Rt530e-2 t4f Ccs Om Ctrl583-00

Grove RT530 I
Operator Manual
THIS PAGE BLANK
You must read and understand the Operator's
Manual and the Load Chart before operating your
new crane. You must also view and understand the
supplied safety video. The Operator's Manual
supplied with and considered part of your crane must
be read and completely understood by each person
responsible for assembly, disassembly, operation
and maintenance of the crane.
OPERATOR MANUAL 1
This manual has been prepared for and is considered part of -
RT530E-2
Crane Model Number
This Manual is divided into the following sections: 2

SECTION 1 INTRODUCTION
SECTION 2 SAFETY INFORMATION
SECTION 3 OPERATING CONTROLS AND PROCEDURES
SECTION 4 SET-UP AND INSTALLATION PROCEDURES
SECTION 5 LUBRICATION
SECTION 6 MAINTENANCE CHECKLIST
NOTICE 3
The crane serial number is the only method your distributor or the factory
has of providing you with correct parts and service information.
The crane serial number is identified on the builder’s decal attached to the
operator’s cab. Always furnish crane serial number when ordering
parts or communicating service problems with your distributor or the
factory.
4
! DANGER
An untrained operator subjects himself and others to death or
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.
• 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.
5
• 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
Published 6-10-2015, Control # 583-00 6
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
CALIFORNIA
PROPOSITION 65 WARNING
Battery posts, terminals, and related accessories contain
chemical lead and lead compounds, chemicals known to
the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.
The original language of this publication is English.

RT530E-2 OPERATOR’S MANUAL TABLE OF CONTENTS
See back of this manual for Alphabetical Index
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Noise/Vibration Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Noise Level Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Vibration Level Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 T
Torque Converter/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
O
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 C
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information

Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
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
Working Area Limiter (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Outrigger Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
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
GROVE TOC-1
TABLE OF CONTENTS RT530E-2 OPERATOR’S MANUAL
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Transporting the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Travel Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Work Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Personal Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Parking and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Temperature Effects on Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Model Specific Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Overload Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Superstructure Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
SECTION 3. . . . . . . . . . . . . . . . . . . Operating Controls and Procedures

Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Steering column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Turn Signal Lever and Windshield Wiper/Washer/Headlight /Horn Controls. . . . . . 3-3
Steering Column Tilt Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Park Brake Control Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Headlights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Drive Axle Selector Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hazard Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Increment/Decrement Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Transmission Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cab Overhead Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Skylight Window Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Skylight Wiper and Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Skylight Sunscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cab Circulating Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Right Side Window Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Overhead Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Skylight Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Heater/Air Conditioner Fan Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Air Conditioner Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Crane Function Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
DPF Regeneration Switch (Tier 4 Engines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Diesel Particulate Filter (Tier 4 Engines Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Inhibit Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
TOC-2
RT530E-2 OPERATOR’S MANUAL TABLE OF CONTENTS
Diesel Exhaust Fluid (Tier 4 Engines—2014 and Later Only) . . . . . . . . . . . . . . . . . 3-7

High Exhaust System Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Control Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Boom Lift/Main Hoist Control Lever (Dual Axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Swing/Telescope or Swing/Auxiliary Hoist Control Lever (Dual Axis). . . . . . . . . . . . 3-9
Main Hoist Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Boom Up Bypass Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Lift Function Enable Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Jog Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Outrigger Function Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Differential Lock On/Off Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Rear Steer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Auxiliary Hoist Enable Switch (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
T
Boom Telescope Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Swing Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 O
Seat Slide Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Air Conditioner/Heater Climate Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Seat Frame Slide Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
C
Armrest Adjustment Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Seat Height Adjustment Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Rated Capacity Limiter (RCL) Bypass Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Level Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Deadman Switches (Optional) (Dual Axis Control Levers only) . . . . . . . . . . . . . . . 3-10
Hoist High Speed Toggle Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Horn Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Free Swing Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Cab Door Release Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hoist Rotation Indicators (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Seat Switch (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Pre-Starting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Crane Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
General Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Crane Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Unattended Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Crane Control System (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Crane Control System (CCS) Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Menu Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Turntable Lock Control (Pin Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CCS Main Screen Symbols and Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
CCS Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
CCS Operation Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Menu Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Rated Capacity Limiter (RCL) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Outrigger Operation Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
RCL Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Switch to RCL Home Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Foot Pedal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
360° Swing Lock Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Telescope Control Pedal (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
GROVE TOC-3
TABLE OF CONTENTS RT530E-2 OPERATOR’S MANUAL
Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Foot Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Miscellaneous Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Fuse Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
RCL Emergency Override Switch (Non-CE Certified Cranes). . . . . . . . . . . . . . . . 3-42
RCL Emergency Override Switch and Indicator (CE Certified Cranes). . . . . . . . . 3-42
RCL Internal Light Bar (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Strobe Light or Beacon (Optional) (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Backup Alarm (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Appendix A: Crane Control System (CCS) Symbols and Icons. . . . . . . . . . . . . . . 3-44
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installing Wedge And Socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Dead-end Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Erecting And Stowing The Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Erecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Setting The Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Changing Boom Extension From Telescoping Type To Fixed Type . . . . . . . . . . . 4-14
Setting The Telescoping Extension Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Counterweights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Arctic Conditions Below -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Arctic Conditions Down To -40°C (-40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Surface Protection For Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CraneLUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Steering and Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
SECTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Checklist

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Daily or 10 Hour Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Weekly or 50 Hour Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
TOC-4
RT530E-2 OPERATOR’S MANUAL INTRODUCTION
SECTION 1
INTRODUCTION 1
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Torque Converter/Transmission . . . . . . . . . . . . . . 1-2
Noise/Vibration Test Results . . . . . . . . . . . . . . . . . 1-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Noise Level Test Results . . . . . . . . . . . . . . . . . . . 1-1 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Vibration Level Test Results . . . . . . . . . . . . . . . . . 1-1 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-2 Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Serial Number Location . . . . . . . . . . . . . . . . . . . . . 1-4
GENERAL NOISE/VIBRATION TEST RESULTS

NOTE: Throughout this handbook, reference is made to Noise Level Test Results
left, front, and rear when describing locations.
These reference locations are to be considered as • When equipped with the CE certification package, the
those viewed from the operator’s seat with the guaranteed sound power level at the operator’s station
superstructure facing forward over the front of the with closed cab operation is LWA is 105 dB(A) as
carrier frame. measured by Directive 2000/14/EC and 80 db(A) at the
This Handbook provides important information for the crane operator position as measured by Annex G.1 of
operator of the Model RT530E-2 Series Grove Crane. EN 13000:2010+A1:2014.
The rough terrain crane incorporates an all welded steel Vibration Level Test Results
frame, using planetary drive axles to provide four-wheel
drive. Axle steering is accomplished utilizing hydraulic steer • At the operator’s station with closed cab operation,
cylinders. The engine is mounted at the rear of the crane and vibration levels are less than 0.5 m/s/s for Whole Body
provides motive power through a six speed forward and Vibration exposure and are less than 2.5 m/s/s for Hand
reverse transmission. Hydraulic, double box, sliding beam Arm Vibration exposure when measured according to
outriggers are integral with the frame. 89/392/EEC Community Legislation on Machinery per
standard ISO 2631/1 - Evaluation of Human Exposure to
The carrier frame incorporates an integral fifth wheel, to Work Body Vibration, ISO 5349 - Guidelines for the
which the rear axle is mounted, to provide axle oscillation. Measurement and Assessment of Human Exposure to
Axle oscillation lockout is automatic when the superstructure Hand Transmitted Vibrations, and ISO/DIS 8041 -
rotates from the travel position. Human Response Vibration Measuring Instrumentation.
The superstructure is capable of 360° rotation in either
direction. All crane functions are controlled from the fully-
Customer Support
enclosed cab mounted on the superstructure. The crane is Manitowoc and our Distributor Network want to ensure your
equipped with a four-section cable synchronized full power satisfaction with our products and customer support. Your
boom. Additional reach is obtained by utilizing a swingaway local distributor is the best equipped and most
boom extension. Lifting is provided by a main hoist and an knowledgeable to assist you for parts, service and warranty
optional auxiliary hoist. issues. They have the facilities, parts, factory trained
personnel, and the information to assist you in a timely
manner. We request that you first contact them for
assistance. If you feel you need factory assistance, please
ask the distributor’s service management to coordinate the
contact on your behalf.
GROVE Published 6-10-2015, Control # 583-00 1-1

INTRODUCTION RT530E-2 OPERATOR’S MANUAL
New Owners Gear Ratios

Forward/Reverse
If you are the new owner of a Grove crane, please register it Lo 1st. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.07
with Manitowoc Crane Care so we have the ability to contact Lo 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.64
you if the need arises. Lo 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00
Hi 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.05
Go to: http://www.manitowoccranes.com/MCG_CARE/ Hi 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.86
Includes/EN/changeOfOwnership.cfm and complete the Hi 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80
form.
Engine
LIST OF SPECIFICATIONS Cummins QSB6.7
General Displacement . . . . . . . . . . . . . . . . . 6.7 l (409 cu in)
Firing Order. . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . RT530E-2 Lube Amount . . . . . . . . . . . . . . . . . . 17.5 l (18.5 qt)
Rated Capacity . . . . . . . . . . See Load Chart in cab Coolant System . . . . . . . . . . . . . . . . . 28.5 l (30 qt)
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4
Gross Weight . . . . . . . . . . . . . . . . See Axle Weight Axles
Distribution Table
Total Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . 20.06:1
Dimensions Carrier Ratio . . . . . . . . . . . . . . . . . . . . . . . . . 5.57:1
Wheel End Ratio. . . . . . . . . . . . . . . . . . . . . . 3.60:1
NOTE: Dimensions listed are for a crane with all
components fully retracted in the travel mode with
Brakes
20.5 x 25-24 Earthmover bias ply tires. Type . . . . . . . . .Hydraulic/Split system acting on all
four wheels
Wheelbase . . . . . . . . . . . . . . . . . . . 3.66 m (144 in)
Overall Crane Length . . . . . . . . .12.29 m (483.7 in) Wheels and Tires
Overall Crane Width . . . . . . . . . . . . 2.54 m (100 in)
Overall Crane Height . . . . . . . . . . . 3.24 m (127 in) Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tail-Swing . . . . . . . . . . . . . . . . . . . . 3.66 m (144 in) Torque. . . . . . . . . . . 461 to 488 Nm (340 - 360 lb-ft)
Outrigger Spread Tire Size
Retracted . . . . . . . . . . . . . . . 2.39 m (7 ft 10 in) Standard . . . . . . . . . . . .20.5 x 25-24 ply rating
Mid Extend . . . . . . . . . . . . . . . . . 4.27 m (14 ft) For roading and lifting pressures, refer to the Load
Fully Extended . . . . . . . . . . . . . . 6.10 m (20 ft) Chart Book in the cab.
Capacities Swing Gearbox

Fuel Tank . . . . . . . . . . . . . . . . . . . . . .220 l (58 gal) Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . 36:1
Coolant System. . . . . . . . . . . . . . . . . . . See Engine Output Torque . . . . . . . . . . . . . .755 Nm (6680 in-lb)
Specifications
Engine Lubrication System . . . . . . . . . . See Engine Boom
Specifications
Hydraulic Tank (Reservoir Capacity) Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Total . . . . . . . . . . . . . . . . . . . . . . 442 l (117 gal) Retracted . . . . . . . . . . . . . . . . . . . .8.8 m (29 ft)
at Full Level . . . . . . . . . . . . . . . .396 l (105 gal) Extended . . . . . . . . . . . . . . . . . . .29.0 m (95 ft)
at Low Level. . . . . . . . . . . . . . . . .369 l (97 gal) Power . . . . . . . . . . . . . . . . . . 4 Section, Full Power
Expansion Space . . . . . . . . . . . . . .46 l (12 gal) Elevation . . . . . . . . . . . . . . . . . . . -3 to +76 degrees
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 l (5.5 qt) Extensions
Swing Gearbox . . . . . . . . . . . . . . . . . . . 4 l (4.25 qt) Fixed Offsettable . . . . . . . . . .7.9 meters (26 ft)
Axle Planetary Hubs . . . . . . . . . . . . . . .1.7 l (3.5 pt) Folding* . . . . . . . . 7.9 - 13.7 meters (26 - 45 ft)
Axle Differentials . . . . . . . . . . . . . . . . . . 9.5 l (20 pt) *Extensions are offsettable at 0, 15, or 30
Transmission (includes Torque Converter) degrees.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 l (25 qt)
Swivel Assembly
Torque Converter/Transmission Electrical . . . . . . . . . . . . . . . . . . . . . . . 20 Slip Rings
Stall Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 2.024:1 Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ports
Charge Pump Capacity . . . . . . .70 l/min (14.5 gpm) Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ports
@ 2000 rpm Air Conditioning . . . . . . . . . . . . . . . . . . . . . . 2 ports
1-2 Published 6-10-2015, Control # 583-00

Hydraulic Pumps Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Output - @ 199.9 bar (2,900 psi) w/no load
Pump #1
Section 1. . . . . . . . . . . . . 57.2 l/min (15.1 gpm)
1
NOTE: Pump output is theoretical @ no-load engine Hoists
speed. Drum Dimensions
Diameter . . . . . . . . . . . . . . . 270 mm (10.63 in)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Length (Standard) . . . . . . . . 437 mm (17.20 in)
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Cable
Output - @ 275.8 bar (4,000 psi) w/no load Diameter . . . . . . . . . . . . . . . . . . 16 mm (5/8 in)
Section 1 . . . . . . . . . . . .283.7 l/min (62.4 gpm) Length-Main . . . . . . . . . . . . . . . .138 m (452 ft)
Length-Aux. . . . . . . . . . . . . . . . .138 m (452 ft)
Pump #2 Max. Permissible Line Pull (6x36)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear . . . . . . . . . . . . . . . . . . . . . . . . . .51.7 kN (11,640 lb)
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Max. Single Line Speed . . . .156.7 m/min (514 fpm)
Output - @ 172.4 bar (2,500 psi) w/no load Hoist Motor Displacement
Section 1 . . . . . . . . . . . . .82.8 l/min (21.9 gpm) Low . . . . . . . . 54.0 cm3 (3.3 in3) per revolution
High . . . . . . . 39.3 cm3 (2.4 in3) per revolution
Pump #3
Type . . . . . . . . . . . . . Gear with priority flow divider
FIGURE1-1

SERIAL NUMBER LOCATION
Frame - Left Front
Manual Cover
8544
Inside Cab - Lower Right FIGURE 1-2

3 24
1
15
14
20
1 23
3 25
19 8512
Top View of Crane
19 20
7 6 1 16
8
5
25
9
3 3
12 2
2 10 22 4 11 8513
Left Side View of Crane FIGURE 1-3
Item Description Item Description

1 Cab 14 Boom Extension
2 Outrigger Float 15 Boom Extension Nose
3 Outrigger Jack Cylinder 16 Boom Pivot
4 Steps 17 Hydraulic Tank
5 Counterweight 18 Hydraulic Filter
6 Lift Cylinder 19 Main Hoist
7 Boom 20 Auxiliary Hoist
8 Boom Nose Sheaves 21 Hookblock
9 Auxiliary Boom Nose 22 Fuel Tank
10 Front Axle 23 Windshield Washer Fluid Container
11 Rear Axle 24 Air Cleaner
12 Engine 25 Diesel Exhaust Fluid (DEF) Tank
13 Boom Extension Mast Sheave

13
19 14
20 16 7
15
8
5
24
3
9
3
21
8514
2 10 2
11 4 18
17
Right Side View of Crane
5
12
5
24
2
2
3
3
3
2
3
8515 8516
2 2 4
Rear View of Crane 2 Front View of Crane
FIGURE 1-3 continued

25
8555
Left Side View
24
8521
Rear View

THIS PAGE BLANK

RT530E-2 OPERATOR’S 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
Accidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15
2-15 2
Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Operator Information . . . . . . . . . . . . . . . . . . . . . . . 2-2
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Operator Qualifications . . . . . . . . . . . . . . . . . . . . . 2-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Transporting the Crane. . . . . . . . . . . . . . . . . . . . . 2-17
Rated Capacity Limiter (RCL) Systems
(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Anti-Two-Blocking Device . . . . . . . . . . . . . . . . . . . 2-4 Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Working Area Limiter (If Equipped). . . . . . . . . . . . 2-5 Personal Considerations . . . . . . . . . . . . . . . . . . . 2-19
Crane Stability/Structural Strength. . . . . . . . . . . . 2-5 Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Outrigger Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Parking and Securing . . . . . . . . . . . . . . . . . . . . . . 2-23
Multiple Crane Lifts . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Pile Driving and Extracting . . . . . . . . . . . . . . . . . . 2-9
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . 2-23
Crane Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Crane Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Temperature Effects on Hook Blocks . . . . . . . . . 2-24
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . 2-9 Temperature Effects on Hydraulic Cylinders . . . 2-24
Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . 2-11 Model Specific Information. . . . . . . . . . . . . . . . . . 2-26
Electrocution Hazard Devices. . . . . . . . . . . . . . . 2-11
Overload Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-26
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Special Operating Conditions and Equipment . . 2-12 Superstructure Inspection . . . . . . . . . . . . . . . . . . 2-29
Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . 2-12 Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-31
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 RT530E-2 OPERATOR’S 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.
Remember, failure to follow just one safety precaution could
DANGER cause an accident that results in death or serious injury to
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
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,
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
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:
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
NOTE: Emphasizes operation or maintenance Phone: 888-777-3378 (888-PSR.DEPT)
procedures. Fax: 717-593-5152
E-mail: [email protected]
GENERAL
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.
An untrained operator subjects himself and others to death

or serious injury.
You must not operate this crane unless:
• You have been trained in the safe operation of this
crane.
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.
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
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.
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,
crane level indicator, hoist drum rotation indicator, load Rated Capacity Limiter (RCL) Systems (If
indicator, and wind speed indicator. Equipped)
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.
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.
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
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
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.
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
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 lines (wire rope), rigging, reeving,
person responsible for supervising the lifting operations and other components to become highly stressed and
shall establish procedures, such as assigning an overloaded in which case the wire rope may fail allowing the
additional signal person to furnish equivalent protection. 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 wire 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,
etc. The closer the load is carried to the boom nose the more
important it becomes to simultaneously let out wire rope as
operating the working area limiter system. Become familiar
with all proper operating procedures and with the 2
identification of symbol usage.
the boom is lowered. Keep load handling devices a minimum
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
preventing this condition. An Anti-Two-Block System is
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.
KEEP THE BOOM SHORT. Swinging loads with a long line

can create an unstable condition and possible structural
failure of the boom.
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
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
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
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
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
Beaufort
Scale
Designation km/h (mph) Effects of wind as observed on land 2
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.
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.
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.
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.
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
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
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
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. 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
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
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.
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
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
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.
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 wire 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:
Pile driving and pile extraction using a mobile crane
introduces many variable and unknown factors that must be
• All cable retainer pins and cable guides/retainers shall
be in place.
2
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.
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
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.
• 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
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
• 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
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.
Crane operation is dangerous when close to an energized If the load, wire 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
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
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 wire rope, hoist cable, 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
A suitable barricade should be erected to physically restrain
the crane and all attachments (including the load) from
electricity. Due to their capacity ratings, some links are not
effective for large cranes and/or high voltages/currents.
2
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
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
boom cages and boom guards is limited by their physical
size, insulating characteristics, and operating environment
(e.g. dust, dirt, moisture, etc.). The insulating characteristics
of these devices can be compromised if not kept clean, free
of contamination, and undamaged.
Proximity sensing and warning devices are available in
different types. Some use boom nose (localized) sensors
and others use full boom length sensors. No warning may be
given for components, cables, loads, and other attachments
located outside of the sensing area. Much reliance is placed
upon you, the operator, in selecting and properly setting the
sensitivity of these devices.
Never rely solely on a device to protect you and your fellow
workers from danger.
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
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
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
power source using the crane’s controls which may have PERSONNEL HANDLING
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:
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
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-
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 wire 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
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
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. 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
in the recognized hazards of personnel platform lifts.
And Locomotive Cranes, and ASME B30.23, Personnel
Lifting Systems, are available by mail from the ASME, 22 2
Law Drive, Fairfield, New Jersey, 0700-2900
• The crane is in proper working order.
• 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.
• 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.
• 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.
• 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:
• For wire 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
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.
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.
• 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
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
fluid to cool before disconnecting any hydraulic lines.
Service and Repairs
• Hydraulic fluid can cause permanent eye injury. Wear
appropriate eye protection.
Moving Parts:
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
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
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 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
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 Always make daily inspections of the wire rope, keeping in
function check of all operating controls. mind that all wire rope will eventually deteriorate to a point
where it is no longer usable. Refuse to work with worn or
• Consult with Manitowoc Crane Care to determine if load
damaged wire rope. Wire rope shall be taken out of service
testing is required after a structural repair is performed.
when any of the following conditions exist:
Lubrication • For rotation-resistant running ropes: more than two (2)
broken wires in a length of rope equal to six (6) times the
The crane must be lubricated according to the
rope diameter, or more than four (4) broken wires in a
manufacturer’s recommendations for lubrication points, time
length of rope equal to thirty (30) times the rope
intervals, and types. Lubricate at more frequent intervals
diameter.
when working under severe conditions.
• For running ropes other than rotation resistant: six (6)
Exercise care when servicing the hydraulic system of the
crane, as pressurized hydraulic oil can cause serious injury.
The following precautions must be taken when servicing the
broken wires in one rope lay or three (3) broken wires in
one strand. 2
hydraulic system: • One valley break where the wire fractures between
strands in a running rope is cause for removal.
• Follow the manufacturer’s recommendations when
adding oil to the system. Mixing the wrong fluids could • Abrasion of the rope resulting in a 5% reduction in the
destroy seals, causing component failure. original wire diameter.
• Be certain all lines, components, and fittings are tight • Any kinking, bird caging, crushing, corrosion, or other
before resuming operation. damage resulting in distortion of the rope structure.
Tires • 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
must be removed from service.
WARNING • In standing ropes, more than three (3) breaks in one

rope lay in sections beyond the end connection or more
Possible equipment damage and/or than two (2) broken wires at an end connection.
personal injury!
Driving the crane with a tire and split-rim assembly under • Core deterioration, usually observed as a rapid
inflated at 80% or less of its recommended pressure can reduction in rope diameter, is cause for immediate
cause the wheel and/or tire to fail. Per OSHA Standard removal of the rope.
1910.177(f)(2), when a tire has been driven under inflated The following is a brief outline of the basic information
at 80% or less of its recommended pressure, it must first required to safely use wire rope.
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 ,
disassembled, and inspected before re-inflation. • Wire ropes wear out. The strength of a wire rope begins
to decrease when the rope is put to use and continues to
Inspect the tires for nicks, cuts, embedded material, and decrease with each use. Wire rope will fail if worn-out,
abnormal wear. overloaded, misused, damaged or improperly
maintained.
Ensure all lug nuts are properly torqued.
• The nominal strength, sometimes called catalog
Ensure pneumatic tires are inflated to the proper pressure strength, of a wire rope applies only to a new, unused
(refer to the Load Chart). When inflating tires, use a tire rope.
gauge, clip-on inflator, and extension hose which will permit
standing clear of the tire while inflating. • The nominal strength of a wire rope should be
considered the straight line pull which will actually break
Wire Rope a new unused rope. The nominal strength of a wire rope
should never be used as its working load.
Use only the wire rope specified by Manitowoc as indicated
on the crane’s Load Chart. Substitution of an alternate wire • Each type of fitting attached to a wire rope has a specific
rope may require the use of a different permissible line pull efficiency rating which can reduce the working load of
and, therefore, require different reeving. the wire rope assembly or rope system.
NOTE: Wire rope may be purchased by contacting • Never overload a wire rope. This means never use the
Manitowoc Crane Care. wire rope where the load applied to it is greater than the
working load determined by the rope manufacturer.

