings could cause these fittings to contact each other
during operation of the boom. b. Remove the offset link clip pins and attachment pins
and lower the boom until the holes for the lesser

degree offset position align in the offset links. Install 10. With the hoist cable still attached to the Insert, lift the
the offset pins and clip pins. assembled unit and move the blocking, erected in step
5, to approximately 8 to 10 ft (2.4 to 3.0 m) ahead of the
c. Slowly elevate and telescope the boom at the same
boom nose attach end of the Insert.
time so that the extension does not move off of the
blocking until the offset links take the full weight of NOTE: Repeat steps 6 through 16 in a similar manner to
the extension. install the second insert if applicable.
d. Reeve the hoist cable as described under normal 11. Lower the bi-fold and insert assembly onto the blocks
erecting procedures. and detach the hoist cable.
12. Retract the boom and lower to minimum elevation.
ERECTING AND STOWING THE BI-FOLD
BOOM EXTENSION USING THE 20 FT (6.1 M) 13. Rig the hoist cable for single part line with nothing but
the wedge socket on the end of the cable.
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INSERT
14. Extend the boom and mate the attachment lugs on the
Insert with the anchor fittings on the boom nose. It may
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be necessary to raise or lower the boom slightly to mate
the attach lugs.
DANGER
Before attempting to erect or stow the bi-fold extension NOTE: If the insert attach lug holes are not in lateral
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with insert (see Figure 4-10), read and strictly adhere to all alignment with the holes in the boom nose anchor
danger decals installed on the boom/boom nose, boom fittings to install the pins, adjust the upper and
extension, insert, and stowage brackets. lower cross strut adjustment screws on the insert to
align the holes.
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Erecting 15. Remove the retainer clips from the four attachment pins
1. Fully extend and set the outriggers. stowed on the insert and install them in the attachment
and anchor fittings on both sides of the boom nose.
2. Position the boom over the rear. Install the retainer clips.
3. If extended, fully retract all the boom sections and lower
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the boom to minimum elevation to permit ease of

installation of pins and access to the boom nose.
CAUTION
Do not attempt to swing the boom extension around to the
NOTE: The auxiliary boom nose (rooster sheave) does not right side of the insert. This could result in damage to the
have to be removed. However, if reeved, the hoist insert.
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cable must be removed from the sheave.

4. Attach the swingaway to the boom nose using steps 5 16. Slowly elevate the boom and remove the blocking from
thru 21 of Erecting and Stowing the Bi-Fold Boom under the insert and bi-fold extension.
Extension, page 4-10. 17. Refer to steps 22 thru 26 of Erecting, page 4-10 to erect
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5. Extend the boom as necessary to permit sufficient the fly section, to set the offset, and rig the hoist cable.
clearance for installation of the 20 ft (6.1 m) extension
insert; then lower it until the tip of the bi-fold extension
Stowing
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assembly is laying on the ground. Block up under the bi- NOTE: If so equipped, the folding fly section must be
fold extension, approximately 8 to 10 ft (2.4 to 3.0 m) stowed on the side of the base section.
ahead of the boom nose.
1. If the fly section is erected, refer to steps 1 thru 5 of
6. Remove the four retainer clips and attachment pins that Stowing the Bi-Fold Boom Extension.
secure the bi-fold extension to the boom nose.
2. Extend the boom approximately 4 to 5 ft (1.22 to 1.52
7. Retract the boom leaving the bi-fold extension on the m). Lower the boom until the sheave is on the ground.
blocking.
3. Block up under the insert approximately 8 to 10 ft (2.4 to
8. Using the main or auxiliary hoist cable, lift the Insert by 3 m) forward of the boom nose.
the lifting lugs and position it at the base end of the bi-
fold extension. 4. Remove the retainer clips from the four pins in the
attachment and anchor fittings and remove the
9. Mate the Insert to the bi-fold extension and install the attachment pins. Stow the pins in the holders on the
four attaching pins and retainer clips removed in step 6. insert.

1
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2
4
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4
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6
7
8
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6055
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7
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FIGURE 4-10

1 Boom Nose Upper Sheaves 6 Bi-Fold Extension Attachment Pins
2 Cable Roller Bi-Fold Extension Attachment Pins Stowage
7
Lugs
3 Insert Attachment Pins
8 Bi-Fold Extension Assembly
4 Insert Attachment Pins Stowage Lugs
9 Mast Assembly
5 6.2 m (20 foot) Insert

5. Retract the boom disengaging the anchor fittings on the

boom nose from the attaching lugs on the insert.
6. Attach a hook to the hoist cable.
7. Attach the hoist cable hook to the lifting lugs on the
insert. Lift the assembly and reposition the blocking
approximately 8 to 10 ft (2.4 to 3 m) forward of the insert
to swingaway attachment points.
8. While supporting the insert with the hoist cable, remove
the retainer clips from the four pins attaching the insert to 2
3 1
the swingaway. Remove the four pins. FIGURE 4-11
9. Remove the insert and position it to one side of the
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5. Push in, turn, and remove the long attach pins from the
crane.
counterweight and carrier frame lugs.
10. Position the boom and extend it to engage the boom
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6. Using the control panel switches, raise the
nose with the swingaway. Install the four attachment
counterweight up under the superstructure frame.
pins and retainer clips removed in step 8.
NOTE: It may be necessary to jog the counterweight
11. Stow the swingaway on the side of the main boom using
control switches to install the upper attach pins.
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steps 6 thru 26 of Stowing the Swingaway Boom
Extension. 7. Remove the upper attach pins from the stowage
bushings and install them into the upper counterweight
REMOVABLE COUNTERWEIGHT and superstructure frame lugs.
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8. Push in on the pins and turn to lock each pin in the
notch.
9. Insert the long pins into the bottom of the counterweight.
DANGER Push in on the pins and turn to lock each pin in the
Ensure that all mounting pins are properly installed and notch.
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locked, during, and after operating the counterweight