• Never “shock load” a wire rope. A sudden application of - Evidence of abuse or contact with another object.
force or load can cause both visible external and internal
- Heat damage.
damage. There is no practical way to estimate the force
applied by shock loading a rope. The sudden release of - Corrosion.
a load can also damage a wire rope.
NOTE: A more detailed wire rope inspection procedure is
• Lubricant is applied to the wires and strands of a wire given in the Service Manual.
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.
information.
When installing a new rope:
• In the U.S.A., regular inspections of the wire rope and
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
determine whether or not a wire rope may continue to be • Never handle the wire rope with bare hands.
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
elongation, have been established by OSHA, ANSI, • Apply back tension to the storage/payoff reel of the new
ASME and similar organizations. See the Service rope to insure tight, even spooling onto the hoist drum.
Manual for inspection procedures. • Operate the new rope - first through several cycles at
When inspecting wire ropes and attachments, keep all light load and then through several cycles at
parts of your body and clothing away from rotating hoist intermediate load to allow the rope to adjust to operating
drums and all rotating sheaves. Never handle the wire conditions.
rope with bare hands. When using a wedge socket:
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.
- Broken wires mean a loss in strength. • Assemble the wedge socket with live end of rope aligned
- Kinks permanently damage a wire rope and must be with the centerline of pin and assure proper length of tail
avoided. (dead end) protrudes beyond the socket.
- Wire ropes are damaged by knots. Wire rope with Sheaves

knots must never be used.
- Environmental factors such as corrosive conditions
and heat can damage a wire rope.
- Lack of lubrication can significantly shorten the
useful life of a wire rope.
- Contact with electrical wires and resulting arcing will
damage a wire rope.
• An inspection should include verification that none of the
specified removal criteria for this usage are met by
checking for such things as:
- Surface wear; nominal and unusual.
- Broken wires; number and location.
Inspect the boom nose and hook block sheaves for proper
- Reduction in diameter. operation, excessive wear, and damage every 50 hours or
- Rope stretch (elongation). weekly. Inoperable, damaged and/or worn sheaves cause
rapid deterioration of wire rope.
- Integrity of end attachments.

Ensure sheaves carrying ropes that can be momentarily • If applicable, maintain battery electrolyte at the proper
unloaded are equipped with close fitting guards or other level. Check the electrolyte with a flashlight.
devices to guide the rope back into the groove when the load
• If applicable to your crane, check battery test indicator
is reapplied. Ensure sheaves in the lower load block are
on maintenance-free batteries.
equipped with close fitting guards that will prevent the ropes
from becoming fouled when the block is lying on the ground • Check battery condition only with proper test equipment.
with loose ropes. Batteries shall not be charged except in an open, well-
ventilated area that is free of flame, smoking, sparks,
To attain maximum wire rope life and minimize hook block
and fire.
rotation, it is recommended that even numbers of parts-of-
line be used in multiple-part reeving whenever possible.
Engine
The use of nylon (polyamide) sheaves, as compared with
Fuel the crane only with the engine turned off. Do not smoke
metallic sheaves, may change the replacement criteria of
rotation-resistant wire rope.
while fueling the crane. Do not store flammable materials on
the crane.
2
NOTE: The use of cast nylon (polyamide) sheaves will
Be familiar with the location and use of the nearest fire
substantially increase the service life of wire rope.
extinguisher.
However, conventional rope retirement criteria
based only upon visible wire breaks may prove Be careful when checking the engine coolant level. The fluid
inadequate in predicting rope failure. The user of may be hot and under pressure. Shut down the engine and
cast nylon sheaves is therefore cautioned that a allow the radiator time to cool before removing the radiator
retirement criteria should be established based cap.
upon the user’s experience and the demands of his
Shut down the engine and disconnect the battery before
application.
performing maintenance. If unable to do so for the task
Batteries required, keep hands clear of the engine fan and other
moving parts while performing maintenance.
Battery electrolyte must not be allowed to contact the skin or
Be careful of hot surfaces and hot fluids when performing
eyes. If this occurs, flush the contacted area with water and
maintenance on or around the engine.
consult a doctor immediately.
Do not use ether to start the engine on cranes equipped with
When checking and maintaining batteries, exercise the
intake manifold grid heaters.
following procedures and precautions:
The engine can enter into a engine exhaust cleaning mode
• Wear safety glasses when servicing batteries.
where the exhaust temperature can be high, ensure the
• If equipped, disconnect battery with the battery exhaust is not pointed at materials that can melt, burn or
disconnect switch before disconnecting the ground explode.
battery cable. For cranes with a Cummins engine using
an engine ECM: TRANSPORTING THE CRANE
a. Ensure that the key switch has been off for 2 Before transporting the crane, check the suitability of the
minutes. proposed route with regard to the crane height, width, length,
b. Turn the battery disconnect switch to the OFF and weight.
position. Check load limits of bridges on the travel route and ensure
c. Remove the ECM power fuse. they are greater than the combined weight of the crane and
transporting vehicle.
d. Remove negative battery cables.
When loading or unloading the crane on a trailer or railroad
• Do not break a live circuit at the battery terminal. car, use a ramp capable of supporting the weight of the
Disconnect the ground battery cable first when removing crane.
a battery and connect it last when installing a battery.
Ensure the crane is adequately secured to the transporting
• Do not short across the battery posts to check charge. vehicle.
Short circuit, spark, or flame could cause battery
explosion. Do not use the dead end lug (1, Figure 2-1) on the boom
nose for tying down the boom during transport. Damage to
the lug and boom can result from usage as a tie down point.

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.
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
with a tilting cab.
Secure the hook block and other items before moving the
crane.
Watch clearances when traveling. Do not take a chance of
1 running into overhead or side obstructions.
When moving in tight quarters, post a signal person to help
guard against collisions or bumping structures.
7116-1A FIGURE 2-1
Before transporting the crane on a road or highway, first Before traveling a crane, check suitability of proposed route
check state and local restrictions and regulations. with regard to crane height, width, and length.
Either the hook block may be reeved over the main boom Never back up without the aid of a signal person to verify the
nose or the headache ball may be reeved over the main area behind the crane is clear of obstructions and/or
boom nose or auxiliary boom nose; the other must be personnel.
removed. If the hook block or headache ball remains reeved On cranes equipped with air-operated brakes, do not attempt
on the boom, it must be secured at the tie down on the carrier to move the crane until brake system air pressure is at
to prevent swinging. operating level.
When using hookblock tie downs, excessive loading can be Check load limit of bridges. Before traveling across bridges,
applied by pulling the cable too tight, particularly when ensure they will carry a load greater than the crane’s weight.
reeved with multiple part lines. When the cable is hooked
into the hookblock tie down, the cable should be merely If it is necessary to take the crane on a road or highway,
“snugged-up” with adequate slack provided at the center line check state and local restrictions and regulations.
of sheave to anchor point. Do not draw cable taut. Care must Keep lights on, use traffic warning flags and signs, and use
be exercised anytime any crane function is being performed front and rear flag vehicles when necessary. Check state and
while the cable is hooked into the hookblock tie down. local restrictions and regulations.
Always drive the crane carefully obeying speed limits and
TRAVEL OPERATION
highway regulations.
Only the crane operator shall occupy the crane when
Stay alert at the wheel.
traveling.
If equipped, ensure that the hoist access platform hand rail
When traveling, the boom should be completely retracted
and step are in the travel configuration.
and lowered to the travel position and the turntable pin swing
lock, if equipped, should be engaged. If equipped with boom Slopes:
rest, lower the boom into the boom rest and engage the
- Pick and carry on level surfaces only.
turntable lock.
- Refer to the Operation Section for more detailed
Strictly adhere to the guidelines and restrictions in the Load
information on traveling on slopes.
Chart for pick and carry operations.
- Driving across a slope is dangerous, as unexpected
RT and Shuttlelift cranes are manufactured with no axle
changes in slope can cause tip over. Ascend or
suspension system. Traveling at high speeds, especially on
descend slopes slowly and with caution.
rough ground, may create a bouncing effect that can result in
loss of control. If bouncing occurs, reduce travel speed. - When operating on a downhill slope, reduce travel
speed and downshift to a low gear to permit
Death or serious injury could result from being crushed by
compression braking by the engine and aid the
revolving tires.
application of the service brakes.

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.
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.
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
keep all unnecessary personnel out of the work area.
2
• Ensure that the crane is properly equipped including
access steps, covers, doors, guards, and controls.
WARNING
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.)
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
Do not make modifications or additions to the crane’s access or retracting the outriggers. Carefully follow the procedures
system that have not been evaluated and approved by in this Operator Manual when extending or retracting the
Manitowoc Crane Care. outriggers. Death or serious injury could result from improper
crane set up on outriggers.
Do not step on surfaces on the crane that are not approved
or suitable for walking and working. All walking and working Be familiar with surface conditions and the presence of
surfaces on the crane should be clean, dry, slip-resistant, overhead obstructions and power lines.
and have adequate supporting capacity. Do not walk on a
surface if slip-resistant material is missing or excessively Working
worn. Operator shall be responsible for all operations under his/her
Do not use the top of the boom as a walkway. direct control. When safety of an operation is in doubt,
operator shall stop the crane’s functions in a controlled
Do not step on the outrigger beams or outrigger pads (floats) manner. Lift operations shall resume only after safety
to enter or exit the crane. concerns have been addressed or the continuation of crane
Use the hoist access platform (if equipped) when working in operations is directed by the lift supervisor.
the hoist area. Know the location and function of all crane controls.
Wear shoes with a highly slip-resistant sole material. Clean Make sure all persons are away from the crane and the
any mud or debris from shoes before entering the crane cab/ Travel Select Lever is in the “N” (Neutral) position with the
operator’s station or climbing onto the crane superstructure. Parking Brake engaged before starting the engine.
Excessive dirt and debris on the hand-holds, access steps,

Sparks from the crane’s electrical system and/or engine

exhaust can cause an explosion. Do not operate this crane
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.
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
visibility restrictions make operation unsafe. Never operate a
crane in thunderstorms or high winds.
Always be aware of your working environment during
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.
Lifting
Use enough parts of line for all lifts and check all lines,
slings, and chains for correct attachment. To obtain
Keep unauthorized personnel clear of the working area maximum lifting capacities, the hook block must be set up
during operation. with enough parts of line. Too few parts of line can result in
failure of the wire rope or hoist. No less than three wraps of
Only the crane operator shall occupy the crane when in wire rope should remain on the hoist drum. When slings, ties,
operation. hooks, etc., are used, make certain they are correctly
You must always be aware of everything around the crane positioned and secured before raising or lowering the loads.
while lifting or traveling. If you are unable to clearly see in the Be sure the rigging is adequate before lifting. Use tag lines
direction of motion, you must post a look out or signal person when possible to position and restrain loads. Personnel
before moving the crane or making a lift. Sound the horn to using tag lines should be on the ground.
warn personnel
Be sure good rigging practices are being used. Refuse to
Operate the crane only from the operator’s seat. Do not use any poorly maintained or damaged equipment. Never
reach in a window or door to operate any controls. wrap the hoist cable around a load.
Operate the crane slowly and cautiously, looking carefully in If using a clam bucket, do not exceed 80% of the crane’s
the direction of movement. capacity.
A good practice is to make a “dry run” without a load before Make certain the boom tip is centered directly over the load
making the first lift. Become familiar with all factors peculiar before lifting.
to the job site.
Ensure that all slings, ties, and hooks are correctly placed
Ensure the wire rope is properly routed on the hook block and secured before raising or lowering the load.
and boom nose and that all rope guards are in place.
Be sure the load is well secured and attached to the hook
with rigging of proper size and in good condition.

Check the hoist brake by raising the load a few inches, If the boom should contact an object, stop immediately and
stopping the hoist and holding the load. Be sure the hoist inspect the boom. Remove the crane from service if the
brake is working correctly before continuing the lift. boom is damaged.
When lowering a load always slow down the load’s descent When lifting a load the boom may deflect causing the load
before stopping the hoist. Do not attempt to change speeds radius to increase—this condition is made worse when the
on multiple-speed hoists while the hoist is in motion. boom is extended. Ensure weight of load is within crane’s
capacity on Load Chart.
Watch the path of the boom and load when swinging. Avoid
lowering or swinging the boom and load into ground Avoid sudden starts and stops when moving the load. The
personnel, equipment, or other objects. inertia and an increased load radius could tip the crane over
or cause it to fail structurally.
Lift one load at a time. Do not lift two or more separately
rigged loads at one time, even if the loads are within the Use tag lines (as appropriate) for positioning and restraining
crane’s rated capacity. loads. Check the load slings before lifting. 2
Never leave the crane with a load suspended. Should it Be sure everyone is clear of the crane and work area before
become necessary to leave the crane, lower the load to the making any lifts.
ground and stop the engine before leaving the operator’s
Never swing over personnel, regardless of whether load is
station.
suspended from or attached to the boom.
Remember, all rigging equipment must be considered as
part of the load. Lifting capacities vary with working areas. If Hand Signals
applicable, permissible working areas are listed in the Load
A single qualified signal person shall be used at all times
Chart. When swinging from one working area to another,
when:
ensure Load Chart capacities are not exceeded. Know your
crane! • Working in the vicinity of power lines.
Stop the hook block from swinging when unhooking a load. • The crane operator cannot clearly see the load at all
times.
Swinging rapidly can cause the load to swing out and
increase the load radius. Swing the load slowly. Swing with • Moving the crane in an area or direction in which the
caution and keep the load lines vertical. operator cannot clearly see the path of travel.
Look before swinging your crane. Even though the original At all times use standardized hand signals - previously
setup may have been checked, situations do change. agreed upon and completely understood by the operator and
signal person.
Never swing or lower the boom into the carrier cab (if
applicable). If communication with the signal person is lost, crane
movement must be stopped until communications are
Never push or pull loads with the crane’s boom; never drag a
restored.
load.
Keep your attention focused on the crane’s operation. If for
Do not subject crane to side loading. A side load can tip the
some reason you must look in another direction, stop all
crane or cause it to fail structurally.
crane movement first.
Obey a signal to stop from anyone.


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
(boom angle, superstructure orientation, boom
extension angle, etc.)
2
DANGER • 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
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
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.
• 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.
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
guards, if used.
! DANGER COLD WEATHER OPERATION

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:
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
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.
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
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
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
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
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,
(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
2
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96
3 3
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in /in / °F) X 12 in/ft
Table 2-3 Boom Drift Chart (Cylinder length change in millimeters)
(1/ °C)
Coef f . = 0.000774 M etri c
STROKE Temperature Change (°C)
(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
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
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
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

MODEL SPECIFIC INFORMATION

The RT530E-2 on rubber load charts have a minimum radius
of 3 m (9.84 ft) with a load. Without a load, a radius of 2.5 m
(8.20 ft) is safe for 360 degrees on rubber. A radius of less
WARNING
than 2.5 m (8.20 ft) must be avoided on rubber because of Overload Hazard!
backward stability considerations. To avoid an accident caused by overload damage to
your crane:
OVERLOAD INSPECTION
• Perform the inspections outlined in this publication
This information supplements the Rated Capacity Limiter for overloads up to 50%.
(RCL) manual supplied with each Grove crane.
• Stop operating the crane and contact Manitowoc
When the RCL system has acknowledged an overload on Crane Care immediately for overloads of 50% and
your crane, you must carry out specified inspections on the higher.
crane.
NOTE: If your crane is equipped with CraneSTAR, an
These inspections apply only to overloads up to 50%. For
overload warning will be posted to the web site for
overloads of 50% or higher, crane operation must be
review by the crane owner.
stopped immediately and Crane Care must be contacted for
corrective action. Overload warnings do NOT indicate real time
events! Warnings could be sent 24 hours (or more)
The following illustrations may not be an exact
after the actual event.
representation of your crane and are to be used for reference
only.

Boom Inspection
1
1
2
9, 10
2
1 8
3, 4
5
1
9, 10

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%
1 Sheaves Inspect all for damage.
Luffing
2 Mechanism/ Inspect for damage/leaks.
Cylinder
Collar-wear
3 Inspect all for damage.
pads
4 Collar-welds Inspect all for cracks.
Telescopic Inspect for bent or twisted sections. Check the boom
5
Sections for straightness.
Lift Cylinder
6 Inspect for bends or cracked welds.
Head Area
Turret-Base
7 Inspect for cracked welds.
Section
Locking Area
8 Inspect for elongated holes.
(Pin Booms)
9 Welds Inspect for cracks.
Inspect for cracked paint which could indicate twisted,
10 Paint
stretched, or compressed members.