removal system. 10. The crane is now ready for operation with the
counterweight installed.
NOTE: The removable counterweight consists of one
standard box and a maximum of two slabs, each
Stowing the Counterweight
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weighing 5500 lb (24 95 k g ) . T he f ol l ow i ng 1. Position the crane on a firm level surface. Fully extend
procedures are applicable for removal and and set the outriggers.
installation of any or all pieces (Figure 4-12).
2. Rotate the superstructure to align the counterweight with
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Mounting the Counterweight the stowage area. Engaging the pin type turntable lock
will aid alignment.
1. Position the crane on a firm level surface. Fully extend
and set the outriggers. NOTE: It may be necessary to jog the counterweight
control switches to remove the weight of the
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2. Rotate and align the rear of the superstructure above the counterweight from the upper attach pins.
removable counterweight stowed on the carrier deck.
Engaging the pin type turntable lock will aid alignment. 3. Using the counterweight cylinders control panel
switches, raise the counterweight cylinders to relieve
3. On the counterweight cylinders control panel weight on the upper attach pins. Push in, turn, and
(Figure 4-11), open the power switch cover (1) and remove the upper attach pins from the superstructure
toggle the switch to the on position. frame lugs and the counterweight.
4. Using the counterweight cylinders control panel, lower 4. Stow the upper attach pins in the bushings on the side of
the counterweight cylinders by pushing down on the left the superstructure.
side cylinder switch (2) and right side cylinder switch (3).
Pin the cylinders to the counterweight using the attach 5. Push in, turn, and remove the long pins from the bottom
pins in the cylinders. Insert the retaining pins in the of the counterweight.
attach pins.

6. Using the counterweight cylinders control panel 8. Remove the attach pins from the counterweight lugs and
switches, slowly lower the counterweight onto the carrier cylinder ends. Raise the cylinders and stow the attach
stowage area. pins in cylinder and insert retainer clip pins.
7. Insert the long pins through the carrier lugs and 9. The carrier is now ready for highway travel with the
counterweight. Push in and turn to lock pin in the notch. counterweight stowed.
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FIGURE 4-12


1 Counterweight Cylinders Control Panel 5 Box Attach Pin
2 Removal Cylinder 6 5500 lb (2495 kg) Slabs
3 Slab Attach Pin 7 5500 lb (2495 kg) Standard Box
4 Cylinder Attach Pin 8 Jack Screws
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TMS700E OPERATOR MANUAL LUBRICATION
SECTION 5
LUBRICATION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Environmental Protection . . . . . . . . . . . . . . . . . . . 5-1 Hydraulic Lubrication . . . . . . . . . . . . . . . . . . . . . . 5-10
Arctic Conditions Below -9°C (15°F) . . . . . . . . . . . 5-1 Superstructure Lubrication . . . . . . . . . . . . . . . . . 5-11
All Weather Package & Lubricants . . . . . . . . . . . . 5-1 Boom, Boom Extension, and Boom Accessories
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Arctic Conditions Down to -40°C (-40°F) . . . . . . . 5-1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Standard Lubricants Package . . . . . . . . . . . . . . . . 5-3 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . 5-14
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Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
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GENERAL Handle and dispose of waste according to local, state, and
federal environmental regulations.
Following the designated lubrication procedures is important
in ensuring maximum crane lifetime and utilization. The When filling and draining crane components, observe the
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procedures and lubrication charts in this section include following:
information on the types of lubricants used, the location of • Do not pour waste fluids onto the ground, down any
the lubrication points, the frequency of lubrication, and other drain, or into any source of water.
information.
• Always drain waste fluids into leak proof containers that
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The service intervals specified are for normal operation are clearly marked with what they contain.
where moderate temperature, humidity, and atmospheric
conditions prevail. In areas of extreme conditions, the • Always fill or add fluids with a funnel or a filling pump.
service periods and lubrication specifications should be • Immediately clean up any spills.
altered to meet existing conditions. For information on
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extreme condition lubrication, contact your local distributor or

ARCTIC CONDITIONS BELOW -9°C (15°F)
In general, petroleum based fluids developed especially for
CAUTION low temperature service may be used with satisfactory
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Chassis grease lubricants must not be applied with air results. However, certain fluids, such as halogenated
pressure devices as this lubricant is used on sealed hydrocarbons, nitro hydrocarbons, and phosphate ester
fittings. hydraulic fluids, might not be compatible with hydraulic
system seals and wear bands.If you are in doubt about the
The multipurpose grease installed during manufacture is
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suitability of a specific fluid, check with your authorized

of a lithium base. Use of a noncompatible grease could
distributor or Manitowoc Crane Care.
result in damage to equipment.
ENVIRONMENTAL PROTECTION
Regardless of temperature and oil viscosity, always use
suitable start-up procedures to ensure adequate lubrication 5
during system warm-up.
Dispose of waste properly! Improperly disposing of waste
can threaten the environment. ALL WEATHER PACKAGE & LUBRICANTS
Potentially harmful waste used in Manitowoc cranes includes
— but is not limited to — oil, fuel, grease, coolant, air Arctic Conditions Down to -40°C (-40°F)
conditioning refrigerant, filters, batteries, and cloths which Engineering recommends the following lubricants for
have come into contact with these environmentally harmful components that will be operated in ambient temperatures to
substances. -40°F. Special lubricants alone are not sufficient to operate at
extreme low temperatures. We also recommend the use of
appropriately sized heaters for the hydraulic tank, engine oil