Superstructure Inspection
2
3
5 4
1
9, 10
7


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.
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.
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.
Pin
Lift Cylinder-
7 Inspect pin and welds.
lower mount
8 Turntable Inspect for deformation, cracked welds.
10 Paint

Carrier Inspection
1
4
1 2
3
3
2 5, 6
1
3


Stabilizer
1 Inspect for leaking.
Cylinders
Outrigger
2 Inspect for deformation and cracked welds.
Pads
Stabilizer
1 Inspect for leaking.
Cylinders
Outrigger
Pads
Outrigger
Beams
Outrigger
Boxes
6 Paint

RT530E-2 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES
SECTION 3
OPERATING CONTROLS AND PROCEDURES
SECTION CONTENTS
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . 3-2 Swing Enable Switch . . . . . . . . . . . . . . . . . . . . . . 3-10
Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Seat Slide Lever . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Turn Signal Lever and Windshield Wiper/Washer/ Air Conditioner/Heater Climate Unit. . . . . . . . . . . 3-10
Headlight /Horn Controls. . . . . . . . . . . . . . . . . . . . 3-3 Seat Frame Slide Lever . . . . . . . . . . . . . . . . . . . . 3-10
Steering Column Tilt Lever . . . . . . . . . . . . . . . . . . 3-3 Armrest Adjustment Knobs . . . . . . . . . . . . . . . . . 3-10
Park Brake Control Switch . . . . . . . . . . . . . . . . . . 3-3 Seat Height Adjustment Lever . . . . . . . . . . . . . . . 3-10
Headlights Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Rated Capacity Limiter (RCL) Bypass Switch . . . 3-10
Drive Axle Selector Switch . . . . . . . . . . . . . . . . . . 3-3 Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . 3-10
Hazard Lights Switch . . . . . . . . . . . . . . . . . . . . . . 3-3 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Increment/Decrement Switch . . . . . . . . . . . . . . . . 3-3 Deadman Switches (Optional)
Ignition Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 (Dual Axis Control Levers only) . . . . . . . . . . . . . . 3-10
Transmission Shift Lever . . . . . . . . . . . . . . . . . . . 3-4 Hoist High Speed Toggle Switches . . . . . . . . . . . 3-10
Cab Overhead Controls . . . . . . . . . . . . . . . . . . . . . 3-4 Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Skylight Window Latch . . . . . . . . . . . . . . . . . . . . . 3-4 Free Swing Button . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Skylight Wiper and Wiper Motor . . . . . . . . . . . . . .
Skylight Sunscreen . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3-4
Cab Door Release Lever . . . . . . . . . . . . . . . . . . . 3-10
Hoist Rotation Indicators (Not Shown). . . . . . . . . 3-10
3
Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Seat Switch (Not Shown). . . . . . . . . . . . . . . . . . . 3-10
Cab Circulating Fan . . . . . . . . . . . . . . . . . . . . . . . 3-4 Operating Procedures. . . . . . . . . . . . . . . . . . . . . . 3-11
Right Side Window Latch . . . . . . . . . . . . . . . . . . . 3-4 Pre-Starting Checks. . . . . . . . . . . . . . . . . . . . . . . 3-11
Overhead Control Panel . . . . . . . . . . . . . . . . . . . . 3-5 Cold Weather Operation . . . . . . . . . . . . . . . . . . . 3-12
Skylight Wiper Switch . . . . . . . . . . . . . . . . . . . . . . 3-5 Engine Operation. . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Heater/Air Conditioner Fan Speed Switch . . . . . . 3-5 Crane Travel Operation . . . . . . . . . . . . . . . . . . . . 3-13
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . 3-5 General Crane Operation . . . . . . . . . . . . . . . . . . 3-20
Air Conditioner Switch. . . . . . . . . . . . . . . . . . . . . . 3-5 Crane Functions . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . 3-27
Crane Function Power Switch. . . . . . . . . . . . . . . . 3-5 Unattended Crane . . . . . . . . . . . . . . . . . . . . . . . . 3-27
DEF Regeneration Switch (Tier 4 Engines Only) . 3-6 Crane Control System (CCS) . . . . . . . . . . . . . . . . 3-28
Diesel Particulate Filter (Tier 4 Engines Only) . . . 3-6 Crane Control System (CCS) Display . . . . . . . . . 3-28
Inhibit Regeneration (Tier 4 Engines Only). . . . . . 3-7 Menu Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Diesel Exhaust Fluid Turntable Lock Control (Pin Type). . . . . . . . . . . . 3-29
(Tier 4 Engines—2014 and Later Only) . . . . . . . . 3-7 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
High Exhaust System Temperature . . . . . . . . . . . 3-7 CCS Main Screen Symbols and Icons. . . . . . . . . 3-30
Control Seat Assembly . . . . . . . . . . . . . . . . . . . . . 3-8 CCS Menu Screen. . . . . . . . . . . . . . . . . . . . . . . . 3-32
Boom Lift/Main Hoist Control Lever (Dual Axis) . . 3-8 CCS Operation Display . . . . . . . . . . . . . . . . . . . . 3-34
Swing/Telescope or Swing/Auxiliary Hoist Control Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Lever (Dual Axis) . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Rated Capacity Limiter (RCL) System . . . . . . . . . 3-35
Main Hoist Enable Switch . . . . . . . . . . . . . . . . . . . 3-9
Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Boom Up Bypass Switch (Optional) . . . . . . . . . . . 3-9
Outrigger Operation Menu . . . . . . . . . . . . . . . . . . 3-36
Lift Function Enable Switch . . . . . . . . . . . . . . . . . 3-9
RCL Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Jog Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Switch to RCL Home Screen Display . . . . . . . . . 3-40
Outrigger Function Enable Switch . . . . . . . . . . . . 3-9
Foot Pedal Controls . . . . . . . . . . . . . . . . . . . . . . . 3-41
Differential Lock On/Off Switch (Optional) . . . . . . 3-9
360° Swing Lock Pedal . . . . . . . . . . . . . . . . . . . . 3-41
Rear Steer Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . 3-41
Auxiliary Hoist Enable Switch (Optional). . . . . . . . 3-9
Telescope Control Pedal (Optional). . . . . . . . . . . 3-41
Boom Telescope Enable Switch . . . . . . . . . . . . . . 3-9

OPERATING CONTROLS AND PROCEDURES RT530E-2 OPERATOR’S MANUAL
Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . 3-41 RCL Emergency Override Switch and Indicator
Foot Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . 3-41 (CE Certified Cranes). . . . . . . . . . . . . . . . . . . . . . 3-42
Miscellaneous Controls and Indicators . . . . . . . 3-41 RCL Internal Light Bar (Optional). . . . . . . . . . . . . 3-43
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Strobe Light or Beacon (Optional) (Not Shown). . 3-43
Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Backup Alarm (Not Shown) . . . . . . . . . . . . . . . . . 3-43
RCL Emergency Override Switch Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
(Non-CE Certified Cranes) . . . . . . . . . . . . . . . . . 3-42 Appendix A: Crane Control System (CCS) Symbols
and Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
CONTROLS AND INDICATORS Steering column

The engine is electronically controlled by the Electronic The steering column assembly (5) (Figure 3-1) is a pedestal
Control Module (ECM); it is the control center of the entire style tilt and telescoping steering column. It has the ability to
engine system. The ECM processes all of the inputs and tilt rearward 30° or be raised vertically approximately 60 mm
sends commands to the fuel systems as well as vehicle and (2.3 in). It also includes the ignition switch and other control
engine control devices. This Operator Manual does not switches (Figure 3-2).
include information on the engine ECM, however a separate
manual as prepared in detail by the engine manufacturer is
shipped with the crane from the factory.
All the controls and indicators to operate and monitor crane
functions are found inside the crane cab Figure 3-2 and
include the following:
1. Foot Pedals
2. Turntable Swing Pin Lock Control
3. Seat Joystick and Armrest Controls 1 9
4. CCS and RCL Display Panels 3 6 7

4 5
8
5. Steering Column 2
6. Overhead Control Panels
7623
FIGURE 3-2
Figure 3-2 Item Numbers
Item Description
Turn Signal Lever and Windshield Wiper/
6 1
Washer/Horn Controls
5
2 Steering Column Tilt Lever
4
3 Park Brake Control Switch
2
3
4 Headlights Switch
1
5 Drive Axle Selector Switch
6 Hazard Lights Switch
Engine Speed Increment/Decrement
7
Switch (RPM)
7649-5
FIGURE 3-1 8 Ignition Switch
9 Transmission Shift Lever

Turn Signal Lever and Windshield Wiper/ mode. This icon will flash if, while the engine is running, the
Washer/Headlight /Horn Controls switch position is changed when the transmission is not in
Neutral and the brake pedal is not pressed. The drive axle
The Turn Signal Lever and Windshield Wiper/washer can only be changed when the gearshift is in Neutral and the
Controls (1) (Figure 3-2) are located on the left side of the brake pedal is pressed. The switch is illuminated when the
steering column. Pushing the turn signal lever down causes key is in the ON or Start position.
the left front and left rear turn signals to flash. Pushing the
turn signal lever up causes the right front and right rear turn Hazard Lights Switch
signals to flash.
The Hazard Lights Switch (6) (Figure 3-2) is located on the
The windshield wiper switch is incorporated in the turn signal front of the steering column. The switch is a two-position
lever. The knob of the lever has four positions: O, I, II and rocker switch (ON/OFF) that causes the four turn signal
interval wiping. Pushing the button in the end of the knob lights to flash at the same time when the switch is positioned
energizes the windshield washer pump to spray washer fluid to ON. When the switch is positioned to ON, the turn signal
on the windshield. Positioning the knob to I operates the indicator lights on the steering column will flash.
wiper at low speed and positioning the knob to II operates
the wiper at high speed. Positioning the knob to O turns the Increment/Decrement Switch
wiper motor off and automatically returns the wiper to the
The Increment/Decrement Switch (7) (Figure 3-2) is a three
parked position.
position momentary rocker switch with center maintained
Pushing the small button on the end of the lever sounds the position being off. Use this switch to adjust engine speed.
horn. Press the top or bottom of the Increment/Decrement Switch
to increase or decrease the low engine idle.
Steering Column Tilt Lever
The steering control column can be rotated rearward
approximately 30° and raised approximately 60 mm (2.3 in).
The Increment/Decrement Switch is used to adjust engine
rpm. Quickly press the top of the switch once to go to full
engine rpm; quickly press the bottom of the switch once to
3
Rotate the control lever (2) (Figure 3-2) down to lock the return to low engine idle. If the engine speed is below the
steering column in place; rotating the lever up releases the minimum rpm setting, pressing and holding the top of the
steering column for adjustment. switch will cause the engine rpm to slowly increase; release
the switch when the desired rpm is attained. If the engine
Park Brake Control Switch speed is above the maximum rpm setting, pressing and
holding the bottom of the switch will cause the engine rpm to
The Park Brake Control Switch (3) (Figure 3-2) is located on
slowly decrease; release the switch when the desired rpm is
the front of the steering column. This two-position rocker
attained.
switch (ON/OFF) is used to apply and release the parking
brake on the drive line. The red Park Brake Indicator light on
Ignition Switch
the display is illuminated when the pressure switch in the
brake release system is activated and the brake is applied. The Ignition Switch (8) (Figure 3-2) is located on the right
side of the steering column and under the transmission shift
Headlights Switch lever (9).
The Headlights Switch (4) (Figure 3-2) is located on the front The switch is key-operated and has three positions: OFF [0],
of the steering column. This three-position rocker switch RUN [1], and START [2]. In the OFF position, all electrical
(OFF/Park/Headlight) controls operation of the instrument power is off except for the lights controlled by the Headlights
lights, switch LED’s, and the marker lights on the front, rear, Switch, turn/hazard/stop lights, dome light and work light.
and side of the crane. The switch is illuminated when the key Positioning the switch to RUN energizes all electrical
is in the ON or Start position. components except for the start solenoid and engine ECM;
the ignition circuit is also energized. Positioning the switch to
Drive Axle Selector Switch START energizes the start relay, which in turn energizes the
cranking motor solenoid and cranks the engine for starting.
The Drive Axle Selector Switch (5) (Figure 3-2) is located on
The switch is spring returned from START to RUN. To shut
the front of the steering column. This two-position rocker
down the engine, position the switch to OFF.
switch is used to select either two-wheel drive (high range) or
four-wheel drive (low range). The switch controls a solenoid The Ignition switch has a mechanical anti-restart built into it.
valve (energized for two-wheel drive) that operates the If the engine does not start after the first attempt, the key
sp ee d r ang e an d a xle disc on ne ct c ylin de rs on t he switch must go to the OFF position and then back to START
transmission. The icon background on the CCS operating in order to try and start the engine another time.
display turns yellow when the crane is in four-wheel drive

Transmission Shift Lever Skylight Window Latch

The Skylight Window Latch (1) (Figure 3-3) is at the front of
the window. Squeeze the latch and slide the window to the
CAUTION rear to open. To close slide the window forward until the latch
Transmission Damage! engages.
To prevent transmission damage: shift between two-
wheel and four-wheel drive only with the crane stopped Skylight Wiper and Wiper Motor
with the transmission in neutral. The Skylight Wiper (2) (Figure 3-3) is controlled by the
Skylight Wiper Switch, (4) (Figure 3-4), and operated by the
The Transmission Shift Lever (9) (Figure 3-2) is located on Wiper Motor.
the right side of the steering column. The control lever
operates the transmission selector valve electrically. Skylight Sunscreen
Positioning the lever up actuates forward and positioning the
lever down actuates reverse. When the lever is in neutral, it The Skylight Sunscreen (3) (Figure 3-3) is used to diminish
rests in a detent. To move the lever up or down, pull up on direct sunlight. The sunscreen is self retracting and can be
the lever first. To shift the transmission to first, second, or set to screen all the light or adjusted rearward by moving it
third gear, rotate the knob to 1, 2, or 3. into the notches provided.
The transmission has six forward gears and six reverse Dome Light
gears. To use the three low gears, put the Drive Axle switch
to four-wheel drive. To use the three high gears, put the Drive The cab Dome Light (4) (Figure 3-3) is on the right rear
Axle switch to two-wheel drive. corner of the cab overhead console and provides illumination
in the cab. The dome light is controlled by a switch on the
CAB OVERHEAD CONTROLS light.
.
Cab Circulating Fan
3
1 2 The Cab Circulating Fan (5) (Figure 3-3) is located on the left
4
front side of the cab, above the window frame. A swivel
allows the fan to be rotated and a switch on the fan base
controls the fan. The switch has a high, low and off position.
Right Side Window Latch

The window on the right side of the cab can be opened.
Squeeze latch (6) (Figure 3-3) to release and slide forward.
To close, slide the window rearward until the latch engages.
7 6
5
FIGURE 3-3
Item Description
1 Skylight Window Latch
2 Skylight Wiper
3 Skylight Sunscreen
4 Dome Light
5 Cab Circulating Fan
6 Window Latch
7 Overhead Control Panels

Overhead Control Panel Heater Control Switch

The Heater Control Switch (3) (Figure 3-4) controls intensity
of heating temperature. Turn the switch to the right
(clockwise) to open the valve for heat. (Heat comes from
1 2 3 4 5 6 7 heated fluid going through the heater coil.) Turn the switch to
the left (counterclockwise) to close the valve to stop fluid flow
and minimize heat.
Air Conditioner Switch

8446
The Air Conditioning Switch (4) (Figure 3-4) controls the
FIGURE 3-4 operation of the optional air conditioning system. Settings
are off (O) and on (I).
Work Lights Switch
Item Description
The Work Lights Switch (5) (Figure 3-4) controls the crane’s
1 Skylight Wiper Switch work lights mounted on the bottom front of the superstructure
2 Heater/Air Conditioner Fan Speed Switch cab. Press the top of the switch to turn on the work lights.
Press the bottom of the switch to turn off the work lights.
3 Heater Control Switch
4 Air Conditioning Switch Crane Function Power Switch
5 Work Lights Switch The Crane Function Power Switch (7) (Figure 3-4) is located
6 Crane Function Power Switch on the overhead control panel. This spring return switch
permits the operator to activate all crane functions at once or
3
7 DEF Regeneration Switch (Tier 4 engine only) disconnect power from the crane functions controlled by the
remote controllers on the armrests. Pressing it turns ON all
Skylight Wiper Switch crane functions. Pressing a second time turns OFF all crane
functions. Turn off all crane functions to prevent inadvertent
The electrically-operated Skylight Wiper is installed to
operation of functions due to bumping the controllers while
remove moisture from the skylight. The Skylight Wiper is
roading or any other operation.
controlled by the Skylight Wiper Switch (1) (Figure 3-4). This
switch has 6 positions, including the intermittent setting.
Heater/Air Conditioner Fan Speed Switch

T h e H e a t e r / A i r C o n d i t i o n e r F a n Sp e e d S w i t c h ( 2 )
(Figure 3-4) controls the cab fan’s speed. Fan speed controls
the volume of heated air output (or cooled air output) of the
fan. Settings are off, low speed, medium speed, and high
speed.

DEF Regeneration Switch (Tier 4 Engines As a warning, the light (1, Figure 3-5) above the exhaust pipe
Only) (2, Figure 3-5) will blink during regeneration.
Pressing brake or throttle pedal during regeneration or
activating the Inhibit Regen Switch will interrupt the
WARNING regeneration process.
Fire or Burn Hazard! Make sure the crane and surrounding area are monitored
During the regeneration process the exhaust becomes during manual regeneration. If any unsafe condition occurs,
very hot. Do not park the vehicle near flammable objects. shut off the engine immediately.
Use caution near the exhaust tailpipe during regeneration During this period the sound of the engine may change.
as it will become very hot. When regeneration is complete the engine will return to it’s
normal idle speed.
The Engine DPF (Diesel Particulate Filter) Switch (7)
(Figure 3-4) is located on the right side of the overhead Diesel Particulate Filter (Tier 4 Engines
control panel. This switch is a three position switch, Inhibit Only)
Regen/Permit Regen/Start Regen. Press this switch to start
The Diesel Particulate Filter (DPF) Indicator (24) is located in
DPF regeneration or to disable regeneration:
the CCS display (Figure 3-14). This indicator illuminates
amber when the diesel particulate filter is getting filled with
• Start Regeneration (7649-10)
soot and needs to be cleaned out.
When the DPF indicator illuminates or flashes, start the
• Inhibit Regeneration (7649-11)
manual regeneration process at the next opportune time.
The indicator will be lit continuously during the early stages
of clogging. If the system continues to clog, the lamp will
1
begin to flash and slight engine derate will occur.
If even more clogging occurs, the engine warning light (17)
2
will illuminate in addition to the DPF indicator (24) and
severe engine derate will occur.
WARNING
Extreme Heat Hazard!
During the regeneration process the exhaust becomes
very hot. Do not park the vehicle near flammable objects.
Use caution near the exhaust tailpipe during regeneration
as it will become very hot.
The regeneration process can take place in three different

8522 FIGURE 3-5 modes:
To manually regenerate, set the crane parking brake, the Passive: the exhaust is hot enough during normal working
crane transmission must be in neutral and have all pedals operation to burn off any hydrocarbon (soot) accumulation
released. Refer to Diesel Particulate Filter (Tier 4 Engines
Active: Active self-regeneration occurs when there is not
Only), page 6 for a description of when manual regeneration
sufficient heat in the exhaust to convert all the hydrocarbon
is needed.
being collected in the DPF. Exhaust temperatures are raised
Set up a safe area around the crane’s exhaust; remove tools, by injecting a small amount of fuel. The resulting chemical
rags, grease or any debris from the engine exhaust area. reaction raises exhaust gas temperatures high enough to
oxidize the hydrocarbon from the filter. This is all done
With the engine idling push the DPF Regen Switch (9) to
without any operator intervention.
initiate regeneration.
Manual: Manual or stationary, regeneration is the same as
Within 5 seconds the engine should rev up to 1000 to 1400
active regeneration but takes place while the equipment is
rpm. The engine will continue to run at this speed for up to 45
not being operated. It offers the equipment operator the
minutes.
option, if needed, of performing regeneration outside the
normal duty cycle.

Inhibit Regeneration (Tier 4 Engines Only)

The Inhibit Regeneration Indicator (25) is located in the CCS
disp la y (Figu re 3 -1 4). Wh en th e Re ge n Switc h (7) CAUTION
(Figure 3-4) is in the inhibit regeneration position, this amber Engine Damage Hazard!
indicator is illuminated and active and manual regeneration Ultra low sulfur diesel fuel is required in Tier 4 engines.
is prevented.
If “Ultra Low Sulfur” fuel is not used in engines that require
it, the Cummins warranty will be void and the engine
Diesel Exhaust Fluid (Tier 4 Engines—2014
performance will quickly deteriorate and may stop
and Later Only) running.
The Diesel Exhaust Fluid (DEF) Indicator (6) (Figure 3-14) is
located in the CCS display. The indicator has four different High Exhaust System Temperature
stages which will be triggered by the fluid level sensor in the
DEF tank: The High Exhaust System Temperature (HEST) Indicator
(26) (Figure 3-14) is located on the CCS Main Screen
Low Tank - First warning to the operator is that the reducing display.
agent in the tank is low. The DEF Indicator (6) will be lit
continuously. During regeneration it is possible for the engine exhaust to
reach temperatures exceeding 650° C (1200° F). The HEST
Derate - The DEF Indicator (6) will start to flash as a warning indicator will illuminate red to warn the operator of when
to the operator that a derate will be activated if the reducing temperatures reach 675° C (1247° F) and will stay on until
agent in the DEF tank is not refilled. the temperatures falls below 625° C (1157° F).
Low Level Inducement - The DEF Indicator (6) will flash and A warning light near the tailpipe will flash during regeneration
the Engine Warning Indicator (17) will be lit continuously.
Derate will be activated at this stage.
when high exhaust temperatures exist.
3
For more information on the regeneration process, refer to
Severe Inducement - Once the DEF (6) tank is empty, the Diesel Particulate Filter (Tier 4 Engines Only), page 3-6.
crane operation will be restricted. The DEF Indicator (6) will
flash and the Stop Engine Indicator (16) is solid red.

CONTROL SEAT ASSEMBLY
23 4
6
3 5
17
23
17 10
24 11 12
7
22 1
25 26
21 13 2
20 22 9
8
19 18
16
14
8044-2
15 FIGURE 3-6
Figure 3-6 Item Numbers Item Description

Item Description 18 Seat Height Adjustment Lever
1 Boom Lift/Main Hoist Control Lever 19 RCL Bypass Switch
Swing/Telescope or Swing/Auxiliary Hoist 20 Emergency Stop Switch
2
Control Lever
21 Level Indicator
3 Main Hoist Enable Switch
Deadman Switches (Optional) (Dual Axis
22
4 Boom Up Bypass (Optional) Control Levers only)
5 Boom Lift Function Enable Switch 23 Hoist Speed Toggle Switches
6 Jog Dial 24 Horn
7 Outrigger Function Enable Switch 25 Free Swing Button
8 Differential Lock On/Off (Optional) 26 Cab Door Release Lever
9 Rear Steer Switch 27 Hoist Rotation Indicators (Not Shown)
10 Auxiliary Hoist Enable Switch (Optional) 28 Seat Switch (Not Shown)
11 Boom Telescope Enable Switch
Boom Lift/Main Hoist Control Lever (Dual
12 Swing Enable Switch
Axis)
13 Seat Slide Lever
The Boom Lift/Main Hoist Control Lever (1) (Figure 3-6) is
14 AC/Heater Climate Unit located on the right armrest. The controller, when pushed to
15 AC/Heater Vents the right lowers the boom, or pushed left raises the boom.
16 Seat Frame Slide Lever When used for main hoist, the controller, when pushed
forward lowers the cable, or pulled back raises the cable.
17 Armrest Adjustment Button(s) (Underside)

Swing/Telescope or Swing/Auxiliary Hoist Jog Dial

Control Lever (Dual Axis) The Jog Dial Control (6) (Figure 3-6) is located on the right
arm rest. It selects and chooses functions on the screen(s) to
navigate the Crane Control System.
DANGER Outrigger Function Enable Switch

Crushing Hazard! The Outrigger Function Enable Switch (7) (Figure 3-6)
Death or serious injury could result from being crushed by allows the operator to switch between extension/retraction of
moving machinery. the outriggers and raising/lowering of the jacks. Press and
Before actuating swing or any other function, sound horn hold this switch to force the lower screen display to change
and verify that all personnel are clear of rotating and to the outrigger page.
moving parts.
Differential Lock On/Off Switch (Optional)
The Swing/Telescope or Swing/Auxiliary Hoist (Swing/Tele The Differential Lock Switch (8) (Figure 3-6) is located on the
or Swing/Aux) Control Lever (2) (Figure 3-6) is located on left arm rest. It engages the differential lock function for
the end of the left armrest. The lever controls the swing and better traction, when Four Wheel Drive is selected, on poor
telescope functions when the crane is not equipped with an road or highway surfaces. It can be activated for a maximum
auxiliary hoist. When equipped with an auxiliary hoist, the of 30 seconds at a time.
lever controls swing and auxiliary hoist functions and
telescope functions are controlled through a foot pedal. NOTE: The differential lock will only work when the crane
is in the 4WD mode.
If not equipped with an auxiliary hoist, positioning the lever to
the left or right actuates a control valve through hydraulic
pilot pressure to provide 360 degree continuous rotation in
Rear Steer Switch 3
the desired direction. Positioning the lever forward actuates The Rear Steer Control Switch (9) (Figure 3-6) is a three-
the control valve to telescope the boom out and pulling the position, spring centered to off, rocker switch, located on the
lever back actuates the boom to telescope in. left armrest. Press the bottom of the switch to actuate a
control valve to turn the rear wheels to the left, causing the
If equipped with an auxiliary hoist, positioning the lever crane to turn to the right. Pressing the top of the switch
forward actuates the control valve to let out hoist cable and actuates a control valve to turn the rear wheels to the right,
pulling the lever back reels the cable in. Moving the lever in a causing the crane to turn to the left. When the wheels are not
diagonal direction actuates the two functions simultaneously. centered the Wheels Not Centered icon on the CCS
Operating Display illuminates. Releasing the switch causes it
Main Hoist Enable Switch to return to the center off position.
The Main Hoist Enable Switch (3) (Figure 3-6) is a To straighten the rear wheels press the switch until the Rear
momentary switch that is located on the right armrest. Press Wheels Not Centered icon indicator light goes off.
once to enable hoist; press again to disable hoist. Pressing
the switch twice rapidly enables hoist at high speed. Auxiliary Hoist Enable Switch (Optional)
Pressing once and holding the switch for about 2 seconds
also enables high speed. The Auxiliary Hoist Enable Switch (10) (Figure 3-6) is
located on the left arm rest. It enables the Auxiliary Hoist and
Boom Up Bypass Switch (Optional) sets the high speed the same as the Main Hoist Enable
Switch does for the Main Hoist.
The Boom Up Bypass Switch (4) (Figure 3-6) is a momentary
two-position rocker switch that, when installed, is located on Boom Telescope Enable Switch
the right armrest. While lift function is enabled and in a RCL
lockout condition, activating the Boom Up Bypass Switch will The Boom Telescope Enable Switch (11) (Figure 3-6) is
enable boom lift up. located on the left arm rest. It enables the boom telescoping
function for the optional Telescope Control Foot Pedal, or for
Lift Function Enable Switch the Control Lever (joystick) if there is no auxiliary hoist.
The Lift Function Enable switch (5) (Figure 3-6) is a

momentary switch that enables boom up and boom down.

Swing Enable Switch CCS operator display. Rotate the knob and pull out to
resume normal operation.
The Swing Enable Switch (12) (Figure 3-6) is located on the
left arm rest. This two-position rocker switch (On/Off) is used Level Indicator
to control a hydraulic valve that directs a regulated flow of
pressure to and from the swing brake. When the joystick The Level Indicator (21) (Figure 3-6) is located on the right
moves to swing the crane the brake releases. When the side of the cab by the Emergency Stop Switch. The indicator
crane stops swinging the swing brake re-engages. provides the operator with a visual aid in determining the
levelness of the crane.
Seat Slide Lever
Deadman Switches (Optional) (Dual Axis
Moving the Seat Slide Lever (13) (Figure 3-6) will enable Control Levers only)
only the seat to slide, either forward or backward.
The Deadman Switches (22) (Figure 3-6) are located on the
Air Conditioner/Heater Climate Unit front of both control levers. Either of these switches can be
used instead of the seat switch to keep crane functions
The crane cab Air Conditioner/Heater Climate Unit (14)
active.
(Figure 3-6) is located in the cab under the driver’s seat. The
vents (15) are part of the climate unit and can be adjusted to Hoist High Speed Toggle Switches
direct the flow of air.
The Hoist High Speed Toggle Switches (23) (Figure 3-6) are
Seat Frame Slide Lever thumb operated two-position center spring return switches.
Pressing the right side maintains high speed until it is de-
Moving the Seat Frame Slide Lever (16) (Figure 3-6) will
activated; pressing the left is momentary speed increase.
slide both the seat and the armrests either forward or
backward. Horn Button
Armrest Adjustment Knobs The Horn Button (24) (Figure 3-6) is located on the upper
front of the right control lever. The button sounds the horn
The left and right armrest and armrest controls can be
during craning operations.
adjusted using the adjustment buttons (17) (Figure 3-6)
found under the rear of the armrest. Press the button to Free Swing Button
rotate the entire armrest; release button at the desired
position. The Free Swing Button (25) (Figure 3-6) is located on the
upper front of the left control lever. The Free Swing Button
Seat Height Adjustment Lever releases the Swing Brake and allows the boom to be
centered over the load.
To adjust the height of the seat, lift the height adjustment
lever (18) (Figure 3-6) and then adjust the seat as needed. Cab Door Release Lever
Rated Capacity Limiter (RCL) Bypass Switch Use the Cab Door Release Lever (26) (Figure 3-6) to open
and close the cab door from inside the cab.
The RCL Bypass (Override) Switch (19) (Figure 3-6) is a
momentary type switch. Turn the key clockwise to bypass Hoist Rotation Indicators (Not Shown)
the 3rd Wrap Indicator and Anti Two-Block Switch. It will be
bypassed only as long as the switch is held in this position. The Hoist Rotation Indicators (27) (Figure 3-6 Item
Numbers) for the auxiliary and main hoists are located on top
Turn the key counterclockwise to bypass the Anti Two-Block
of each hoist control lever (1, 2) (Figure 3-6). Each indicator
Switch, Telescope extend/retract, 3rd Wrap Indicator (hoist
is electronically driven by an input signal from a sensor
lowering limit) and Boom up/down. It is important to read and
attached to its related hoist and an output signal from a
understand the RCL Override Warning information before
control module. Each hoist control lever (1, 2) pulses when
using the RCL Bypass or On/Off Switch.
its hoist is running so the operator’s thumb can sense it.
Emergency Stop Switch Seat Switch (Not Shown)
The crane Emergency Stop Switch (20) (Figure 3-6) is
This switch (28) (Figure 3-6 Item Numbers) is located within
located on the cab right console and is used to shut down the
the seat. An operator must be sitting in the seat, enabling the
crane’s engine. Push the red button in to shut down the
switch, before any crane functions can be activated.
engine, which illuminates the Emergency Stop icon on the

OPERATING PROCEDURES Hook Block and Headache Ball

Inspect for nicks, gouges, cracks, and evidence of any other
Pre-Starting Checks damage. Replace a hook that has cracks or shows evidence
A complete walk-around visual inspection of the crane of excessive deformation of the hook opening (including
should always be made with special attention to structural twist). Be sure the safety latch is free and aligned.
damage, loose equipment, leaks, or other conditions that
Seats and Mirrors
would require immediate correction for safe operation. Refer
to Maintenance Checklist, page 6-1. Adjust seat and mirrors for clear vision and safe driving.
The following items are suggested to be checked to ensure Seat Belts
the crane is prepared for starting the day’s work.
Seat Belt Maintenance
Fuel Supply
Seat belt assemblies are maintenance-free; however, they
Fill the fuel tank and ensure the cap is on tight. should be periodically inspected to ensure that they are not
damaged and are in proper operating condition, especially if
Engine Oil they have been subjected to severe stress.
Cleaning Seat Belt Webbing
CAUTION Wash the seat belt webbing with any mild soap or detergent.
Do not overfill. Do not use commercial solvents. Also, bleaching or re-
dyeing the webbing is not recommended because of
Check the oil level in the crankcase and ensure it is within possible loss of webbing strength.
3
the ADD and FULL marks on the dipstick. Do not overfill.
Signal and Running Lights
Engine Coolant
Check all signal and running lights for proper operation.
Replace burned out lamps with those of the same number, or
equivalent.
DANGER Service and Parking Brakes
Do not loosen radiator cap while engine and radiator are
Check for proper operation.
hot. Steam or hot coolant will cause severe burns.
Tires
Check the coolant level in the radiator and fill to the proper
level. Do not overfill, and ensure the radiator cap is secure. Check for severe cuts, foreign objects embedded in treads,
and for correct inflation pressures. A tire inflation chart,
Batteries providing the correct air pressures, is located in the Load
Chart Manual in the crane cab.
Check that the battery cables and clamps are tight and not
corroded. Wheels
Hydraulic Reservoir and Filter Maintain proper torque on wheel lugs and check for proper
wheel mounting. If equipped with steel or aluminum wheels,
Check the hydraulic level sight gauge and filter condition
the wheels should be retorqued 80 to 160 km (50 to 100 mi)
indicator on the hydraulic tank. Hydraulic fluid should be at
after initial installation or after any time the tires and wheels
normal operating temperature, with both the boom and
are removed. Doing this will reseat the lug nuts. Recheck the
outriggers in a retracted position, and the boom level.
lug nuts for proper torque every 800 km (500 mi) thereafter.
Check breather for cleanliness and ensure it is secure.
Safety Equipment
Wire Rope
Check all lights, windshield wipers, washers, washer liquid
Inspect the wire rope in accordance with applicable Federal supply, horn, instruments, signaling devices, etc.
Regulations. Sheaves, guards, guides, drums, flanges, and
any other surfaces that come in contact with the rope should Daily Lubrication
be inspected for any condition that could cause possible Ensure all components requiring daily lubrication have been
damage to the rope. serviced. Refer to Lubrication, page 5-1.

Boom
Before extending the boom, ensure the large access cover
on top of the boom base section is installed. CAUTION
Never crank engine for more than 30 seconds during an
Cold Weather Operation attempted start. If engine does not start after 30 seconds,
allow starter motor to cool for two minutes before
The following recommendations are for operating Grove attempting another start.
cranes in very low (i.e. freezing) temperatures.
Use particular care to ensure that cranes being operated in
very cold temperatures are operated and maintained in
accordance with the procedures as provided by Manitowoc CAUTION
Crane Care. Cranes should have appropriate hydraulic oil, If engine does not start after four attempts, correct
lubricants, and other auxiliary items required for operation in malfunction before attempting another start.
sub-zero temperatures. Individual crane functions should be
operated to ensure they are sufficiently warmed prior to Use the correct grade of oil for the prevailing temperature in
performing a lift. the crankcase to prevent hard cranking. Diesel fuel should
have a pour point of 5°C (10°F) less than the lowest
Operation of cranes at full rated capacities in temperatures
expected temperature. In case of an emergency, white
between 0°C and -40°C (+32°F and -40°F) or lower shall be
kerosene can be added to the fuel to bring the pour point
accomplished only by competent operators who possess the
down to the required temperature. This will prevent clogging
skill, experience, and dexterity to ensure smooth operation.
of filters and small passages by wax crystals. The addition of
Shock loading shall be avoided. See Section 5 of this manual
kerosene is NOT recommended for general use.
for more detailed information on operation of cranes down to
-40°F. Ensure Battery Disconnect Switch handle (1) (Figure 3-7) is
in the ON position (handle shown in the OFF position)
Operation Below -40°C (-40°F)
For crane operation below -40°C (-40°F), capacities shall be
derated 3.67% of the capacities shown on the load chart for
each 1°C below -40°C (1.8°F below -40°F).
Engine Operation
Start-up and shutdown procedures for most diesel engines
are generally the same. Therefore, the following procedures 1
can be applied, except where specific differences are noted.
(Refer to the applicable engine manufacturer’s manual for
detailed procedures).
Start-Up Procedure
Make an under-the-hood inspection for fuel, oil, and coolant
leaks, worn drive belts, and trash build-up.
DANGER
Diesel engine exhaust can be harmful to your health. Only 8013-1 FIGURE 3-7
operate the engine in a well ventilated area or vent
exhaust outside.

Cold Engine in downhill operation or downshifting). Engine bearings,

pistons, and valves may be damaged if these precautions
The engine warning and engine stop indicators will illuminate
are not taken.
and go off in sequence after about two seconds (as a check)
when the key is first turned on. If an indicator comes on and Shutdown Procedure
continues to blink after initial start-up, there is a problem that
needs to be corrected. If the engine warning icon is selected, 1. Allow the engine to run at fast idle speed for about five
a screen will open listing the engine error codes. minutes to avoid high internal heat rise and allow for
heat dissipation.
An engine block heater and grid heater are provided to aid in
cold-starting. 2. Position the ignition switch to off (vertical position).
1. Ensure the emergency stop switch is not pressed. 3. Drain the fuel filter-water separator.
2. Set the parking brake to ON and position the Battery Disconnect

transmission shift lever to neutral.
NOTE: The engine will not crank unless the transmission
shift lever is in neutral.
NOTE: The engine “wait to start” indicator located on the
top left side of the front console illuminates amber
for a period of time when the ignition is turned to
the on position. The engine should not be cranked
until the indicator turns off.
3. Turn the key to the first position. The CCS screen will
provide data for the various engine systems and alert 3
the operator to any detected fault codes. Sound the horn
(left of steering wheel) once.
4. Turn the ignition switch to start (far right position) and
release immediately when the engine starts. Do not
push or hold the throttle down. The ECM will
automatically provide the proper amount of fuel to start
the engine.
CAUTION The battery disconnect switch is located in the battery box on

If oil pressure and/or temperature indicator(s) do not the left side of the crane. To disconnect the batteries, turn the
display the proper readings, shut down engine and battery disconnect switch to OFF. Turn the switch to ON to
correct malfunction. connect the batteries.
5. Allow the engine to warm up for about five minutes Crane Travel Operation
before applying a load. Do not race the engine for a
faster warm up. Seat Belts
Idling The Engine Latch Plate
Idling the engine unnecessarily for long periods of time

wastes fuel and fouls injector nozzles. Unburned fuel causes
carbon formation; oil dilution; formation of lacquer or gummy
deposits on the valves, pistons and rings; and rapid
accumulation of sludge in the engine.
Buckle
NOTE: When prolonged engine idling is necessary,
maintain at least 800 rpm.
Racing The Engine

DO NOT race the engine during the warm-up period or FIGURE 3-8
Push Button
operate the engine beyond governed speed (as might occur

1. Before fastening a seat belt, always adjust the driver’s

seat to the position in which you will drive.
CAUTION
2. Pull the belt across your lap and push the latch plate into
the buckle until it clicks (Figure 3-8). Machine Damage Hazard!
Do not travel with an empty hook in a position where it can
3. To reduce the risk of sliding under the belt during a
swing freely (except where noted). Either remove the
collision, position the belt across your lap as low on your
hook block and/or headache ball from the hoist cable(s)
hips as possible and pull it toward the door to a snug fit.
and stow securely or make sure the hook block or
Traveling — General headache ball is properly secured to the tie down
provided for that purpose.
Do not drive the crane with the lift cylinder bottomed. At a
minimum, position the boom slightly above horizontal.
WARNING Fully retract the outrigger jacks and properly store the
Inadvertent Operation Hazard! floats.
Before traveling, ensure that the crane functions are fully Disengage the pumps (if applicable) for extended
disabled. The crane function enable switch is a spring traveling.
return switch and cannot be put in a specific OFF
position.This will prevent inadvertent operation of craning
functions due to bumping of the controllers while
traveling. CAUTION
Machine Damage Hazard!
RT machines are subject to the same road regulations as Manitowoc recommends towing or pulling another vehicle
any truck, regarding gross weight, width, and length with the optional pintle hook (if equipped) or by attaching
limitations. at a point no higher than the pintle hook height, or severe
Although RT machines are specifically designed for rough damage may occur to the drivetrain.
terrain, the operator should be extremely cautious and aware Do not tow or pull by attaching to the tie-down lugs unless
of the terrain in which he is operating. the attaching point is no higher than the pintle hook
height.
Use four-wheel drive when greater traction is necessary
to avoid severe damage to the drivetrain.
WARNING Should the crane become mired down, use a tow truck or
Tipping Hazard! tractor to free the vehicle. Severe damage to the
drivetrain may occur if the operator attempts to free the
Avoid holes, rocks, extremely soft surfaces, and any other
crane unassisted.
obstacles which might subject the crane to undue
stresses or possible overturn.
• Use four-wheel drive only when greater traction is
Do not drive the crane with the boom off center because necessary. (Refer to Four-Wheel Drive Operation, page
automatic oscillation lockout will occur, making the crane 3-18 for operating instructions.)
subject to tipping on uneven surfaces. Center the boom
over the front, disable swing functions and engage the • Ensure the outrigger beams and jacks are fully retracted
Turntable Lock Pin (if equipped). with the floats properly stowed.
Fully retract the boom and ensure the swingaway jib is • Conduct all travel with the assistance of a ground person
properly stowed and secured. to warn the operator of any changing conditions in the
terrain being traversed.
The owner/lessee must take appropriate measures to
ensure that all persons operating or working with the affected
models are in compliance with The Manitowoc Company,
Inc. recommendations. The operator of the crane assumes
responsibility for determining the suitability of traveling
conditions. Traveling under the controlled conditions
specified in these guidelines, must be conducted with the
utmost diligence and care to ensure the safety of all

personnel performing the operation and/or working around

the crane.
CAUTION
Traveling — Towing/Pulling
It is recommended to attach cables/straps to the optional
pintle hook (if equipped) or evenly attach to the tie-down
CAUTION lugs if being towed by another vehicle.
Machine Damage Hazard! Should the crane become mired down, use a tow truck or
Manitowoc recommends towing or pulling another vehicle tractor to free the vehicle. Severe damage to the
with the optional pintle hook (if equipped) or by attaching drivetrain may occur if the operator attempts to free the
at a point no higher than the pintle hook height, or severe crane unassisted.
damage may occur to the drivetrain.
Do not tow or pull by attaching to the tie-down lugs unless • Ensure the boom is in a horizontal position and not
the attaching point is no higher than the pintle hook elevated above 0°.
height. • Ensure the outrigger beams and jacks are fully retracted
Use four-wheel drive when greater traction is necessary with the floats properly stowed.
to avoid severe damage to the drivetrain.
Should the crane become mired down, use a tow truck or
tractor to free the vehicle. Severe damage to the
CAUTION
crane unassisted. Machine Damage Hazard!
To avoid severe damage to the drive train while using the

It is recommended to attach cables/straps to the pintle
hook if one is available or evenly attach to the tie-down 3
crane to tow or pull another vehicle, follow these lugs if being towed by another vehicle.
recommendations: Should the crane become mired down, use a tow truck or
• Ensure the boom is in a horizontal position and not tractor to free the vehicle. Severe damage to the
elevated above 0°. drivetrain may occur if the operator attempts to free the
crane unassisted.
• Ensure the outrigger beams and jacks are fully retracted
with the floats properly stowed. To avoid severe damage to the drive train while the crane
• Tow or pull on open ground when possible. engine is disabled:
• Connect to the optional pintle hook (if equipped) or • Disconnect drivelines.

attach cables/straps to the crane at a point no higher • Disengage parking brake by manually turning parking
than the pintle hook height. brake adjustment until axle turns free.
• Use four-wheel drive when greater traction is necessary.
(Refer to Four-Wheel Drive Operation, page 3-18 for
operating instructions.)
• Should the crane become mired down, use a tow truck DANGER
or tractor to free the vehicle. Severe damage to the
Run-away Crane Hazard!
crane unassisted. Disabling the parking brake may result in the crane rolling
away freely without the ability of the operator to stop the
• Conduct all travel with the assistance of a ground person crane.
to warn the operator of any changing conditions in the
Ensure wheel chocks are properly placed when parking
crane with the parking brake disabled.
Traveling — Being Towed/Pulled Death or serious injury and damage to machinery could
result from moving machinery.
Manitowoc recommends connecting to a pintle hook (if
equipped) or evenly attaching to the tie-down lugs when • Secure steering to prevent turning while towing.
being towed by another vehicle.
• Conduct all travel with the assistance of a ground person
to warn the operator of any changing conditions in the