LUBRICATION TMS700E OPERATOR MANUAL
pan, engine water jacket and batteries. The operator needs • Petro-Canada Duratran Synthetic THF
to follow the guide lines as stated in this Operator's Manual.
• Chevron All Weather THF
We assume that the customer has taken steps for use of an
appropriate engine antifreeze coolant, taken care of the fuel, • Texaco TDH Oil SS
fuel system and starting system, and has done whatever
Hoist - Spec 6829103636:
they feel necessary to add insulation for under hood
temperatures and meet the engine manufacture's intake air • Petro-Canada ENDURATEX Synthetic EP 150
temperature requirements. Other lubricants may be used if
they meet the specifications of the lubricant that is • Mobil SHC629
requested. Please consult the factory. Grease - Spec 6829104275:
Axles and Swing Box - Spec 6829014058: • Petro-Canada Precision Synthetic EP1
• Petro-Canada Traxon E Synthetic 75W-90 • Mobil: Mobilith SHC 220
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• CITGO, Synthetic Gear Lube 75W-90 Open Gear Lube (bearing/swingdrive teeth) - No Spec:
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• Eaton, Roadranger EP75W-90 • Vultrex OGL Synthetic All Season
• Mobil, Mobilube SCH 75W-90 Antifreeze Coolant - Spec 6829104212:
• Shell, Spirax S 75W-90 • Petro-Canada AFC 60/40
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• Sunoco Duragear EP75W-90 • Old World Industries, Inc Fleet Charge SCA Pre-
Engine - Pre-2007 ISM and QSM engine burning non-ULSD charged Antifreeze/ Coolant-60/40
fuel- Spec 6829101560: • Fleetguard Compleat EG Antifreeze/Coolant Premix 60/
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• Petro-Canada Duron Synthetic CI-4 5W-40 40
• Mobil Delvac 1 5W-40 Supplemental Coolant Additive (SCA) - Spec 6829012858:
2007 ISM engine, 2010 ISX and QSM engines burning • Fleetguard DCA4
ULSD- Spec 6829104412: • Fleetguard DCA2
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• Citgo Citgard Syndurance Synthetic Engine Oil CJ-4 • Penray Pencool 3000
5W-40
Diesel Exhaust Fluid (DEF)– Spec 80019225:
• Maxtron DEO Synthetic Engine Oil CJ-4 5W-40
• Fleetguard StableGuard™ Urea 32 Premix
Transmission:
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• AdBlue®
• Use Standard Lubricants Package
• TerraCair Ultrapure® DEF
Hydraulic tank - Spec 6829101559:
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STANDARD LUBRICANTS PACKAGE • Chemtool Inc, Lube-A-Boom-Grease
Axle and Swing Box - Spec 6829012964: Open Gear Lube (bearing/swingdrive teeth) - Spec
6829102971:
• Century Unigear Semi-synthetic SAE 80W-90
• Fuchs CEPLATTYN 300 SPRAY
• Texaco Multigear SS 80W-90
Antifreeze Coolant - Spec 6829101130:
• Chevron DELO 80W-90
• AFC - 50/50 Old World Industries, Inc.
Engine - Pre-2007 ISM and QSM engine burning non-ULSD
fuel - Spec 6829003483: • Fleet Charge SCA Pre-charged Antifreeze/Coolant
• Engine Oil Exxon XD-3 CI-4 15W-40 • Caterpillar DEAC Antifreeze/Coolant
• Conoco Fleet Supreme CI-4 15W-40 • Fleetguard Complete EG Antifreeze/Coolant
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2007 ISM, 2010 ISX and QSM engines burning ULSD- Spec Supplemental Coolant Additive (SCA) - Spec 6829012858:
6829104182:
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• Fleetguard DCA4
• Conoco Fleet Supreme EC CJ-4 15W-40 • Fleetguard DCA2
• Mobil Delvac 1300 Super CJ-4 15W-40 • Penray Pencool 3000
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Transmission - Fuller Manual - Spec 6829013433: Diesel Exhaust Fluid (DEF)– Spec 80019225:
• Citgo Synthetic Gear Lubricant CD50 • Fleetguard StableGuard™ Urea 32 Premix
• Eaton Roadranger SAE50 • AdBlue®
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• Mobil Delvac Synthetic Transmission Fluid 50 • TerraCair Ultrapure® DEF
• Shell Spirax GSX SAE 50
LUBRICATION POINTS
• Texaco Syn-Star TL SAE 50
A regular frequency of lubrication must be established for all
• Petro-Canada Traxon E Synthetic CD50
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lubrication points. Normally, this is based on component

• Chevron Delo Transmission Fluid SAE 50 operating time. The most efficient method of keeping track of
lube requirements is to maintain a job log indicating crane
• Conoco/Phillips/Union 76 Triton Synthetic Transoil 50
usage. The log must use the engine hourmeter to ensure
Hydraulic Tank - Spec 6829006444: coverage of lube points that will receive attention based on
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their readings. Other lubrication requirements must be made

• Hyden 052-10W-20
on a time basis, i.e. weekly, monthly, etc.
• Exxon Torque Fluid 56- 10W-20
All oil levels are to be checked with the crane parked on a
• Esso Torque Fluid 56- 10W-20 level surface in transport position, and while the oil is cold,
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unless otherwise specified.

• BP-Eldoran UTH & Trak-Tran 9 - 10W20
On plug type check points, the oil levels are to be at the
• BP- Blend- 7367 -10W20 bottom edge of the check port.
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• Exxon Mobil 424- 10W-30 On all hoists with a check plug in the drum, the fill plug shall
Hoist - Spec 6829100213: be directly on top of the hoist, and the check plug level.
• AGMA No. 4 EP Extreme Pressure Gear Lube All grease fittings are SAE STANDARD unless otherwise
indicated. Grease non-sealed fittings until grease is seen
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• Mobil: Mobilfluid 629 extruding from the fitting. A measure of 1 oz (0.28 kg) of EP-
• Texaco: Meropa 150 MPG equals one pump on a standard 1 lb (0.45 kg) grease
gun.
Grease - Spec 6829003477:
Over lubrication on non-sealed fittings will not harm the
• Citgo Lithoplex MP # 2 fittings or components, but under lubrication will definitely
• Texaco Starplex Moly # 2 lead to a shorter lifetime.
• Phillips 66 Philube M Grease On sealed U-joints, care must be exercised to prevent

rupturing seals. Fill only until expansion of the seals first
• Mobil Mobilgrese XHP 222 Special, # 53055-0 becomes visible.

Unless otherwise indicated, items not equipped with grease Grease fittings that are worn and will not hold the grease
fittings, such as linkages, pins, levers, etc., should be gun, or those that have a stuck check ball, must be replaced.
lubricated with oil once a week. Motor oil, applied sparingly,
Where wear pads are used, cycle the components and
will provide the necessary lubrication and help prevent the
relubricate to ensure complete lubrication of the entire wear
formation of rust. An Anti-Seize compound may be used if
area.
rust has not formed, otherwise the component must be
cleaned first. Table 5-1
Lube Symbol Chart
Symbol Description
AFC Antifreeze/Coolant - 50/50 Blended, Fully Formulated - SAE Grade J1941
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EO Engine Oil - SAE 15W-40, API Service Classification CJ-4. (CI-4 for pre-2007 ISM engines)
EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2.
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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.
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ASC Anti-Seize Compound - Military Specifications MIL-A-907E.
EP-OGL Open Gear Lubricant - Fucs Ceplattyn 300 Spray, NLGI Class 1-2
EPGL-5H Extreme Pressure Gear Lubricant - SAE Grade 80W-140
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DEF Diesel Exhaust Fluid
SCA Supplemental Coolant Additive
Table 5-2
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Lube Description
Lubrication Description Lube Specification

50/50 Fully Formulated Anti-Freeze Coolant 6829101130
Engine Oil SAE 15W40, CJ4 6829104182
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Engine Oil SAE 15W40, CI4 6829003483

Extreme Pressure Multi-Purpose Grease 6829003477
Synthetic Gear Lube 6829013433
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Hydraulic Oil 6829006444

Semi-Synthetic Gear Lube 6829012964
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Anti-Seize Compound 6829003689

Open Gear Lube 6829102971
EPGL Gear Lube 6829006240
Supplemental Coolant Additive 6829012858
Diesel Exhaust Fluid 80019225
Wire Rope See Service Manual
The following describe the lubrication points and gives the corresponds to the index number shown on the Lubrication
lube type, lube interval, lube amount, and application of Chart (refer to Figure 5-1 through 5-3, Table 5-1 and Table 5-
each. Each lubrication point is numbered, and this number 2).

Drain, fill, and replace filter every 80,000 km (50,000 mi)

or 2 years, whichever interval occurs first.
CAUTION
Lube Amount - Capacity - 19 liters (20 quarts)
The following lube intervals are to be used as a guideline
only. Actual lube intervals should be formulated by the
operator to correspond according to conditions such as
CAUTION
continuous duty cycles and/or hazardous environments. Axle fluid levels shall be adjusted to bottom of fill plug
threads. Check with crane on level ground, at its normal
ride height; cold or room temperature oil only.
CARRIER LUBRICATION
1. Engine Crankcase Application - Final fluid levels shall be adjusted to
indicating arrows, dipstick markings, or to bottom of fill
Lube Type - EO - 15W40 plug threads.
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T3 Engine - CI-4, Grove spec. 6829003483
4. Pump Drive
T4 Engine - CJ-4, Grove spec. 6829104182
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Lube Type - SSGL-5
Lube Interval - Check fluid level every 10 hours or daily,
whichever interval occurs first. Drain, fill and replace Lube Interval - Check fluid level every 100 hours or
filter every 400 hours. monthly, whichever interval occurs first. Drain and fill
every 500 hours.
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Lube Amount - Capacity
Lube Amount - Capacity - 2.4 liters (2.5 quarts)
QSM Engine - 38 qt (36 l)
ISX Engine - 47 qt (44 l) Application - Through fill pipe (dipstick pipe) to oil level
mark on dipstick.
Application - Fill to full mark on dipstick.
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5. Pump Drive Shaft
2. Engine Cooling System
a. U-Joints
Lube Type - AFC
Lube Type - EP-MPG
Lube Interval - Check coolant level every 10 hours or
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daily, whichever interval occurs first. Test and refresh Lube Interval - 250 hours
per instructions in Service Manual.
Lube Amount - Until grease extrudes
Lube Amount - Capacity
Application - 2 grease fittings
QSM Engine - 57 qt (54 l)
b. Spline
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ISX Engine - 79 qt (75 l)

Lube Type - EP-MPG
Lube Interval - 500 hours
CAUTION
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Improper filling of the engine coolant system can result in Lube Amount - Until grease extrudes
engine damage.
Application - 1 grease fitting
Lube Type - SCA
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Lube Interval - Change filter and check SCA levels every
Ensure crane is on jacks and wheels are off ground,
500 hours. Check coolant for contamination every 1000
parking brakes are set, transmission is in neutral gear,
hours. Test and refresh per instructions in Service
Manual.
and an assistant is depressing the clutch pedal before
trying to grease the clutch throw-out bearing. Doing so
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3. Transmission allows the transmission input shaft -- shielded by the
transmission’s clutch housing -- to turn and distribute
Lube Type - SGL-5
grease without the other drive shafts turning and posing
Lube Interval - Check fluid level every 500 hours, 6 further hazards to workers. Allowing crane to move could
months, or 9,000 miles, whichever interval occurs first. cause workers death or serious injuries.