Traveling on Slopes Should the operator need to traverse slopes outside the
criteria defined in the above guidelines contact the The
Crane operators need to exercise caution whenever
Manitowoc Company, Inc. for further guidance.
operating the crane on uneven surfaces. Travel on slopes is
permitted as long as the following conditions are met. Traveling with Elevated Boom
• Do not exceed a 15% (8.5°) slope side-to-side or fore-
and-aft.
• Travel must be on an improved surface or on hard- WARNING
packed dry earth having a minimum 0.5 coefficient of
adhesion. Overhead Objects Hazard
Contacting overhead objects while driving the crane may
• Limit travel to a forward direction only. result in death, severe injury, and/or equipment damage.
• Do not exceed a speed of 1.6 km/h (1 mph). Traveling with the boom elevated should only be
attempted under the controlled conditions specified in this
• Fully retract all boom sections. section.
• Stow or remove the boom extension from the crane.
Exercise caution whenever driving the crane with the boom
• Lower the boom to horizontal and position over the front elevated. Travel with the boom elevated is permitted as long
of the crane. as the following steps are followed.
• Engage the swing brake and turntable lock pin. • Limit travel to firm, level surfaces.
• Either the hook block may be reeved over the main • Inspect the route of travel prior to moving the crane. Pay
boom nose or the headache ball may be reeved over the particular attention to any changing conditions in the
main boom nose or auxiliary boom nose; the other must terrain being traversed. Also, avoid any overhead
be removed. If the hook block or headache ball remains obstructions.
reeved on the boom, it must be secured at the tie down
on the carrier to prevent swinging. • Travel must be performed in a controlled fashion.
• Inflate tires to the recommended pressure for pick and • Do not exceed a speed of 24 km/h (15 mph).
carry operations. • Inflate tires to the recommended pressure for travel
• Ensure the hydraulic tank is filled to the specified level. operations.
Ensure the fuel tank is over half full. • When using the towing attachments, the boom must
• Do not support any loads by the boom (i.e., no pick and remain horizontal.
carry loads) while traversing a slope. • Fully retract all boom sections.
• Remove all cribbing or other non-standard accessories • Refer to Traveling with Boom Extension Erected, page
from the crane. 3-17 if the boom extension is in the erected position.
• Avoid holes, rocks, extremely soft surfaces, and any • Position the boom over the front of the crane.
other obstacles that might subject the crane to undue
stresses and possible overturn. • Engage the swing brake and turntable lock pin.
• Conduct all travel with the assistance of a ground person • The hook block may be reeved over the main boom
to warn the operator of any changing conditions in the nose. The headache ball may be reeved over the main
terrain being traversed. boom nose or auxiliary boom nose. The block and ball
may be suspended below the boom nose. It is also
The owner/lessee must take appropriate measures to acceptable to secure the block or the ball to the tie down
ensure that all persons operating or working with the affected point on the carrier to prevent swinging if necessary.
models are in compliance with The Manitowoc Company,
Inc. recommendations. The operator of the crane assumes • Limit boom angle to a maximum of 20°.
responsibility for determining the suitability of traveling on a
• Do not support any load from the boom (see Pick and
slope. Traveling on a slope should only be attempted under
Carry Load chart for limitations for this application).
the controlled conditions specified in these guidelines, and
must be conducted with the utmost diligence and care to • Remove all cribbing or other non-standard accessories
ensure the safety of all personnel performing the operation from the crane.
and/or working around the crane.

• Avoid holes, rocks, extremely soft surfaces and any

other obstacles that might subject the crane to undue
stresses and possible overturn. CAUTION
• Ensure adequate clearance to any overhead Tire Damage Hazard!
obstructions that the crane may be required to travel For extended travel, check the cold tire pressure prior to
beneath. start. (Refer to tire inflation chart in Load Chart Book.)
After every one hour of travel time, regardless of ambient
• Ensure that all personnel involved in the operation and
temperature, stop and allow the tires to cool off for at least
those working around the crane are aware of any
30 minutes. At the destination, the tires must be allowed
hazards that may be encountered and are trained about
to cool to ambient temperature before crane lifting on
how to avoid the hazards.
rubber.
Traveling with Boom Extension Erected
Traveling — Forward
7.9 m (26 ft) Boom Extension
Follow the steps below when traveling with the 7.9 m (26 ft)
extension erected. CAUTION
• Position the 7.9 m (26 ft) boom extension at minimum
offset. Pin the 5.8 m (19 ft) extension in the fully Engage the turntable lock pin for extended travel. Failure
retracted position. to engage the lock pin may allow the superstructure to
swing uncontrolled, damaging the machine and/or
• Travel only on a firm, level surface. property.
• Fully retract the main boom.
• Limit main boom angle to a minimum of 0° and a
1. With the Transmission Shift Lever in the neutral (N)
position, start the engine and allow it to adequately
3
maximum of 30°. warm up.
• Do not exceed a speed of 2.7 km/h (1.7 mph) and 2. Depress the Service Brake Foot Pedal.
ensure crane is in low range, first gear.
• Ensure main counterweight is installed.
WARNING
• Position the boom over the front of the crane.
Run-away Crane Hazard!
• Engage the swing brake and turntable lock pin. Releasing the parking brake while the low service brake
• Remove hookblock from main boom nose. pressure indicator is illuminated and the buzzer is
sounding, indicating the service brakes are inoperable,
• Headache ball may be reeved over boom extension, may result in the crane rolling away freely without the
hanging 0.9 m (3 ft) below sheave. ability of the operator to stop the crane.
13.7 m (45 ft) Boom Extension Never release the parking brake while the low service
brake pressure indicator is illuminated and the buzzer is
Travel with the 13.7 m (45 ft) boom extension erected is not sounding.
permitted.
Extended Travel 3. Disengage the parking brake.
Depending upon the tire manufacturer, the higher inflation 4. Position the Drive Axle Switch to either two-wheel high
pressures normally specified for lifting on rubber are not or four-wheel low.
recommended for site to site transfer over extended
distances. The higher static/creep 8 km/h (5 mph) inflation
pressures may remain in the tire while operating the crane CAUTION
on site within a distance of less than 6.4 km (4 mi). Use four-wheel drive only when more traction is required.
5. Lift the Transmission Shift Lever up out of its detent and

push the lever to the forward (F) position, then rotate the
Transmission Shift Lever Knob to the first (1) gear
position. The gear selection “F1” will appear in the CCS
Display to indicate that forward propulsion and first (1)
gear have been selected; if the Service Brake Foot

Pedal is not depressed prior to shifting to a gear, the Four Wheel Steering
gear selection will flash in the CCS Display until the
Four wheel steering is accomplished with the steering wheel
Transmission Shift Lever is returned to the neutral (N)
and the Rear Steer Control Switch. Depending upon which
position, and the transmission will not shift.
direction the operator wishes to travel, the steering wheel is
6. Release the Service Brake Foot Pedal and depress the turned opposite direction of the Rear Steer control position.
Foot Throttle Pedal until maximum first gear speed is This allows the crane to turn or maneuver in close, restricted
attained, then rotate the Transmission Shift Lever Knob areas.
to the second (II) gear position to continue to increase
speed. For additional speed, continue shifting to a Crabbing
higher gear. Crabbing is accomplished with the steering wheel and the
Rear Steer Control Switch. Depending upon which direction
the operator wishes to travel (crab), the steering wheel is
CAUTION turned in the same direction as the Rear Steer Control
Possible Machine Damage! Switch. This permits driving the crane forward or backward in
Do not downshift to a lower gear if the road speed is a crabbing manner.
greater than the maximum speed of the lower gear.
Traveling — Reverse
Traveling in reverse is accomplished the same way as
traveling forward, except for shifting the Transmission Shift
Lever to reverse (R). Refer to Traveling — Forward, page 3-
17. 6402-1
Front-Wheel Rear Wheel
CAUTION
Possible Machine Damage!
Apply service brakes and bring crane to a complete stop
before shifting transmission into reverse.
Steering 6402-2
Steering is accomplished by the steering wheel and the rear Four-Wheel Crabbing
steer control. These controls, used singly or together, FIGURE 3-9
provide front wheel steering, rear wheel steering, four-wheel
steering, and crabbing capabilities (Figure 3-9). Four-Wheel Drive Operation
Front Wheel Steering
Conventional front wheel steering is accomplished with the
steering wheel. This method of steering should always be CAUTION
used when traveling at higher speeds. Machine Damage Hazard!
Do not tow or pull in 1st gear with the Drive Axle Selector
Switch in two-wheel drive position. Severe damage to the
drive train will result. Always engage four-wheel drive.
WARNING
Unexpected Operation Hazard! If more traction is required due to slipping or spinning
Operate the rear steer ONLY at slow speeds for added job wheels, engage the front axle drive as follows:
site maneuverability.
Rear Wheel Steering CAUTION

Possible Machine Damage!
Rear wheel steering is controlled by the Rear Steer Control
Switch. Moving the control switch to the desired position Before shifting from two-wheel drive to four-wheel drive
activates the rear steer cylinders, thereby steering the crane (or from four back to two), crane travel must be stopped.
in the selected direction.

1. Stop the crane by depressing the Service Brake Foot Follow the steps below when engaging/disengaging the
Pedal. differential lock function.
2. Position the Transmission Shift Lever to the neutral (N) 1. Lock the differentials by pressing and holding the Axle
position. Differential Control Switch in the lock position;
disengage the function by releasing the switch.
3. Position the Drive Axle Selector Switch to four-wheel
low. 2. Lock/unlock the differentials only when the vehicle is
standing still or moving at a constant low speed with the
NOTE: If the Drive Axle Selector Switch is positioned to
wheels not slipping.
four-wheel low and the Service Brake Foot Pedal is
not depressed and the Transmission Shift Lever is
not in neutral (N) position, the Four-Wheel Drive
CAUTION
Indicator will flash and the four-wheel drive function
will not engage. Possible Machine Damage!
When driving on hard, dry surfaces with the differentials
4. Select gear speed and direction of travel using the
locked, do not turn the wheels. Damage to the drive line
Transmission Shift Lever and Knob.
components can result.
5. Drive the crane as described under Traveling — Do not lock the differentials when the wheels are slipping.
Forward, page 3-17. Damage to the differentials can result.
6. Return the Drive Axle Selector Switch to the two-wheel
high position as soon as two-wheel traction will suffice 3. Locked differentials cause the crane’s turning radius to
and crane motion has stopped; again, the Service Brake increase, creating an understeer condition; use caution,
Foot Pedal must be depressed and the Transmission good judgement and drive at low speeds when operating
Shift Lever must be in the neutral (N) position to shift
from four-wheel low to two-wheel high. 4.
the vehicle with lock differentials.
Lock the differentials only when maximum traction is
3
needed on poor road or highway surfaces.
Differential Lock Operation (Optional)
CAUTION
CAUTION
Unexpected Operation!
Possible Loss of Vehicle Stability!
When using the differential lock, steering characteristics
may be affected. Do not lock the differentials when the vehicle is traveling
down steep grades and traction is minimal.
Try to use four-wheel drive to gain adequate traction
before using the differential lock.
5. Always unlock the differentials when the need for
Do not operate the differential lock when traveling maximum traction has passed or when traveling on good
downhill; at speeds above 16.1 km/h (10 mph); on hard, road or highway surfaces.
dry surfaces; and/or during axle spin-out.
Operation
NOTE: The differential lock will not operate unless the The differential lock function should preferably be engaged
Drive Selector Switch is in the four-wheel low when the crane is stationary but may be engaged when
position. moving, if the following conditions are met:
General 1. The crane is moving very slowly (creep speed).
The purpose of the differential lock is to provide maximum 2. The wheels are not spinning at the time of engagement.
traction and control on poor road or highway surfaces. When
the differential locks are actuated, the clutch collar When traveling with the differentials locked, do not deviate
completely locks the differential case, gearing, and axle from a straight path more than is absolutely necessary.
shafts together, thus maximizing traction to both wheels of Engage the differential locks by doing the following:
each axle. The lock position will also protect against spinout. 1. Position the Axle Differential Lock Control Switch to the
When normal driving conditions exist (during periods of good locked position with the crane stationary or moving at a
traction), the differential locks should not be actuated. The slow speed.
axles should be allowed to operate with differential action
between both wheels. If moving at a slow speed, let up momentarily on the
Foot Throttle Pedal to relieve torque on the differential
gearing. This will fully engage the differential locks.

NOTE: When the differentials are locked, the Axle working properly, the crane will not re-level itself. If the
Differential Locked Indicator illuminates. rear axle does not lock or unlock properly, evaluate the
lockout system and repair as necessary.
2. Proceed over the poor road condition cautiously.
When the adverse condition has passed, disengage the General Crane Operation
differential locks by doing the following:
Pump Drive
1. Release the Axle Differential Lock Control Switch,
allowing it to return to the unlocked position while The main #1 hydraulic pump is driven by a transmission
maintaining a slow speed. PTO. The #2 hydraulic pump is mounted to the rear of pump
#1 and is direct engine driven.
2. Let up momentarily on the Foot Throttle Pedal to relieve
torque on the differential gearing, allowing the Control Lever Operation
differential to fully unlock.
The control lever operation for crane functions is
NOTE: When the differentials are unlocked, the Axle proportional, i.e., the closer the lever is to neutral (center),
Differential Locked Indicator will not be illuminated. the slower the system responds. Return the control lever to
neutral to hold the load. Do not feather the hoist control to
3. Resume driving at a normal speed using good driving hold the load.
judgement.
NOTE: Always operate the control levers with slow, even
Axle Oscillation Lockouts Operation pressure.
The following procedure should be used to periodically Preload Check
check the axle oscillation system and ensure that it is in
proper working condition. After the crane has been readied for service, an operational
check of all crane functions (with no load applied) should be
1. Ensure the tires are inflated to the recommended performed. Preload check is as follows:
pressure. Refer to the Load Chart Book in the crane cab
for proper inflation pressures. • Extend and set the outriggers and level the crane.
2. With the hook unloaded, the boom fully retracted and • Raise, lower, and swing the boom right and left at least
centered over the front at no more than a 10° to 15° 45 degrees.
boom angle, position the crane on a block or curb so that
• Telescope the boom out and back in, ensuring all
one rear tire is approximately 6 to 12 in (15 to 30 cm)
sections extend and retract properly.
above the level of the opposite tire.
• Raise and lower the cable a few times at various boom
3. Slowly swing the superstructure to the left or right until
lengths. Make sure there are no kinks and that the cable
the axle oscillation lockout valve is activated. This will
is spooling on the hoist properly.
lock the rear axle out of level. Do not swing beyond the
tire track.
4. After engaging the swing brake, slowly drive off of the CAUTION
block or curb and stop. The rear tires should both be Run the engine at or near the governed RPM during
touching the road surface and the opposite front tire operation of all crane functions.
should be light or slightly off the road surface.
NOTE: Carefully read and become familiar with all crane
5. Release the swing brake and swing the superstructure
operating instructions before operating the crane.
until it is centered over the front.
Using Your Load Chart
NOTE: One of the most important tools of every Grove
DANGER crane is the load chart found in the crane operator's
cab.
Tipping Hazard!
Do not operate the crane if the axle oscillation lockout NOTE: Refer to (Figure 3-10) for terms to know in
system is not functioning properly. determining lifting capacities.
Failure to comply with this warning may result in death or The load chart contains the lifting capacities of the crane in
serious injury. all allowable lifting configurations, and must be thoroughly
understood by the operator.
If the axle oscillation lockout valve is functioning
properly, the crane will re-level itself; if the valve is not

The load chart is divided into capabilities limited by crane extended (with swingaway extension). The number at the
structural strength and stability which is shown by a bold line intersection of the left column and top row is the total load
across the chart. Structural strength limits are above the line limit for that load radius and boom length. The number in
and stability limits are below the line. parentheses below the total load limit is the required boom
angle (in degrees) for that load. The lower weight limit for the
The left column is the load radius, which is the distance from
2 boom lengths should be used.
the axis of the crane rotation to the load center of gravity. The
top row lists various boom lengths from fully retracted to fully
MA
IN
BO
OM
LE
NG AXIS OF ROTATION
TH
BOOM ANGLE
HORIZONTAL 3
4605
OPERATING RADIUS
TERMS TO KNOW
FIGURE 3-10
Another important section is the range diagram. The range considered as part of the load. The weight of any other load
diagram shows the operating radius and tip height that can handling devices such as chains, slings, or spreader bars
be achieved at a given boom length and angle. If the must also be added to the weight of the load.
operator knows the radius and tip height required for a
NOTE: The information in the following paragraph is an
specific lift, the angle and boom length can quickly be
example of how to compute a lift. The numbers
determined from the range diagram. Or if he knows the boom
used in the example may not coincide with the load
length and angle, he can quickly determine the tip height and
chart in the crane cab.
operating radius.
Problem: A concrete beam weighing 2268 kg (5000 lb)
A lifting diagram is included for over-side, over-rear, and
needs to be lifted to a height of 9.1 m (30 ft) at a radius of
over-front lifting areas. The lifting area diagram shows that
15.2 m (50 ft) (maximum). The range diagram indicates the
the locations of the outrigger jack cylinders in the full
boom must be extended to 18.9 m (62 ft) in order to reach a
extended position are used to mark the boundaries of the
height of 9.1 m (30 ft) at a radius of 15.2 m (50 ft).
lifting areas.
First we need to check the crane for load handling devices.
Another section contains notes for lifting capacities. Be sure
In our example, the crane is equipped with a auxiliary boom
to read and understand all notes concerning lifting
nose (rooster sheave) and a five ton overhaul ball. The
capacities.
rooster sheave is 50 kg (110 lb), and the overhaul ball is
The load chart also gives weight reductions for Manitowoc/ 78 kg (172 lb) for a total of 128 kg (282 lb). The lift requires
Grove load handling devices such as hookblocks, overhaul slings and spreader bars weighing 159 kg (350 lb) which
balls, boom extension sections, etc., which must be

makes the total weight for the load handling devices 286 kg Crane Functions
(632 lb).
Using the Outriggers
A check of the load chart for a 15.2 m (50 ft) radius and
19.5 m (64 ft) of boom length shows a capacity of 3601 kg The outriggers are operated from the front console in the cab
(7940 lb) on outriggers over-front and 4970 lb on outriggers or by using the jog dial on the armrest.
360 degrees. We subtract the load handling weight of 632 lb
from the load capacity of 3601 kg (7940 lb) and 2254 kg
(4970 lb). The result is a weight capacity of 3315 kg
(7308 lb) over-the-front and 1968 kg (4338 lb) for 360 DANGER
degrees. We are constricted in making the lift over-front only
To prevent serious injury or death, keep clear of moving
and the boom angle will be about 29 degrees.
outrigger beams/jacks.
Proper Leveling of the Crane
ASME B30.5 specifies that if a crane is not level within 1% of
grade, the allowable capacities must be reduced. Therefore,
whether lifting on rubber or outriggers, it is essential that the
DANGER
crane is level to within 1% of grade. The bubble level
indicator that is provided on the crane is calibrated to be Death or serious injury could result from improper crane
accurate within 1% of grade. setup on outriggers.
To properly level the crane, the boom must be positioned

over the front of the crane, fully lowered to horizontal and
fully retracted (for cranes fitted with a boom rest, the boom
shall be stowed onto the rest). Raise and level the crane WARNING
using the outriggers; refer to The crane also allows
Be sure the outriggers are properly extended and set, and
operations with the outriggers fully retracted., page 3-22.
the crane is level for operation on outriggers.
A working crane may settle during lifting operations. All four outrigger beams must be equally extended to the
Frequently check the crane for level. When rechecking the mid position vertical stripe or fully extended position
crane for level, the boom must be positioned over the front of before beginning operation.
the crane, fully lowered to horizontal and fully retracted (for
cranes fitted with a boom rest, the boom shall be stowed
onto the rest). If necessary, relevel the crane using the
procedures under The crane also allows operations with the
outriggers fully retracted., page 3-22.
WARNING
Level Indicator Adjustment When operating the crane on outriggers, the outriggers
should always be fully extended or locked in the mid-
The Level Indicator should be checked periodically; if it is extend position.
suspected that the Level Indicator is out of adjustment, verify
and adjust the level as follows: NOTE: The crane also allows operations with the
1. Position the crane on a firm, level surface. outriggers fully retracted.
2. Extend and set the outriggers. Level the crane, as Setting the Outriggers
indicated by the level indicator, using the outriggers.
1. Engage the Parking Brake.
3. Place a miracle pointer level, carpenter level, or similar
type device on a machined surface such as the turntable NOTE: To enable outrigger functions: The crane must be in
bearing or bearing mounting surfaces. four wheel drive, the parking brake must be
engaged, the swing brake must be engaged, and
4. Using the outriggers, level the crane as indicated on the all crane functions must be off.
leveling device used in step 3.
2. Position the outrigger floats directly out from each
5. Using the level indicator mounting screws, adjust the outrigger to where the outriggers will be properly
level indicator to show level. extended.