6. Clutch Throw-Out Bearing 11. Front Aluminum Wheel Pilots

Lube Type - EP-MPG Lube Type - ASC
Lube Interval - 250 hours Lube Interval - When wheels are removed for service.
Lube Amount - Until grease extrudes Lube Amount - Generously coat the wheel pilot or hub
pads with antiseize compound. Do not apply antiseize
Application - 1 grease fitting, apply with engine running
compound to the face of the wheel of the hub.
for equal distribution of grease
7. Clutch Linkage Application - Brush on. 4 places
Lube Type - EP-MPG 12. Front Axle Hubs

CAUTION
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Lube Amount - Until grease extrudes Axle fluid levels shall be adjusted to bottom of fill plug
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8. Transmission
a. Shift U-Joints/Control Unit Lube Type - SSGL-5
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Lube Type - EP-MPG Lube Interval - Check fluid level every 250 hours and
refill as necessary.
Lube Amount - 0.95 liters (1.0 quart)
Application - Fill to the oil level mark on the housing with
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Application - 3 grease fittings the fill plug and the oil level mark horizontal. 4 places
b. Driveline Slip 13. Front Axle Tie Rod Ends
Lube Type - EP-MPG Lube Type - EP-MPG
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Lube Interval - 500 hours or 10,000 miles, whichever Lube Interval - 1000 hours
interval occurs first
14. Front Axle King Pins
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9. Power Steering Gearbox

Lube Type - EP-MPG
Lube Type - EP-MPG
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Application - 1 grease fitting
15. Front Axle Brake Slack Adjusters
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10. Steering Relay Arms

Lube Type - EP-MPG
Lube Type - EP-MPG
16. Front Axle Brake Camshafts
Lube Type - EP-MPG

17. Rear Aluminum Wheel Pilots

Lube Type - ASC
Lube Interval - When wheels are removed for service.
Lube Amount - Generously coat the wheel pilot or hub
pads with antiseize compound. Do not apply antiseize
compound to the face of the wheel of the hub.
Application - Brush on. 8 places
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4 5 5 1 7 2 23 8
10
8 10 7
23 3 5
30
Far
Side
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22 24 11, 12 13 14 15, 16 11, 12 13 14 15, 16 7 9
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28a
23 19 18 25
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6772-2
8 20, 21
24 17 8
22
17
20, 21
FIGURE 5-1

18. Front Rear Axle Differential
Item Description Lube Type - SSGL-5
1 Engine Crankcase Lube Interval - Check lubricant level every 250 hours
and refill as necessary. Drain, fill, change filter, and
2 Engine Cooling System
clean magnetic drain plug every 80,000 km (50,000 mi)
3 Transmission or 2 years, whichever interval occurs first.
4 Pump Drive Lube Amount - Capacity - 27 liters (57 pints) Normal
5 Pump Drive Shaft U-Joints and Spline makeup - less than 0.23 liter (0.5 pint)
6 Clutch Throw Out Bearing Application - Fill to bottom of fill plug threads.
7 Clutch Linkage
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8 Transmission Shift U-Joints and Control Unit
CAUTION
9 Power Steering Gearbox
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Use of non-semi-synthetic lubricant may damage
10 Steering Relay Arms components and/or invalidate published lubrication
11 Front Aluminum Wheel Pilots intervals.
If the makeup amount is substantially more than 0.23 liter
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12 Front Axle Hubs
(0.5 pint) check for leaks.
13 Front Axle Tie Rod Ends
14 Front Axle King Pins NOTE: Lube level (Figure 5-2) close enough to the hole to
be seen or touched is not sufficient. It must be level
15 Front Axle Brake Slack Adjusters
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with the hole.
16 Front Axle Brake Camshafts When checking lube level, also check and clean
17 Rear Aluminum Wheel Pilot housing breathers.
18 Front Rear Axle Differential
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19 Rear Rear Axle Differential

20 Rear Axle Brake Slack Adjusters
21 Rear Axle Brake Camshafts
22 Outrigger Beams
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23 Jack Cylinder Support Tubes

___ Correct: Lube level at bottom of
24 Jack Cylinder Barrels filler hole.
- - - Incorrect: Lube level below filler
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25 Hydraulic Reservoir
hole.
26 Hydraulic Filter
27 Fuel Filter FIGURE 5-2
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28 Air Cleaner
NOTE: Figure 5-2 pertains to the differentials and the
28a DEF Tank planetary hubs and wheel bearings.
28b DEF Filter 19. Rear Rear Axle Differential 5
29 Coolant Strainer (Superstructure Cab Heater) Lube Type - SSGL-5
30 Fuel Filter
Lube Interval - Check lubricant level every 250 hours
and refill as necessary. Drain, refill, and clean magnetic
CAUTION drain plug every 80,000 km (50,000 mi) or 2 years,
Axle fluid levels shall be adjusted to bottom of fill plug whichever interval occurs first.