6. Extend the rear jacks approximately 8 to 10 cm (3 to 4

in).
CAUTION
NOTE: If crane is equipped with tilting cab, ensure cab is in
Possible Equipment Damage! the lowered position before leveling machine.
Always depress one of the outrigger/selector switches
7. Repeat step 4 until all wheels are clear of the ground
before positioning the outrigger extension/retraction
and the crane is level as indicated by the level indicator
switch to extend or retract. Failure to do this may cause a
located on the right side of the cab.
hydraulic lock against the individual solenoid valves,
preventing them from opening. NOTE: If it is suspected that the level indicator is out of
adjustment, verify and adjust the level using the
procedures under Level Indicator Adjustment,
page 3-22.
DANGER
Electrocution Hazard!
To avoid death or serious injury, keep all parts of this DANGER
machine, the rigging, and materials being lifted at least 20 Tipping Hazard!
feet away from electrical power lines and equipment. The mid-extend outrigger beam lock pin must be engaged
before operating on any beam from the mid-extend
3. If extending the outrigger to the mid-extend or fully position.
extended position, use the Outrigger Function Enable For cranes not equipped with an Outrigger Monitoring
Switch and the CCS menu with either the CCS display
3
System (OMS), the operator must select the proper
buttons or the jog dial to select the outrigger. The rigging code from the load chart and RCL program for the
appropriate outrigger beam will extend. Refer to outrigger position selected. The OMS will NOT change
Engaging the Mid Extend Lock Pin, page 3-23 if the the rigging code to match the existing outrigger position.
crane is to be operated with any outrigger at the mid-
extend position. Outrigger Monitoring System (OMS) (Optional—
Standard in North America)
The Outrigger Monitoring System (OMS) aids the operator in
DANGER accurately programming the Rated Capacity Limiter (RCL)
by automatically identifying the horizontal position of each
Tipping Hazard! outrigger beam. The OMS uses four sensors, one per
All four outrigger beams must be deployed to one of three outrigger beam, to indicate when an outrigger beam is
positions before beginning operation, which include fully positioned to one of three pre-defined locations, including
retracted, mid-extend, or fully extended; do not operate fully retracted, mid-extend, and fully extended.
the crane with the outriggers in any other position.
Set up of the outriggers is the same for cranes equipped with
OMS; refer to The crane also allows operations with the
NOTE: More than one outrigger beam can be extended at
outriggers fully retracted., page 22.
a time. However, to ensure that each outrigger is
fully extended, repeat step 3 for each outrigger If the crane is setup on outriggers and “On Outriggers” is
after a multi-outrigger extension. chosen when programming the RCL, then the OMS indicates
to the RCL the horizontal position of each of the four
4. After deploying the four outrigger beams to one of the
outrigger beams. When the outriggers are at the proper
three proper positions (fully retracted, mid-extend, fully
position, the screen icon is transparent; if an outrigger is not
extended), navigate to the jack operation on the CCS
in the proper position it will be shown as red The RCL does
screen and select the jack extend function on the
not lock out the crane or select a different chart based on
Outrigger Function Enable Switch.
outrigger position.
Extend each jack, using either the CCS display buttons
or the jog dial, positioning the float as necessary, until Engaging the Mid Extend Lock Pin
the locking levers of the float engage the jack cylinder NOTE: It may be necessary to jog the outrigger extension/
barrel. retraction switch slightly to ensure proper pin
NOTE: More than one jack can be extended at a time. engagement.
5. Extend the front jacks approximately 8 to 10 cm (3 to 4 1. With the outriggers fully retracted, turn the locking pin
in). 90° from its stowed position and allow the pin to slip into

the lug on the jack beam. If the pin will not slip into the 2. Use the screen buttons or jog dial with the Outrigger
lug, slowly extend or retract the outrigger beam, allowing Function Enable Switch to select the left or right front
the locking pin to drop into the lug. outrigger on the CCS screen. Retract until the front jacks
have retracted several inches.
2. Slowly extend or retract the outrigger beam, allowing the
locking pin to drop into the hole in the top of the outrigger
beam, engaging the outrigger beam at the desired
length.
DANGER
Stowing The Outriggers Keep feet and hands clear of floats when unlocking the
floats from the jacks.
NOTE: To enable outrigger functions, the crane must be in
four wheel drive, the parking brake must be
engaged and swing must be off. 3. Repeat steps 1 and 2 until the crane is resting on all
wheels and the jack floats are several inches off the
1. Use the screen buttons or jog dial with the Outrigger ground.
Function Enable Switch to select the left or right rear
outrigger on the CCS screen. Retract until the rear jacks 4. Release the locking levers and allow the floats to drop to
have retracted several inches. the ground.
3 2
3 4
1 FIGURE 3-11

NOTE: The swing brake activates automatically, when the

Item Description control lever is returned to the stop or neutral
position, to prevent further rotation.
1 Outrigger Float Assembly
Elevating and Lowering the Boom
2 Quick Pin With Lanyard
3 Rubber Bumper Elevating the Boom
4 Cotter Pin
5. Continue to retract the jacks until they are fully retracted. DANGER
6. Use the screen buttons or jog dial with the Outrigger Crushing Hazard!
Function Enable Switch to select and retract each Keep the area above and below the boom clear of all
outrigger beam. Refer to Stowing the Mid-Extend Lock obstructions and personnel when elevating the boom.
Pin below if the crane was operated at the mid-extend
position.
NOTE: More than one outrigger beam may be retracted at
one time.
7. After all outriggers have been fully retracted, stow the
outrigger floats (Figure 3-11).
Stowing the Mid-Extend Lock Pin

NOTE: If the lock pin is wedged in the hole in the outrigger
beam, it may be necessary to jog the outrigger
3
extend/retract switch slightly while pulling upward
on the pin.
Swinging the Superstructure

1. To elevate the boom, activate the Lift Enable Switch,
push the controller on the right hand armrest to the left
(raises the boom), and hold until the boom reaches the
desired elevation.
DANGER
Lowering the Boom
Crushing Hazard!
moving machinery. Before activating swing, sound the
steering wheel horn and verify that all personnel are clear
of rotating and moving parts. DANGER
Keep the area beneath the boom clear of all obstructions Crushing and/or Tipping Hazard!
and personnel when lowering the boom. Keep the area beneath the boom clear of all obstructions
The operator must select the proper load chart and RCL and personnel when lowering the boom.
program for the outrigger position selected. Long cantilever booms can create a tipping condition,
even when unloaded and in an extended, lowered
position.
CAUTION
Never push or pull the swing control lever through neutral
to the opposite direction to stop swing motion. The
automatic swing brake is activated by the control lever to WARNING
stop swing rotation. Machine Damage!
When lowering the boom, simultaneously let out the hoist
To swing the boom, activate the Swing Enable Switch, push
cable to prevent two-blocking the boom nose and hook
the control lever on the left hand armrest to the right for right
block.
swing (rotates turntable clockwise), or to the left for left swing
(rotates turntable counterclockwise). Always operate the
control lever with a slow, even pressure.

Telescope Enable Switch, then push on the top of the pedal

CAUTION to extend the boom or push on the bottom of the pedal to
The closer the load is carried to the boom nose, the more retract the boom.
important it becomes to simultaneously let out the hoist
cable as the boom is lowered. Lowering and Raising the Hoist Cable
1. To lower the boom, activate the Lift Enable Switch, push

the controller on the right hand armrest to the right
(lowers the boom) and hold until the boom is lowered to DANGER
the desired position. Crushing Hazard!
Telescoping the Boom Keep the area beneath the load clear of all obstructions
and personnel when lowering or raising the cable (load).
NOTE: The telescope function is controlled by a foot pedal
if the crane is equipped with an auxiliary hoist.
Extending the Boom
DANGER
Crushing Hazard!
DANGER Do not jerk the control lever when starting or stopping
hoist. Jerking the lever causes the load to bounce, which
Crushing Hazard!
could result in possible damage to the crane.
Check the Load Chart for the maximum load at a given
radius, boom angle, and length before extending the
NOTE: When the load is stopped at the desired height, the
boom with a load.
automatic brake will engage and hold the load as
long as the controller remains in neutral.
CAUTION Lowering the Cable
Before extending the boom, ensure the large access
Turn on the Hoist Enable Switch, push the main hoist (right
cover on top of the boom base section is installed.
hand armrest) or auxiliary hoist (left hand armrest) controller
When extending the boom, simultaneously let out the forward, away from the operator, and hold until the hook or
hoist cable to prevent two-blocking the boom nose and load is lowered to the desired height.
hookblock.
Raising the Cable
To extend the boom on cranes with no auxiliary hoist, Turn on the Hoist Enable Switch, pull the main hoist (right
activate the Telescope Enable Switch, push the controller on hand armrest) or auxiliary hoist (left hand armrest) controller,
the left hand armrest forward and hold until the boom toward the operator, and hold until the hook or load is raised
reaches the desired length. to the desired height.
Retracting the Boom
Hoist Speed Range Selection
While there is no separate hoist speed switch on a CCS
crane, high speed may be activated in one of several ways:
DANGER 1. When enabling the function, hold the hoist selector
Crushing Hazard! switch for 1.5 seconds.
When retracting the boom, the load will lower unless the
2. When enabling the function, double click the hoist
hoist cable is taken in at the same time
enable switch.
To retract the boom on cranes with no auxiliary hoist, activate 3. On a dual axis joystick, tap the thumb rocker switch
the Telescope Enable Switch, pull the controller on the left towards the operator to enable/disable high speed
armrest back and hold until the boom retracts to the desired (persistent state).
position. 4. On a dual axis joystick, hold the thumb rocker switch
Telescope Control Pedal away from the operator to temporarily enable/disable
high speed (momentary state). High speed mode is
The telescope control pedal is used on cranes equipped with disabled when the rocker switch is released.
an auxiliary hoist. Activate the telescope function with the

10. Shut down engine following proper procedures specified

in this Operator Manual and the applicable engine
CAUTION manual.
Do not change speeds while the hoist is active. 11. Remove the keys.
Stowing and Parking 12. Close and lock, if applicable, all windows, covers, and
doors.
When parking the crane, do the following:
13. Turn battery disconnect to OFF position if machine will
be inactive for over 24 hours (Figure 3-7).
DANGER Unattended Crane

Tipping Hazard!
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. WARNING
Tipping Hazard!
1. Remove the load from the hook.
Changing weather conditions including, but not limited to,
2. Remove or stow boom extensions if so equipped. wind, ice accumulation, precipitation, flooding, lightning,
etc. should be considered when determining the location
3. Fully retract all boom sections.
and configuration of a crane when it is to be left
4. Lower the boom to normal travel position. unattended.
5.
6.
Engage the swing brake and swing lock pin.
Retract all jack cylinders and outrigger beams.
Failure to comply with these instructions may cause death
or serious injury. 3
7. Park the crane on a stable surface. The configuration in which the crane should be left while
unattended shall be determined by a qualified, designated
8. Apply the parking brakes and if necessary, chock individual familiar with the job site, configuration, conditions,
wheels. and limitations.
9. Ensure all operating controls are in neutral position.

CRANE CONTROL SYSTEM (CCS) Item Description

The RT530E-2 is equipped with the electronic CCS (Crane 9 Anti Two-Block Indicator
Control System). CCS includes a control unit in the cab and
10 Swing Brake Engaged Indicator
several control units (MWSCM and MWCCM) distributed
over the superstructure and carrier. 11 Brightness Sensor
12 Internal Temperature Warning Indicator
Crane Control System (CCS) Display
13 Turntable Pin Swing Lock Control
Menu Control
The Jog Dial operates the CCS identically to the buttons on
the display console, providing easier access for the operator.
7
Spinning the jog dial performs the same function as the
1
navigation arrow buttons on the display console. The icon in
8
4 5 11 the lower left corner of the display screen reminds the
operator which display is being controlled by the jog dial at
12
that time. The Screen Toggle Button (4) (Figure 3-13) is used
to switch screens. The tab button can also be used to
3 temporarily silence audible alarms. The functionality of the
6 other buttons is different depending on the area, screen and
menu.
4 5 11 2
12 1
9
3
6 10
3 4
13 6
5
C9521
FIGURE 3-12
FIGURE 3-13

Item Description
Item Description
1 Rated Capacity Limiter (RCL) Display
1 Escape Button
2 CCS Operation Display
2 Tab Button
3 USB Diagnostic Connector
3 Menu Button
4 Escape Button
4 Screen Toggle Button
5 Tab Button
5 Jog Dial (Rotate dial to move cursor)
6 Menu Button
6 OK/Enter Button (Press Jog Dial to select)
7 RCL Shutdown Warning Indicator
8 RCL Early Warning Indicator

Turntable Lock Control (Pin Type) superstructure in place. When the control handle is pulled
up, the pin is pulled out of the socket, unlocking the
The Swing Lock Pin Control Handle (13) (Figure 3-12) is superstructure.
located beside the front console on the right side of the cab.
The purpose of the swing lock pin is to lock the Sensors
superstructure in position directly over the front for pick and
carry loads. When the control handle is pushed down and There is a Temperature Sensor (12) and a Brightness
the superstructure is directly over the front, the swing lock Se ns or (11) (F ig ure 3-1 2). Th e Brigh tn es s Se ns or
pin drops into the socket on the carrier frame, locking the automatically adjusts the brightness of all displays.

CCS Main Screen Symbols and Icons
31
30
1 2 3 4 5 6
8 9 10 11 12 13 14 15
16 17 18 19 20
21 22
28
23 24 25 26 27 FIGURE 3-14
29

Item Description
1 Transmission Temperature
2 Fuel Level
3 Battery Voltage
4 Engine Speed (Tachometer)
5 Engine Coolant Temperature
6 Diesel Exhaust Fluid (Optional)
7 Direction/Gear Number
8 Engine Warm-up Indicator (Wait-to-start)
9 Park Brake
10 Emergency Stop
11 Marker/Position/Side Light
12 Rear Wheels Not Centered
13 Four-Wheel Drive Indicator
14 Differential Lock Indicator (Optional)
15 Cold Temperature Warning (Optional) 3
16 Engine Stop
17 Engine Warning Indicator
18 Hydraulic Oil Temperature
19 Low Brake Pressure
20 System Fault
21 Boom Angle Too Low (Optional)
22 Third Wrap Indicator (Optional)
23 Low Steering Pressure (Optional)
24 Regen Needed (Optional)
25 Regen Inhibited (Optional)
26 High Exhaust Temperature (Optional)
27 Work Range Limiter Indicator (Optional)
28 Active Screen Indicator
29 Alerts Area
30 Status Bar
31 Status Area

CCS Menu Screen
1 2
3 4
5 6 7 8 9 10
12 13 14 15
11
16 17 18 19 20
21
FIGURE 3-15

Item Description
1 Menu Screen Indicator
2 Status Indicator Bar
3 Outrigger Group
4 Outrigger Button
5 WRL Swing Group
6 WRL Height Limit
7 WRL Boom Angle Limit
8 WRL Swing Angle Limit
9 WRL Radius Limit
10 WRL Virtual Wall Limit
11 Tools Group
12 Display Brightness Settings
13 Standard/Metric Display
14 Control Lever Settings
15 Function Speed Setting 3
16 Information Group
17 Operating Hours
18 Engine System Warning
19 Crane Error
20 Software Revision
21 Active Screen Indicator

CCS Operation Display Menu Screen

There are three different levels: The Main Screen, the Menu When the menu button on the jog dial (3) (Figure 3-13) or
Screen and the Sub Level menus. control panel of the CCS is pressed, the overview of the
menu groups appears, for opening menus and submenus.
The main screen (below) appears on the operating display
(lower screen) when the key is turned on. The main screen The menu buttons are categorized by groups. Each group
displays the status of the crane systems. The amber lit icons has its own group icon that is displayed at the beginning of
are enabled. It also displays data from codes on other each group bar. Each group has its own member buttons,
screens. The operator can choose and activate areas from such as telescope group has 3 member buttons.
this screen. The Escape Button (1) (Figure 3-13) defaults
A symbol is selected with the jog dial or the arrow keys to call
back to the main screen.
up a menu. The selected symbol is shown in orange. A menu
is opened by pressing the jog dial or the OK button on the
control panel. There is always one symbol shown selected.
In this case, it is the outrigger function. Press the jog dial
enter button for the Outrigger Operation Menu.
When one of the icons on the right side vertical bar is

flashing, it indicates that the joystick was not at a zero
position when either the function enable button or the all
crane functions button was pressed. To enable the function,
the operator must move the joystick to the center/no motion
position, then try to enable the function again.
For example, if the Swing Enable icon is flashing, it is NOT
enabled. To enable swing, the operator must allow the Swing
Enable joystick to move to the center/no motion position,
then try to enable the swing function again

RATED CAPACITY LIMITER (RCL) SYSTEM

The Rated Capacity Limiter (RCL) is an electro-mechanical
sensing system designed to alert the crane operator of
impending capacity when the system has been properly DANGER
preset by the operator. The control panel is mounted in the Electronic equipment on this crane is intended as an aid
front console of the operator cab. When an overload to the operator. Under no condition should it be relied
condition is sensed, the system provides the operator with a upon to replace the use of capacity charts and operating
visual and audible warning, and locks out the control levers instructions. Sole reliance upon these electronic aids in
to prevent lowering the boom, extending the boom, or raising place of good operating practices can cause an accident.
the main or auxiliary hoist cables.
Three additional features are included within the RCL Mode of Operation
system: The rigging options on this screen enable the operator to
• Swing Angle Set Limitation select static rubber, pick and carry or outrigger configuration.
The Outrigger Operation Menu is navigated on the lower
• Working Range Limiter
CCS Screen.
• Anti-two Block Device
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.
Working Range Limiter 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
3
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 both a visual and an audible warning if the boom
approaches a virtual wall.
The RCL Setup Screen appears on the RCL Display (upper

screen) when the key is turned on. The operator can select
the rigging first, or go directly into the setup wizard. To choose one of the outriggers’ proper positions, fully
retracted, mid-extend or fully extended.

Outrigger Operation Menu Raising the Jacks

For choosing options during rigging. This is the only function Spin the jog dial clockwise and press OK button to select and
w h e r e t h e m e n u b u t t o n ( 3 ) ( F i g u r e 3 -1 3 ) w i l l n o t choose jack operation. Press the lower side of the Outrigger
automatically navigate directly to the menu screen. It must Function Enable Switch on the left armrest to enable jack
be selected and chosen with the menu icon on the lower left operation.
of this screen
Set the outriggers
The operator can choose which beam, or combination of The operator can now choose which jack, or combination of
beams, to extend or retract. Press the top of the Outrigger jacks, to raise or lower.
Function Enable Switch on the left armrest to select outrigger
extension.

Toggle counterclockwise and select the menu icon to exit this Press OK/enter button on display or jog dial (6) (Figure 3-13)
group. to exit the outrigger screen.
3
Press escape button (1) (Figure 3-13) to leave menu and
CAUTION return to CCS main screen. The operator can now navigate
The operator must select the proper load chart and RCL to the RCL screen.
program for the outrigger position selected.

RCL Setup Wizard Set the Counterweight

The RCL can be set graphically, or by direct number input or When rigging is complete, the operator can toggle clockwise
rigging code. The rigging code is determined using the load to exit the outrigger position and move on to setting the
chart. This screen always appears with some rigging code counterweight.
displayed, even if it does not match the actual crane NOTE: Rough Terrain cranes have a fixed counterweight;
configuration. for them, the next function will be setting the boom.
The RCL is working correctly at this point if no error message Toggle clockwise and select the counterweight icon. The
is showing. If any fault codes are present, the fault indicator available choices will assemble on the right of the screen.
on the main CCS screen will be illuminated in red.
NOTE: If the RCL is not working correctly, do not start work

with the crane but notify Manitowoc Crane Care.
NOTE: When the RCL override icon (above, the third icon
from the top on the status indicator bar on the right)
is flashing, it means that the override switch was
active at crane startup. In this case the override is
NOT active. To override the RCL, turn the switch
OFF for 1 second. Then, the override can be turned
ON again, and the RCL will be bypassed.

Set the Boom Set the Jib Angle (if installed)

Turn jog dial clockwise to set boom, including aux nose and Turn jog dial clockwise to program the jib angle after the
reeving options. length is selected.
NOTE: If no jib configuration is chosen for the boom, the

3
following selection will be for reeving.
Set the Jib Length (if installed) Hoist Selection

Turn jog dial clockwise and select to determine and choose Turn jog dial clockwise to select between the main and
the length of the jib, including inserts. optional auxiliary hoists.

Reeving Selection Switch to RCL Home Screen Display

Turn jog dial clockwise to select the icon for reeving options. Press Screen Toggle button (4) (Figure 3-13) on the Jog Dial
Press ENTER a second time and turn dial to change reeving menu control to switch to the RCL main menu screen.
number options.
Press ENTER button on Jog Dial to choose and set the

desired reeving option and move on to the next screen.
Press ENTER on Jog Dial or Menu button to access RCL
Main Screen. This screen appears after the key is turned on,
but the operator must press the tab button to display the tare
value.