HYDRAULIC LUBRICATION
CAUTION NOTE: Environmental and other conditions can
Axle fluid levels shall be adjusted to bottom of fill plug dramatically affect the condition of hydraulic oil and
threads. Check with crane on level ground, at its normal filters. Therefore, specific intervals for servicing/
ride height; cold or room temperature oil only. changing hydraulic oil, filters and hydraulic tank
breathers cannot be set. However, it is imperative
If the makeup amount is substantially more than 0.23 liter for the continued satisfactory performance of
(0.5 pint) check for leaks. Grove cranes that inspections be performed on the
basis of how and where each crane is used. Air
Lube Amount - Capacity - 17.5 liters (37 pints) Normal borne and ingested contaminants can significantly
makeup - less than 0.23 liter (0.5 pint) reduce the life of oil and the condition of hydraulic
Application - Fill to bottom of fill plug threads. oil filters and tank breathers.
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20. Rear Axle Brake Slack Adjusters Under normal operating conditions, it is
recommended that hydraulic oil, filters and
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Lube Type - EP-MPG breathers be inspected and oils sampled at least
Lube Interval - 1000 hours every 3 to 6 months and more frequently for severe
operating conditions. The inspections should be for
Lube Amount - Until grease extrudes air borne and/or ingested particles and water that
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Application - 4 grease fittings deteriorate and contaminate the oil (e.g., oil
appears “milky” or no longer has a transparent
21. Rear Axle Brake Camshafts clear to amber color). The return filter by-pass
Lube Type - EP-MPG indicator should be observed daily to determine if
the contaminants content may be high. If the
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Lube Interval - 1000 hours indicator reaches the red zone or indicates a by-
Lube Amount - Until grease extrudes pass condition, the hydraulic oil must be sampled.
The hydraulic tank breather should also be
Application - 4 grease fittings inspected to assure that it is not restricting air flow
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22. Outrigger Beams into and out of the reservoir.
Lube Type - EP-MPG To inspect hydraulic oil, fill a small glass container
with a sample of reservoir oil and another glass
Lube Interval - 50 hours or 1 week, whichever interval container with fresh oil. Let the samples stand,
occurs first undisturbed, for one to two hours and then
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Lube Amount - Brush on outrigger beams. compare the samples. If the reservoir oil is heavily
contaminated with water the sample will appear
Application - Brush on; 8 places “milky” with only a small layer of transparent oil on
top. If the “milky” appearance was due to air
23. Jack Cylinder Support Tubes
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foaming, it will dissipate and the oil should closely

Lube Type - EP-MPG match the fresh oil. Should you have any
questions, please contact your local distributor or
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Lube Amount - Brush lubrication on ID of jack cylinder

25. Hydraulic Reservoir
support tubes and wear bands before installing jack
cylinders. Lube Type - Standard Hydraulic Oil - Above -9°C (15°F).
Application -Brush on; 5 places The factory fill standard hydraulic oil is Exxon Mobil 424
10W-30. This fluid is acceptable for operating temperatures
24. Jack Cylinder Barrels
above Above -9°C (15°F). For alternate hydraulic oil
Lube Type - EP-MPG products, refer to Manitowoc lube specifications in the
Service Manual.
Lube Interval - 50 hours or 1 week, whichever interval
occurs first Lube Interval - Check fluid level every 10 hours or daily,
using sight gauge on side of tank, with boom retracted
Lube Amount - Fully extend outriggers and brush
and in boom rest and all outrigger cylinders retracted;
lubricant onto cylinder barrels.
drain and refill as necessary. Replace oil every 2000
Application - Brush on; 5 places hours or 2 years, whichever interval occurs first.

NOTE: After 2000 hours or 2 years of service, an oil 30. Turntable Gear and Drive Pinion
sample should be taken and laboratory analyzed. If
Lube Type - EP-OGL
it continues to meet a minimum cleanliness level of
ISO 16/13 (SAE J1165), the service interval can be Lube Interval - 500 hours or 6 months, whichever
increased to 3000 hours or 3 years. interval occurs first
Lube Amount - 507 liters (134 gal.) (tank only), to the Lube Amount - Coat all teeth
FULL mark on sight gauge.
Application - Spray on
Application - Remove the breather; fill through the
31. Turntable Bearing
breather hole on top of tank; reinstall breather. When
tank is drained, clean the magnetic pipe plug. Lube Type - EP-MPG
Replace breather every 500 hours or 6 months, Lube Interval - 500 hours or 6 months, whichever
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whichever interval occurs first. interval occurs first
Check filter every 500 hours or 6 months, whichever Lube Amount - Until grease extrudes the whole
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interval occurs first. circumference of the bearing.
26. Fuel Filter Application - 2 grease fittings at the front of the turntable.
Rotate the turntable 90° and apply grease to fittings.
Drain water trap every 10 hours or daily and change filter
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Continue rotating 90° and grease the fittings until the
when clear cover is full of fuel.
whole bearing is greased.
27. Air Cleaner Filter
31a. Swivel Lock Pin
Replace air cleaner filter element when indicator shows
Lube Type - EP-OGL
red (25” H2O).
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Lube Interval - 500 hours or 6 months, whichever
28. Coolant Strainer (Superstructure Cab Heater)
Close the shutoff valves. Unscrew the hex plug and
Lube Amount - Coat pin
clean the strainer screen after first 100 hours and every
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2000 hours or 12 months thereafter. Application - Spray on

28a.Diesel Exhaust Fluid Reservoir 32. Upper Lift Cylinder Pivot Pin
Lube Type - DEF.
Lube Type - EP-MPG
Lube Interval - As Required.
Lube Amount - 10 gal (38 l). Lube Interval - 500 hours or every 3 months, whichever
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Application - Fill through cap on top of tank. interval occurs first