FOOT PEDAL CONTROLS spring pressure to overcome the hydraulic pressure being
applied to the brake release circuit and applies the spring
brake according to the pressure from the swing power brake
2 valve.
Telescope Control Pedal (Optional)

The Telescope Control Pedal (4) (Figure 3-16) is supplied
when the crane is equipped with an auxiliary hoist, is located
in the middle of the cab floor. Pushing forward on the top of
the pedal will extend the boom and pushing down on the
bottom of the pedal will retract the boom.
Service Brake Pedal

The Service Brake Pedal (5) (Figure 3-16) is the second
pedal from the right on the cab floor. Depressing the pedal
controls the application of the service brakes.
Foot Throttle Pedal

The Foot Throttle Pedal (6) (Figure 3-16) is located on the
right side of the floor. It is used to control engine RPM which
1 3 4 5 6 increases or decreases proportionately with the amount of
7649-8A FIGURE 3-16
foot pressure applied to the pedal. The pedal is electrically
connected to the superstructure control module which sends
the signal to the engine ECM via the J1939 data link.
3
Item Description MISCELLANEOUS CONTROLS AND
1 360° Swing Lock Pedal INDICATORS
2 360° Swing Lock Release Lever
Fuse Panel
3 Swing Brake Pedal
The fuse panel (1) (Figure 3-17) is located behind the cab
4 Telescope Control Foot Pedal (Optional) seat on the cab fuse and relay panel assembly. It contains up
5 Service Brake Pedal to 20 fuses that protect the various electrical components of
the crane.
6 Foot Throttle Pedal
Buzzer
360° Swing Lock Pedal
The buzzer in the display sounds when the following
The 360° Swing Lock Pedal (1) (Figure 3-16) is located on conditions exist:
the left side of the crane cab floor. The pedal is used to
• Engine Alarms
activate the swing lock to prevent the superstructure from
turning. To release the swing lock, pull up on the 360° Swing • Emergency Stop Switch activated
Lock Release Lever (2).
• Low brake pressure
Swing Brake Pedal • High hydraulic oil temperature
The Swing Brake Pedal (3) (Figure 3-16) is located on the • High transmission oil temperature
left side of the cab floor. The swing brake pedal is used to
actuate the swing brake to slow or stop swing motion. • Low steer pressure condition (for CE units)
Braking is proportional to pedal depression. With the pedal • Hoist third wrap condition (for CE units)
not depressed and the swing brake control valve
disengaged, hydraulic pressure is applied to the brake, • Anti Two-Block alarm
overcoming spring pressure and releasing the brake. • Engine compartment protection program
Depressing the pedal actuates a swing power brake valve to
apply pressure to the brake assembly. This pressure aids the

RCL Emergency Override Switch (Non-CE RCL Emergency Override Switch and
Certified Cranes) Indicator (CE Certified Cranes)
WARNING WARNING
Loss of RCL Monitoring Hazard! Loss of RCL Monitoring Hazard!
The RCL Emergency Override switch is to be used in The RCL Emergency Override Switch is to be used in
emergency situations only. emergency situations only.
Do not operate the crane with the RCL overridden during Do not operate the crane with the RCL overridden during
normal operations. normal operations.
When the RCL is overridden always have a helper on the When the RCL is overridden, always have a helper on the
ground to signal you. ground to signal you.
The RCL system, when programmed accurately, will lockout The RCL system, when programmed accurately, will lockout
nearly every crane function—boom up/down, telescope nearly every crane function—boom up/down, telescope
extend/retract, hoist up and swing left/right—when a lift is extend/retract, hoist up and swing left/right—when a lift is
attempted at or above the crane's capacity or when a two- attempted at or above the crane's capacity or when a two-
block condition exists. Only the particular function(s) that block condition exists. Only the particular function(s) that
cause the existing lockout condition are blocked. Locking out cause the existing lockout condition are blocked. Locking out
these functions prevents the overload or two-block condition these functions prevents the overload or two-block condition
from worsening. from worsening.
The RCL emergency override switch (2) (Figure 3-17) is a The RCL emergency override switch is located inside a key-
key operated switch that is located inside the operator cab locked single-door enclosure (1) (Figure 3-18) that is
on the panel assembly behind the seat. When actuated attached to the outside rear of the operator's cab. The switch
(turned clockwise), the switch will override and prevent the is a two-position momentary rocker switch that, when
RCL from locking out craning functions (Third Wrap Limit and actuated, will override and prevent the RCL, for a period of
Anti Two-Block) should an overload condition occur. Turn the 30 minutes, from locking out craning functions (boom down,
key counterclockwise to bypass the Anti Two-Block Switch, telescope extend, third wrap limit and hoist up) should an
Telescope extend/retract, 3rd Wrap Indicator (hoist lowering overload condition occur.
limit) and Boom up/down.
The other RCL emergency override switch (19) (Figure 3-6)
Overriding the RCL with this switch should only be done in is a key operated switch that is located inside the operator
the case of an emergency or when servicing the boom. cab below the CCS screen, in front of the Emergency Stop
Switch. When actuated (turned clockwise), the switch will
A flashing light on the RCL display indicates the switch has
override and prevent the RCL from locking out craning
been activated.
functions (Third Wrap Limit and Anti Two-Block) should an
overload condition occur. Turn the key counterclockwise to
bypass the Anti Two-Block Switch, Telescope extend/retract,
1 3rd Wrap Indicator (hoist lowering limit) and Boom up/down.
Overriding the RCL with this switch should only be done in
the case of an emergency or when servicing the boom.
Upon activation, all craning function movements are reduced
to 15% of their normal maximum speeds.
The RCL override function is automatically cancelled after 30
2
minutes. The RCL override function can also be cancelled by
the operator by either pressing the RCL emergency override
switch a second time or by turning off the engine. However,
turning off crane functions does not disable the RCL
override.
NOTE: Before powering up crane, ensure that the RCL
7649-9A
Override Switch is in the Normal (not Override)
FIGURE 3-17 position to avoid an error code.

Strobe Light or Beacon (Optional) (Not

Shown)
The strobe light or beacon is on the right side of the
superstructure. It is on when the ignition switch is on.
1
Backup Alarm (Not Shown)
The backup alarm is an audio system used to warn
personnel outside the crane when the crane is backing up.
The alarm system is electrical and consists of the backup
alarm and its associated wiring. The alarm is connected to
the electrical wiring for the transmission reverse solenoids. It
is activated when the transmission shifter is in the reverse
position. The backup alarm is installed in the rear outrigger
box behind the grill plate.
Emergency Exit
7649-36
FIGURE 3-18
The windshield is considered the Emergency Exit. In an
emergency, push out on the windshield and escape through
RCL Internal Light Bar (Optional)
the opening.
The Rated Capacity Limiter (RCL) Internal Light Bar is
located on the upper left hand corner of the crane cab. The
RCL is an operational aid that warns a crane operator of
approaching overload conditions and other conditions that
3
could cause damage to equipment and personnel.

Appendix A: Crane Control System (CCS) Symbols and Icons
Symbol Description
3rd Wrap Warning
4-Wheel Drive
Auxiliary Hoist Status
Auxiliary Hoist Disabled
Auxiliary Hoist Enabled
Auxiliary Hoist Raise
Auxiliary Hoist Not In Use
Auxiliary Hoist Lower
Battery Voltage
Boom Lift Status
Boom No Load Chart
Bypass 1 Active
Bypass 2 Active
Bypass 3 Active
Bypass 1 Pressed
Bypass 2 Pressed

Symbol Description
Bypass 3 Pressed
Coolant Temp
Differential Lock
Engine Preheat
Engine Speed (RPM)
Engine Warning (Error)
Emergency Stop
Fuel Level
3
Hoist Limit Switch Shutdown
Hydraulic Oil Temp
Information Group
Jib Angle Difference
Jib Angle Too High
Jib Angle Too Low
Jib Load Too High
Jib No Load Chart
Load Too Low

Symbol Description
Low Brake Pressure
Low Steering Fluid Pressure
Main Hoist Status
Main Hoist Disabled
Main Hoist Enabled
Main Hoist Raise
Main Hoist Not In Use
Main Hoist Lower
Marker/Position/Side Light
Rear Wheels Not Centered
Oil Feed Filter Contaminated
Outrigger Button
Outrigger Front Left
Outrigger Front Right
Outrigger Group
Outrigger Rear Left
Outrigger Rear Right
Park Brake

Symbol Description
RCL Override
Status Light Bar Error
Swing Status
Swing Brake
Swing Group
SLI Early Warning
SLI Shutdown
Swing Brake
3
Telescope Status
Tools Group
Transmission Temperature Warning
Transmission Status
WRL Area Limit
WRL Height Limit
WRL Radius Limit
WRL Swing Angle Limit

THIS PAGE BLANK

RT530E-2 OPERATOR’S MANUAL SET-UP AND INSTALLATION PROCEDURES
SECTION 4
SET-UP AND INSTALLATION PROCEDURES
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Erecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Installing Cable On The Hoist . . . . . . . . . . . . . . . . 4-1 Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Setting The Offset . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Changing Boom Extension From Telescoping Type To
Dead-end Rigging/Wedge Sockets . . . . . . . . . . . . 4-5 Fixed Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Installing Wedge And Socket . . . . . . . . . . . . . . . . 4-5 Setting The Telescoping Extension Length . . . . . 4-14
Dead-end Rigging . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Erecting And Stowing The Boom Extension . . . . 4-7
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
GENERAL
2 2
This section provides procedures for installing the hoist
cable on the hoist drum, cable reeving, and erecting and
stowing the boom extension.
INSTALLING CABLE ON THE HOIST
CAUTION 3
If cable is wound from the storage drum, the reel should
be rotated in the same direction as the hoist. 1
NOTE: The cable should preferably be straightened before

4
installation on the hoist drum.
Install cable on the hoist drum in accordance with the
following procedure.
1. Position the cable over the boom nose sheave and route 7312
to the hoist drum. FIGURE 4-1
2. Position the hoist drum with the cable anchor slot on top. NOTE: If the wedge does not seat securely in the slot,
carefully tap (3) the top of the wedge with a mallet.
3. Insert the cable through the slot and position around the
anchor wedge (1) (Figure 4-1).
NOTE: The end of the cable should be even with the
bottom of the slot for the anchor wedge.
4. Position the anchor wedge in the drum slot; pull firmly on
the free end (2) of the cable to secure the wedge.
5. Slowly rotate the drum, ensuring the first layer of cable is
evenly wound onto the drum. 7196-a
6. Install the remainder of the cable, as applicable.

SET-UP AND INSTALLATION PROCEDURES RT530E-2 OPERATOR’S MANUAL
CABLE REEVING
NOTE: The type of cable (wire rope) available on this
crane is 35 x 7 (non-rotating).
Within the limits of the load and range charts and permissible
line pull, multi-part lines allow the operator to raise a greater
load than can be raised with a single part line. Various cable
reeving (part line) is possible with the boom nose and hook
block. This reeving should be accomplished by a qualified
rigger using standard rigging procedures (Figure 4-3).
In order to quick reeve the hook block without removing the
wedge socket on the end of the cable, see (Figure 4-2).
FIGURE 4-2

Upper Boom
Upper Boom Nose Sheaves
Nose Sheaves To Main Hoist
To Hoist
To Aux Hoist
Bottom Boom
Nose Sheaves
Aux. Nose
Boom Nose
Dead End
Bottom Boom
Nose Sheaves
Ball
Ball
Hookblock
Single Part Line Sheaves
4-Sheave Hookblock
Four Parts Line
3-Sheave Hookblock
Upper Boom
Nose Sheaves
To Main Hoist
To Aux Hoist
4
Bottom Boom
Nose Sheaves
Aux. Nose
Boom Nose
Dead End
Ball
Hookblock
Sheaves
Six Parts Line
3-Sheave Hookblock
FIGURE 4-3

Mast On Boom To Hoist

Extension
One Part Line

Using Fixed Boom Extension
6284
Ball
Upper Boom
Nose Sheaves
To Main Hoist
Bottom Boom
Nose Sheaves
Hookblock
Sheaves
Hookblock
Dead End
Seven Parts Line

6710-4
3-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 6755
responsible and should proceed in compliance with the
regulations in force. If there are any questions, contact your FIGURE 4-4
local Grove Distributor or Manitowoc Crane Care. When anchoring the socket to the boom, ensure the flat face
Do not mix components from different manufacturers. The of the socket is in position, as shown, toward the boom
selection, installation and use of a wedge socket assembly sections (Figure 4-4).
must be in accordance with the requirements of the wedge
socket manufacturer and the wire rope manufacturer upon Installing Wedge And Socket
whose wire rope the wedge socket assembly will be used. 1. Inspect the wedge and socket. Remove any rough
Manitowoc Crane Group specifies the size, type, class and edges and burrs.
line pulls for wire rope, predominately rotation resistant wire 2. The end of the wire rope should be seized using soft, or
rope, and rigging accessories such as overhaul balls and annealed wire or strand. If the end of the rope is welded,
hook blocks for use with each new crane that it the welded end should be cut off. Do not weld on size
manufactures. Other wire ropes and rigging accessories are 6X37 rope. This will allow the distortion of the rope
available from various vendors. Different wire rope strands, caused by the bend around the wedge, to
man uf ac ture rs ha ve differ ing re qu ire men ts fo r t he adjust themselves at the end of the line. Refer to
construction, handling, cutting, seizing, installation, SECTION 1 - INTRODUCTION in the Service Manual
termination, inspection and replacement of the wire ropes for wire rope procedures.
they produce. Their advice should be sought for each
specific type of wire rope a crane user intends to install on a 3. Make sure the live-end (Figure 4-5) of the rope is directly
mobile crane. in line with the ears of the socket and the direction of pull
When assembly is complete, raise the boom to a working
position with a load suspended to firmly seat the wedge and
to which the rope will be subjected. If the rope is loaded
into the socket incorrectly, under a load the rope will
bend as it leaves the socket, and the edge of the socket
4
rope into the socket before the crane is used operationally. will wear into the rope causing damage to the rope and
eventual failure.
.
CAUTION Wedge Socket
If the socket is not positioned with the flat face toward the
boom sections, structural damage will occur. Live
End Dead
Dead Live End is
End
End Entering
Wrong Side
20 x Cable Dia
Minimum
RIGHT WRONG
FIGURE 4-5

4. Insert the end of the wire rope into the socket, form a dead end. DO NOT CLAMP THE LIVE END. The U-bolt
loop in the rope, and route the rope back through the should bear against the dead end. The saddle of the clip
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.
NOTE: The use of swivels is not allowed in conjunction
5. Insert the wedge into the loop and pull the live-end of the with non-rotation resistant wire ropes
rope until the wedge and rope are snug inside the
Other sources for information with which crane users should
socket. It is recommended that the wedge be seated
be familiar and follow is provided by the American Society of
inside the socket to properly secure the wire rope by
Mechanical Engineers, American National Standard, ASME
using the crane’s hoist to first apply a light load to the
B30.5, latest revised. ASME (formerly ANSI) B30.5 applies
live-end.
to cableways, cranes, derricks, hoists, hooks, jacks, and
6. After final pin connections are made, increase the loads slings. It states, in section 5-1.7.3, “(c) Swaged,
gradually until the wedge is properly seated. compressed, or wedge socket fittings shall be applied as
recommended by the rope, crane or fitting manufacture.”
7. The wire rope and wedge must be properly secured
Wire ropes are addressed in ASME B30.5, section 5-1.7.2,
inside the socket before placing the crane into lifting
ROPES, it states, in pertinent part, “(a) The ropes shall be of
service. It is the wedge that secures the wire rope inside
a c onst ruction rec ommende d by the ro pe or crane
the socket. The dead-end treatment is used to restrain
manufacturer, or person qualified for that service.” Additional
the wedge from becoming dislodged from the socket
information is published by the Wire Rope Technical Board in
should the rope suddenly become unloaded due to the
the Wire Rope Users Manual, latest revised edition.
headache ball or hook block striking the ground, etc;
refer to Dead-end Rigging, page 4-6. Table 4-1
Dead-end Rigging Wire Rope Clip Torque Values

Clip Sizes Torque
Sketches A through F (Figure 4-6) illustrate various ANSI
Inches mm lb-ft Nm
approved methods for treating the dead-ends of wire ropes
1/8 3.18 4.5 6
which exit a wedge socket assembly. While use of the loop-
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
7/16 11.11 65 90
Of the methods shown below, Manitowoc prefers that
1/2 12.70 65 90
method A or F be used, i.e., clipping a short piece of wire
rope to the dead-end or using a commercially available 9/16 14.29 95 130
specialty clip or wedge. Typically, it is recommended that the 5/8 15.88 95 130
tail length of the dead-end should be a minimum of 6 rope 3/4 19.05 130 175
diameters but not less that 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
dead end by clamping a short extra piece of rope to the rope 1-3/8 38.68 360 490
1-1/2 38.10 360 490

Specialty Clip
Specialty Wedge
Wedge Socket
FIGURE 4-6
ERECTING AND STOWING THE BOOM

EXTENSION
General Warnings DANGER
Always secure the boom extension with a tag line (rope)
on the main boom before removing any connections. This
will prevent the extension from swinging around and
knocking you off the carrier or injuring other persons in the
DANGER swing range.
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection, The extension may swing out on its own accord when you
gloves and metatarsal boots. remove the last connection that held the extension at the
Boom angles are used to control speed at which side of the main boom.
extensions swing during erecting and stowage. Improper
boom angles will cause uncontrollable swing speeds of
You must therefore secure the extension before you begin
the erection procedure.
4
extension.
Secure the boom extension as follows:
NOTE: Tag line used in these procedures is to control the
• Attach a tag line (rope) at the front of the extension.
movement of the boom extension.
• Have a helper hold the tag line (rope) tight while you
are removing the last connection.
NOTE: If you are alone, secure the other end of the tag line
DANGER (rope) on the crane (e.g., on the steps of the
Before attempting to erect or stow the boom extension; access ladder or to the superstructure. Leave
read and strictly adhere to all danger decals installed on enough play in the tag line that it is tight only when
the boom/boom nose, boom extension, and stowage you swing the extension towards the main boom
brackets. head later in the procedure.
Securing the Boom Extension with Tag Line (Rope) Erecting

NOTE: A tag line attached to the tip of the extension is
used to control the movement of the boom
extension.
DANGER
To prevent serious injury or death, do not stand on
decking until extensions are secure.

1. Visually check to ensure all pins are installed. 6. Attach a length of rope to the boom extension tip
(Figure 4-8) to aid in swinging the boom extension into
2. Crane should be set up on outriggers using normal
place ahead of the boom nose.
setup procedures. Refer to Section 3 - OPERATING
CONTROLS and PROCEDURES.
a. Fully retract boom.
b. Lower boom to horizontal for erecting over the front
of the crane.
NOTE: The auxiliary boom nose (rooster sheave) does not
have to be removed. However, if reeved, the hoist
cable must be removed from the sheave.
3. Rig either the main hoist or optional auxiliary hoist cable
for single part line with nothing but the wedge socket on
the end of the cable. Refer to CABLE REEVING and
DEAD END RIGGING in this section.
4. Remove the retainer clips from the right side attachment
pins (6) (Figure 4-7) (Figure 4-10) stowed in the base of
the boom extension and remove the attachment pins
from the boom extension (2) (Figure 4-7) (Figure 4-10).
Insert the right side attachment pins through the boom 6717-4 Tag Line FIGURE 4-8
attachment and boom extension anchor fittings. Install
the retainer clips in the attachment pins. 7. Raise the boom to horizontal and extend the boom
approximately 51 to 64 cm (20 to 25”). Make certain that
the boom extension stowage lugs clear the guide pins
and ramp on the front (Figure 4-12) (Detail B) and rear
(Figure 4-12) (Detail A) stowage brackets.
2
DANGER
When erecting the boom extension, ensure that all
personnel and equipment are kept clear of the swing path.
6717-3 8. Slightly raise and/or lower the boom to help control the
boom extension. Using the rope attached to the tip of the
6 FIGURE 4-7 boom extension, manually swing the extension into
place ahead of the boom nose (Figure 4-9), engaging
5. Remove the retaining pin from the hitch pin that secures the attachment fittings with the anchor fittings on the left
the boom extension to the rear stowage bracket side of the boom nose.
(Figure 4-12) (Detail A). Remove the hitch pin, unlocking
the boom extension from the boom.

Boom Extension Boom Nose

CAUTION
Do not place blocking under the boom extension sheave
wheel. Damage to the sheave wheel may occur.
9. Install the top left side attachment pin and retainer clip
into the upper anchor and attachment fittings of the
boom nose (Figure 4-9).
10. Extend the boom extension alignment jack until the
lower left side boom nose and boom extension adapter
lugs are aligned.
11. Install the bottom left side attachment pin and retainer
clip into the lower anchor and attachment fittings of the
boom nose.
12. Connect RCL cables:
a. Remove cable from boom extension.
b. Remove dummy plug from junction box on the boom
6717-5
FIGURE 4-9 nose.
c. Install cable end connector from the boom
extension where dummy plug was removed
13. Release pressure on the boom extension alignment
DANGER jack.
Do not modify the attachment points to permit the
installation of the attachment pins. NOTE: The hoist cable must be routed over the mast
assembly and under the roller on the mast for all
configurations.
14. Reeve the hoist cable. Refer to Cable Reeving in this
section.