28b.Diesel Exhaust Fluid Filter Lube Amount - Until grease extrudes
Replace filter every 200,000 miles or 4500 hours of Application - 1 grease fitting
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crane operation.
33. Lower Lift Cylinder Pivot Pin
SUPERSTRUCTURE LUBRICATION Lube Type - EP-MPG
29. Turntable Gear Box Lube Interval - 500 hours or 3 months, whichever
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Lube Type - SSGL-5
NOTE: Remove one valve to equalize the pressure before
checking the swing gearbox oil level. This will keep
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the oil from pushing out.
Lube Interval - Check and fill every 50 hours. Drain and
fill after first 250 hours and every 500 hours or 12
months thereafter, whichever interval occurs first.
Lube Amount -
Gearbox - 1.30 liters (2.75 pints)
Application - Fill until oil level is at top of sight gauge

34. Main Hoist environmental conditions and/or operating

conditions necessitate.
Lube Type - EPGL-5H
Lube Interval - Check and fill every 1000 hours or 12
interval occurs first.
months, whichever interval occurs first. Drain and fill
annually. Lube Amount - Until grease extrudes
Lube Amount - Capacity - 14.7 liters (15.5 quarts) Application - To each grease fitting.
Application - Fill until level with the check plug opening
or in middle of sight glass. Hoist must be at 21°C ±7 BOOM, BOOM EXTENSION, AND BOOM
(70°F ±20), level and idle for 20 minutes. ACCESSORIES LUBRICATION
35. Auxiliary Hoist (Optional) 37. Boom Pivot Shaft
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Lube Type - EPGL-5H Lube Type - EP-MPG
Lube Interval - Check and fill every 1000 hours or 12 Lube Interval - 250 hours or 3 months, whichever
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months, whichever interval occurs first. Drain and fill interval occurs first
annually.
Lube Amount - Capacity - 14.7 liters (15.5 quarts)
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Application - 2 grease fittings, one on each side
Application - Fill until level with the check plug opening
38. Extend Cable Sheaves
or in middle of sight glass. Hoist must be at 21°C ±7
(70°F ±20), level and idle for 20 minutes. Lube Type - EP-MPG
36. Cable Guard Roller and Guide Roller Lube Interval - 250 hours or 3 months, whichever
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Lube Type - EP-MPG
NOTE: Rollers may or may not have bearings that need
lubrication. Those that do will have grease fittings. Application - 1 grease fitting; extend boom for entry
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Lubricate more frequently than interval indicated, if through access holes in fly and outer mid sections.
36 37 35 37 30 34 33
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31a FIGURE 5-3

31 32

42. Boom Section Upper Wear Pads

Item Description Lube Type - EP-MPG
30 Turntable Gear Box Lube Interval - 50 hours or 1 week, whichever interval
31 Turntable Gear and Drive Pinion occurs first
31a Swivel Lock Pin Lube Amount - Until grease extrudes
32 Turntable Bearing Application - 6 grease fittings; with boom in extended

position through access holes.
33 Upper Lift Cylinder Pivot Pin
43. Boom Section Upper and Lower Wear Pads
34 Lower Lift Cylinder Pivot Pin
Lube Type - EP-MPG
35 Main Hoist
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36 Auxiliary Hoist (Optional) Lube Interval - 50 hours or 1 week, whichever occurs
first.
37 Cable Guard Roller and Guide Roller (possible)
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Lube Amount - Thoroughly coat all areas the wear pad
moves on.
39. Retract Cable Sheaves Application - By brush; 6 places; with boom in extended
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Lube Type - EP-MPG position.
Lube Interval - 250 hours or 3 months, whichever 44. Upper Boom Nose Sheave
interval occurs first Lube Type - EP-MPG
Lube Amount - Until grease extrudes Lube Interval - 250 hours or 3 months, whichever occurs
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Application - 2 grease fittings; extend boom for entry first
through access holes in front of inner mid section. Lube Amount - Until grease extrudes
40. Telescope Cylinder Wear Pads Application - 1 grease fitting per sheave (2 total)
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Lube Type - EP-MPG 45. Lower Boom Nose Sheave

Lube Interval - Every boom teardown. Lube Type - EP-MPG
Lube Amount - Thoroughly coat all areas the wear pads Lube Interval - 250 hours or 3 months, whichever occurs
move on. first
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Application - By brush: 2 places. Lube Amount - Until grease extrudes

NOTE: Should boom chatter or rubbing noises in the boom Application - 1 grease fitting per sheave (5 total)
occur, it will be necessary to lubricate the telescope
46. Boom Extension Sheaves
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cylinder wear pads. By adding an extension

adapter to a grease gun the wear pads and wear Lube Type - EP-MPG
areas can be reached through the lubrication
access holes in the side of the boom and through Lube Interval - 250 hours or 3 months, whichever occurs
first
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the access hole in the boom nose between the

sheaves. Extend boom for access to holes as Lube Amount - Until grease extrudes
needed.
41. Inner Mid Side Wear Pads
Application - 1 grease fitting 5
47. Boom Extension Mast Sheave
Lube Type - EP-MPG
Lube Type - EP-MPG
interval occurs first Lube Interval - 500 hours or 6 months, whichever occurs
first
Lube Amount - Thoroughly coat all areas the wear pads
move on. Lube Amount - Until grease extrudes
Application - By brush: 2 places; with boom in extended Application - 1 grease fitting

position through access holes in base section.

48. Auxiliary Boom Nose Sheave 51. Headache Ball Swivel Top
Lube Type - EP-MPG Lube Type - EP-MPG
Lube Interval - 250 hours or 3 months, whichever Lube Interval - 250 hours or 3 months, whichever
interval occurs first interval occurs first
Lube Amount - Until grease extrudes Lube Amount - Until grease extrudes
Application - 1 grease fitting Application - 1 grease fitting
49. Hook Block Swivel Bearing
WIRE ROPE LUBRICATION
Lube Type - EP-MPG
Wire rope is lubricated during manufacturing so that the
Lube Interval - 250 hours or 3 months, whichever strands, and individual wires in strands, may move as the
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interval occurs first rope moves and bends. A wire rope cannot be lubricated
Lube Amount - Until grease extrudes sufficiently during manufacture to last its entire life.
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Therefore, new lubricant must be added periodically
Application - 1 grease fitting throughout the life of a rope to replace factory lubricant which
50. Hook Block Sheaves is used or lost. For more detailed information concerning the
lubrication and inspection of wire rope, refer to WIRE ROPE
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Lube Type - EP-MPG in Section 1- Introduction of the Service Manual.
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Application - 1 grease fitting per sheave
(5 fittings total - 60 ton)
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38 40 42 43 41 39 44 45
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6772-3 52
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48
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6772-4

Item Description
38 Boom Pivot Shaft
39 Extend Cable Sheaves
40 Retract Cable Sheave
41 Telescope Cylinder Wear pads
42 Inner Mid Side Wear Pads
43 Boom Section Upper Rear Wear Pads
44 Boom Section Upper and Lower Wear Pads
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45 Upper Boom Nose Sheave
46 Lower Boom Nose Sheave
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47 Boom Extension Sheaves
48 Boom Extension Mast Sheave
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49 Auxiliary Boom Nose Sheave
50 Hook Block Swivel Bearing
51 Hook Block Sheaves
52 Headache Ball Swivel Top
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TMS700E OPERATOR MANUAL MAINTENANCE CHECKLIST
SECTION 6
MAINTENANCE CHECKLIST
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
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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
nl
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.
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6
MAINTENANCE CHECKLIST TMS700E OPERATOR 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
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Verify Crankcase and Transmission have the
6 D
proper fluid levels
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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.
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10 Gauges and Instruments are functional D
Back-up Alarm operates properly when operating

11 D
machine
12 Swing Brake operates properly D

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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

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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
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20 D
Inspector's Initials
22 0 D
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23 0 D
24 0 D
25 0 D
Inspector's Initials
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TMS700E OPERATOR MANUAL
Alphabetical Index
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
All Weather Package & Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Arctic Conditions Below -9°C (15°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . 5-12
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
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Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
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Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Erecting and Stowing the Bi-Fold Boom Extension Using the 20 ft (6.1 m) Insert. . . . . 4-19
Erecting and Stowing the Bi-Fold Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
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Hydraulic Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Installing Cable on the Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Noise/vibration test results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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Operator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Overload Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Parking and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
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Pile Driving and Extracting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Removable Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Standard Lubricants Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
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Superstructure Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Superstructure Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Temperature Effects on Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
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Trailing Boom (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Transporting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Grove
APL APL-1-1
OPERATOR MANUAL TMS700E
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APL-1-2
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Grove TMS700E

has of providing you with correct parts and service information.

serious injury. Do not operate this crane unless:

The original language of this publication is English.

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

Operator Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Working Area Limiter (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Multiple Crane Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Regen Initiate/Inhibit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

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

Hydraulic Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

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

superstructure facing forward over the front of the

The mobile crane carrier incorporates an all welded steel

speed forward and 3 speed reverse manual transmission.

Grove Published 1-30-2015, Control # 511-01 1-1

1-2 Published 1-30-2015, Control # 511-01

FIGURE 1-1 continued

15 Center Front Jack

Grove Published 1-30-2015, Control # 511-01 1-3

LIST OF SPECIFICATIONS Engine

Output Torque . . . . . . . . . . . 5.54 Nm (49,825 lb-in)

Speeds . . . . . . . . . . . . . . . . . 11 forward - 3 reverse Elevation . . . . . . . . . . . . . . . . . . . -3 to +78 degrees

Low and 6.1 and 12.2 m (40 ft)

1-4 Published 1-30-2015, Control # 511-01

Grove Published 1-30-2015, Control # 511-01 1-5

1-6 Published 1-30-2015, Control # 511-01

Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Electrocution Hazard Devices . . . . . . . . . . . . . . . 2-11 Temperature Effects on Hydraulic Cylinders. . . .2-25

Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Grove Published 1-30-2015, Control # 511-01 2-1

Identifies hazards that could result in minor or moderate Crane Care.

NOTE: Emphasizes operation or maintenance Phone: 888-777-3378 (888-PSR.DEPT)

It is impossible to compile a list of safety precautions OPERATOR INFORMATION

2-2 Published 1-30-2015, Control # 511-01

Do not remove the Load Chart, this Operator Manual, or

dutifully performed. Don’t operate a damaged or poorly

Grove Published 1-30-2015, Control # 511-01 2-3

made to expedite repairs and recalibration.

2-4 Published 1-30-2015, Control # 511-01

Grove Published 1-30-2015, Control # 511-01 2-5

outriggers must also be pinned when operating from the mid-

injury could result from improper crane setup on outriggers.

Do not remove the Load Charts from the crane.

2-6 Published 1-30-2015, Control # 511-01

Table 2-1 Beaufort Wind Scale

Large branches in motion. Whistling heard in overhead wires.

Grove Published 1-30-2015, Control # 511-01 2-7

boom is damaged. planned and coordinated by a designated person. If it is

2-8 Published 1-30-2015, Control # 511-01

• The pile driver and piling shall be suspended from a occurring.

Grove Published 1-30-2015, Control # 511-01 2-9

29 C F R 19 26 , su bpart C C a nd A S M E B 3 0. 5 If operation within 3 m (10 ft) of any power lines cannot be

the vicinity of power lines. injured or killed.

2-10 Published 1-30-2015, Control # 511-01