Detail A
1 Detail B
Item Description
1 Boom Extension Sheave
2 Boom Extension base
3 Main Boom Base Section
4 Upper Boom Nose Sheaves
7 5
5 Lower Boom Nose Sheaves 8 6
6 Attach Pins
7 Attach Pins
8 Mast Assembly
FIGURE 4-10

3
13
14
4
5
12
11
7
4
6717-2
8
10 9
15
FIGURE 4-11
Item Description Item Description

1 Boom Base Section 9 Alignment Jack
2 Inner Mid Section 10 Offset Pin
3 Outer Mid Section 11 Mast Assembly Stowage Pin
4 Fly Section 12 Mast Assembly
5 Upper Sheave Cable Retainer 13 Mast Assembly Cable Retainer
6 Left Side Attachment Pins 14 Right Side Attachment Pins
7 Boom Nose Dead End Lug 15 Jack Handle
8 Lower Sheave Cable Retainer

5 7
7 4
5 4
6
6
3
3
2
1
1
6035
OUT POSITION 6034
IN POSITION
DETAIL A
8 Item Description
12
1 Handle
10
2 Retainer Pin
3 Wear Pads
13
4 Clip Pin and Hitch Pin
5 Swingaway
10 6 Sliding Support and Ramp
7 Stowage Lug for Hitch Pin
8 Hanger Weld
9 Vertical Adjustment Bolt
11 10 Horizontal Adjustment Bolt
11 Lower Support Weld
12 Base Boom Section
6036
13 Swingaway
DETAIL B
FIGURE 4-12

Stowing 13. Using the rope attached to the tip of the boom extension,
manually swing the extension to the side of the boom.
1. With crane set up on outriggers, fully retract the boom
and swing to over-the-front. 14. Align the stowage lugs on the boom extension with the
guide pins and ramp on the stowage brackets and fully
2. Lower the boom to minimum elevation. retract the boom.
3. Remove the cable retainer pin from the boom extension 15. Install the hitch pin and clip pin securing the boom
tip and the mast assembly. Remove the hoist cable from extension to the rear stowage bracket (Figure 4-12)
the sheaves. Install the cable retainer pins. (Detail A).
4. Remove the mast assembly retainer pin and the pin 16. Remove the attachment pins and clip pins from the
securing the mast assembly in the upright position. Lay anchor and attachment fittings on the right side of the
the mast assembly over to the stowed position. Insert boom nose and stow them in the base of the boom
the pins securing the mast to the base section. extension. Stow left side attachment pins and clips in
5. Attach a length of rope to the boom extension tip. outside attachment fitting on swingaway.
6. Disconnect RCL cable: 17. On the rear stowage bracket, remove the pin securing
the sliding support in the “OUT” position. Push in on the
a. Remove connector from junction box on boom handle to push the swingaway against the rear of the
nose. boom and disengage the swingaway anchor fittings from
b. Install dummy plug in junction box. the boom nose attachment lugs. Install the retainer pin
securing the sliding support in the “IN” position.
c. Route cable to and attach to boom extension
18. Rig the boom nose and hoist cable as desired and
7. Raise the boom to horizontal. operate the crane using normal operating procedures.
8. Extend the boom approximately 20 to 25 in (51 to
64 cm). Make certain that the boom extension stowage
Setting The Offset
lugs will line up in front of the guide pins and ramp on the
stowage brackets when the boom extension is
positioned to the side of the boom. CAUTION
The mast assembly must be positioned on top of the base
9. Ensure the hitch pin and clip pin are removed from the
section before attempting to offset the swingaway to 30
rear stowage bracket (Figure 4-12) (Detail A).
degrees. Failure to do so can cause damage to the mast
10. Extend the boom extension alignment jack (Figure 4-11) and/or swingaway adapter.
until the bottom left side attachment pin is free. Remove
the bottom left side boom extension clip pin and
attachment pin.
1. Extend and set the outriggers. Swing the boom over to
the front of the crane.
4
11. Release pressure on the boom extension alignment 2. To set the offset from zero degrees (0°) to thirty degrees
jack. Completely retract the jack. (30°), perform the following:
12. Remove the top left side attachment pin and clip pin from
the upper anchor and attachment fittings of the boom CAUTION
nose.
Do not overload the swingaway or the attachment points
when lowering the boom.
a. Slowly lower the boom until the tip of the swingaway

DANGER is on the ground and the pressure on the offset pin is
When stowing the boom extension, ensure that all relieved.
personnel and equipment are kept clear of the swing path.
b. Remove the lock pin, two washers, and offset pin.
c. Slowly elevate and telescope the boom at the same
time until the offset shaft takes the full load of the
CAUTION swingaway.
Do not allow the boom extension to slam into the stowage
bracket when swinging into the stowed position. 3. To set the offset from thirty degrees (30°) to zero
degrees (0°), perform the following:

a. Slowly lower the boom until the tip of the swingaway 6. If not already reeved, reeve the hoist cable over the
is on the ground and the offset pin can be installed. mast and boom extension nose sheave. Install all cable
retainer pins.
b. Install the offset pin, two washers, and lock pin.
c. Raise the boom and operate as desired. Stowing
Changing Boom Extension From 1. Unreeve the boom extension nose.
Telescoping Type To Fixed Type 2. Position the boom to horizontal.
1. Erect the boom extension. 3. Remove the hitch pin and retainer pin securing the
telescoping section in the base.
2. Position the boom to horizontal.
4. Push the telescoping section into the base and secure
3. Disconnect the anti-two block cable connector from the with the retainer pin and hitch pin.
junction box.
5. Loop the anti-two block cable over the spool on the side
4. Remove the telescoping section hitch pin and retaining of the base section.
pin.
NOTE: The telescoping section weighs approximately COUNTERWEIGHTS
250 kg (551 lb).
5. Extend the telescoping section and attach an adequate
Fixed Counterweight Description
lifting device to support the telescoping section. Remove The counterweight is pinned to the rear of the turntable and
the stop bolts from the base section and remove the weighs approximately 3817 kg (8416 lb). For cranes without
telescoping section from the base. an auxiliary hoist, an additional 350.6 kg (773 lb)
NOTE: The pin-on boom extension nose weighs counterweight is bolted to the hoist mounting area in lieu of
approximately 60 kg (132 lb). the auxiliary hoist.
6. Using a adequate lifting device, position the pin-on Fixed Counterweight Removal
boom extension nose in the base section and secure
with the two pins and hitch pins.
7. Connect the anti-two block cable connector to the
junction box. DANGER
Setting The Telescoping Extension Length a falling counterweight.
Extending
1. Position the boom to over the front.
2. Lower the boom to horizontal. DANGER
3. Remove the loop of anti-two block cable from the spool Ensure the primary retainer pin assembly is properly
on the side of the base section and let the cable hang installed to secure the counterweight.
free.
NOTE: Use of a forklift to remove/install the fixed
4. Remove the hitch pin and retainer pin securing the
counterweight is not recommended.
telescoping section in the base.
NOTE: Refer to (Figure 4-13) for fabricated counterweight
5. Carefully pull the telescoping section from the base until
and refer to (Figure 4-14) for cast counterweight
the holes in the base and telescoping section line up.
configurations.
Install the retainer pin and hitch pin.

4
5
2 5
3
6830
FIGURE 4-13
Fabricated Counterweight 6830-2
5. Remove and cap hydraulic lines from auxiliary hoist (if

4
Item Description installed).
1 Counterweight NOTE: Attach an adequate lifting device to the

counterweight. NOTE: For cast counterweight
2 Primary Retainer Pin Assembly configurations (Figure 4-14), remove polyurethane
3 Leveling Capscrews plugs from the two upper threaded inserts (7)
before inserting eyebolts (two 1-1⁄4 X 7UNC
4 Turntable
eyebolts are needed.)
5 Grill (not on cast counterweight)
6. Ensure the four counterweight leveling capscrews (3)
1. Fully extend and set the outriggers. are set for maximum clearance with the turntable.
2. Rotate the superstructure so the counterweight is over 7. For cast counterweight; remove the redundant pin
the front of the carrier to gain additional clearance. assembly (6) prior to removing the primary retainer pin
Engaging the pin type turntable lock will aid alignment. assembly (2).
NOTE: The counterweight weighs approximately 3817 kg 8. Slowly raise counterweight until primary retainer pin
(8416 lb). assembly (2) can be removed by pushing and turning
the pin.
3. Lower and fully retract the boom.
9. Remove primary retainer pin assembly (2) from opposite
4. Shut down crane.
side.

10. Lower counterweight until attaching lugs are clear of the 12. Replace primary retainer pin assembly (2) in turntable
turntable. counterweight mounting lugs.
11. Back counterweight away from turntable until it is clear 13. Move counterweight far enough from crane to allow the
of crane. turntable/superstructure to clear during repositioning.
14. Rotate superstructure to the normal travel position.
7 2
Cast Counterweight 6
FIGURE 4-14
7251
Item Description
1 Counterweight
2 Primary Retainer Pin Assembly
3 Leveling Capscrews
4 Turntable
6 Redundant Pin Assembly
7 Threaded Insert

Fixed Counterweight Installation NOTE: Use of a forklift to remove/install the fixed

counterweight is not recommended.
1. Fully extend and set the outriggers.
5. Attach an adequate lifting device to the counterweight
2. Rotate the superstructure so the counterweight will be and lift the counterweight into place on the
over the front of the carrier to gain additional clearance. superstructure, aligning the mounting holes on the
3. Shut down crane. counterweight to the holes in the superstructure.
4. Remove and cap hydraulic lines from auxiliary hoist (if 6. Install the counterweight primary retainer pin assemblies
installed). (2) and secure them in place. Note: With cast
counterweight re-install the two redundant pin
assemblies (6).
CAUTION 7. Remove the lifting device from the counterweight.
When lifting/handling the counterweight, keep the chains/
straps vertical to minimize side pull on the lifting lugs. 8. Using the four counterweight leveling capscrews (3),
level the counterweight and eliminate any relative
NOTE: The counterweight (1) weighs approximately movement between the counterweight and turntable.
3817 kg (8416 lb). Maximum width of counterweight shall not exceed
6.0 mm (0.25 in) out of level with the turntable bearing
when measured from either counterweight outer edge.

THIS PAGE BLANK

RT530E-2 OPERATOR’S MANUAL LUBRICATION
SECTION 5
LUBRICATION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Steering and Suspension. . . . . . . . . . . . . . . . . . . . 5-6
Environmental Protection . . . . . . . . . . . . . . . . . . . 5-1 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . 5-1
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . 5-12
Arctic Conditions Below -18°C (0°F). . . . . . . . . . . 5-3
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Arctic Conditions Down To -40°C (-40°F) . . . . . . . 5-3
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Surface Protection For Cylinder Rods . . . . . . . . . 5-5
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . 5-5 Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
GENERAL • Always fill or add fluids with a funnel or a filling pump.
Following the designated lubrication procedures is important • Immediately clean up any spills.
in ensuring maximum crane lifetime and utilization. The
procedures and lubrication charts in this section include LUBRICATION INTERVALS
information on the types of lubricants used, the location of
The service intervals specified are for normal operation
the lubrication points, the frequency of lubrication, and other
where moderate temperature, humidity, and atmospheric
information.
conditions prevail. In areas of extreme conditions, the
service periods and lubrication specifications should be
ENVIRONMENTAL PROTECTION altered to meet existing conditions. For information on
Dispose of waste properly! Improperly disposing of waste extreme condition lubrication, contact your local Manitowoc
can threaten the environment. distributor or Manitowoc Crane Care.
Potentially harmful waste used in Manitowoc cranes includes

— but is not limited to — oil, fuel, grease, coolant, air CAUTION
conditioning refrigerant, filters, batteries, and cloths which
Chassis grease lubricants must not be applied with air
have come into contact with these environmentally harmful
pressure devices as this lubricant is used on sealed
substances.
fittings.
Handle and dispose of waste according to local, state, and
federal environmental regulations.
When filling and draining crane components, observe the
following:
CAUTION 5
The multipurpose grease installed during manufacture is
• Do not pour waste fluids onto the ground, down any of a lithium base. Use of a noncompatible grease could
drain, or into any source of water. result in damage to equipment.
• Always drain waste fluids into leak proof containers that
are clearly marked with what they contain.

LUBRICATION RT530E-2 OPERATOR’S MANUAL
Standard Lubricants down to -9°C (15°F). Refer to Table 5-1 for a list of the
recommended standard lubricants.
Standard lubricants are used on all Manitowoc cranes unless
the crane is ordered with a cold weather package. These
standard lubricants are effective in ambient temperatures
TABLE 5-1: Standard Lubricants
Recommended Lubricant
Lubricant/Fluid Grove Spec.
Type Grade Classification
Axle/Swing Box Gear Oil Century Unigear Semi-synthetic
6829012964 Texaco Multigear SS 80W-90
Chevron DELO
Tier 3 Engine Oil Exxon XD-3 CI-4
6829003483 15W-40
Conoco Fleet Supreme
Tier 4 Engine Oil Conoco Fleet Supreme EC CJ-4
6829104182 15W-40
Mobil Delvac 1300 Super
Hydraulic/Transmission Oil Kendall Hyken 052 Must Meet John
Exxon Torque Fluid 56 Deere Std. JDM
Esso Torque Fluid 56 10W-20 J20C
6829006444 BP-Eldoran UTH & Trak-Tran 9
BP- Blend- 7367
Exxon Mobil 424 10W-30
Hoist Gear Oil Mobil: 600XP 150 AGMA No. 4 EP
6829100213
Texaco: Meropa 150
Grease, Multipurpose Citgo Lithoplex MP# 2
Texaco Starplex Moly # 2
Phillips 66 Philube M
6829003477 NLGI 2
Mobil Mobilgrease XHP 222
Special
Chemtool Inc, Lube-A-Boom
Open Gear Lube 6829102971 Fuchs Ceplattyn 300 Spray NLGI 1-2
Antifreeze Coolant Old World Industries, Inc. Fleet
Charge SCA
6829101130 Mix 50/50
Caterpillar DEAC
Fleetguard Complete EG
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
Penray Pencool 3000
Diesel Exhaust Fluid Fleetguard StableGuardTM Urea ISO 22241-1
6829003476 32 Premix DIN V 70070
80019225 AdBlue®
TerraCair Ultrapure® DEF

Arctic Conditions Below -18°C (0°F) -29°C (-20°F) Package
In general, petroleum based fluids developed especially for • Battery heater

low temperature service may be used with satisfactory • Fuel line heater
results. However, certain fluids, such as halogenated
hydrocarbons, nitro hydrocarbons, and phosphate ester • Engine hood insulation
hydraulic fluids, might not be compatible with hydraulic • Fan clutch
system seals and wear bands. If you are in doubt about the
suitability of a specific fluid, check with your authorized • Radiator air shutters
distributor or Manitowoc Crane Care. • Air diverter
NOTE: All fluids and lubricants may be purchased by • Diesel fired cab heater
contacting Manitowoc Crane Care.
• Cold weather alternator
Regardless of temperature and oil viscosity, always use
suitable start-up procedures to ensure adequate lubrication • Fluids suitable to -29°C (-20°F)
during system warm-up.
- Arctic windshield washer fluid
Arctic Conditions Down To -40°C (-40°F) - Arctic fuel
-40°C (-40°F) Package
All Weather Package and Lubricants
• Coolant heater (to circulate warm coolant through
Engineering recommends the following lubricants for heaters and engine)
components for ambient temperatures to -40°F. Special
lubricants alone are not sufficient to operate at extreme low • Transmission heater
temperatures. We also recommend the use of appropriately
• Swivel heater
sized heaters for the hydraulic tank, engine oil pan, engine
jacket water and batteries. The operator needs to follow the • Battery heater
guide lines as stated in the operator manual. We assume
• Fuel line heater
that the customer has take steps for use of an appropriate
engine antifreeze coolant, have taken care of the fuel, fuel • Hydraulic reservoir heater
system and starting system. And has done whatever they
• Engine hood insulation
feel necessary to add insulation for under hood temperatures
and meet the engine manufacture's intake air temperature. • Fan clutch
Other lubricants may be used if they meet the specification of
• Radiator shutters
the lubricant that is requested. Please consult factory. It is
also recommended that the crane be equipped with the • Air diverter
following accessories:
• Diesel fired cab heater
• Cold weather alternator
• Super-capacitor starting system
• Fluids suitable to -40°C (-40°F):
- Arctic windshield washer fluid
- Arctic fuel
5

TABLE 5-2: All Weather Lubricants

Recommended Lubricant
Lubricant/Fluid Grove Spec.
Type Grade Classification
Axle/Swing Box Gear Oil Petro-Canada Traxon E Syn-
thetic
CITGO, Synthetic Gear Lube
6829014058 Eaton, Roadranger EP 75W-90
Mobil, Mobilube SCH
Shell, Spirax S
Sunoco Duragear EP
Tier 3 Engine Oil Petro-Canada Duron Synthetic
6829101560 5W-40 CI-4
Mobil Delvac 1
Tier 4 Engine Oil Citgo Citgard® Syndurance®
6829104412 Synthetic 5W-40 CJ-4
Mobil Delvac 1 ESP SW-40
Hydraulic/Transmission Oil Petro-Canada Duratran Syn- Must Meet John
thetic THF Deere Std. JDM
6829101559 J20C
Chevron All Weather THF
Texaco TDH Oil SS
Hoist Gear Oil Petro-Canada ENDURATEX AGMA No. 4 EP
6829103636 Synthetic EP 150
Mobil SHC629
Grease, Multipurpose Petro-Canada Precision Syn-
6829104275 thetic EP1 NLGI 2
Mobil, Mobilith SHC 220
Open Gear Lube Vultrex OGL Synthetic All Sea-
__ NLGI 1-2
son
Antifreeze Coolant Petro-Canada AFC
Old World Industries, Inc Fleet
Premix
6829104212 Charge SCA
60/40
Fleetguard Compleat EG Anti-
freeze/Coolant
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
Penray Pencool 3000
Windshield Washer fluid 90037773 Splash De-icer
Diesel Exhaust Fluid Fleetguard StableGuardTM Urea ISO 22241-1
6829003476 32 Premix DIN V 70070
80019225 AdBlue®
TerraCair Ultrapure® DEF

SURFACE PROTECTION FOR CYLINDER On plug type check points, the oil levels are to be at the
RODS bottom edge of the check port.
All grease fittings are SAE STANDARD unless otherwise
Steel cylinder rods include a thin layer of chrome plating on
indicated. Grease non-sealed fittings until grease is seen
their surfaces to protect them from corroding. However,
extruding from the fitting. One ounce(28 grams) of EP-MPG
chrome plating inherently has cracks in its structure which
equals one pump on a standard one pound (0.45 kg) grease
can allow moisture to corrode the underlying steel. At typical
gun.
ambient temperatures, hydraulic oil is too thick to penetrate
these cracks. Normal machine operating temperatures will Over lubrication on non-sealed fittings will not harm the
allow hydraulic oil to warm sufficiently to penetrate these fittings or components, but under lubrication will definitely
cracks and if machines are operated daily, protect the rods. lead to a shorter lifetime.
Machines that are stored, transported, or used in a corrosive
environment (high moisture, rain, snow, or coastline On sealed U-joints, care must be exercised to prevent
conditions) need to have the exposed rods protected more rupturing seals. Fill only until expansion of the seals first
frequently by applying a protectant. Unless the machine is becomes visible.
operated daily, exposed rod surfaces will corrode. Some Unless otherwise indicated, items not equipped with grease
cylinders will have rods exposed even when completely fittings, such as linkages, pins, levers, etc., should be
retracted. Assume all cylinders have exposed rods, as lubricated with oil once a week. Motor oil, applied sparingly,
corrosion on the end of the rod can ruin the cylinder. will provide the necessary lubrication and help prevent the
It is recommended that all exposed cylinder rods be formation of rust. An Anti-Seize compound may be used if
protected using Boeshield® T-9 Premium Metal Protectant. rust has not formed, otherwise the component must be
Manitowoc Crane Care has Boeshield® T-9 Premium Metal cleaned first.
Protectant available in 12 oz. cans that can be ordered Grease fittings that are worn and will not hold the grease
through the Parts Department. gun, or those that have a stuck check ball, must be replaced.
Cylinder operation and inclement weather will remove the Where wear pads are used, cycle the components and
Boeshield® protectant; therefore, inspect machines once a relubricate to ensure complete lubrication of the entire wear
week and reapply Boeshield® to unprotected rod. area.
WIRE ROPE LUBRICATION CraneLUBE

Wire rope is lubricated during manufacturing so that the Manitowoc highly recommends the use of CraneLUBE
strands, and individual wires in strands, may move as the l u b r i c a n ts t o i n c r e a s e y o u r c r a n e ’s r e l i a b i l i t y a n d
rope moves and bends. A wire rope cannot be lubricated performance. Contact your Manitowoc Distributor for
sufficiently during manufacture to last its entire life. information about the Manitowoc’s CraneLUBE lubrication
Therefore, new lubricant must be added periodically program.
throughout the life of a rope to replace factory lubricant which
is used or lost. For more detailed information concerning the Safety
lubrication and inspection of wire rope, refer to WIRE ROPE To lubricate many of the locations the engine will need to be
in Section 1- INTRODUCTION in the Service Manual. started. After positioning areas of the unit for lubrication the
engine must be turned off and the moved areas stable before
LUBRICATION POINTS approaching.
A regular frequency of lubrication must be established for all
lubrication points. Normally, this is based on component
operating time. The most efficient method of keeping track of
lube requirements is to maintain a job log indicating crane DANGER
5
usage. The log must use the engine hourmeter to ensure Crushing Hazard!
coverage of lube points that will receive attention based on
Movement of the superstructure and the boom may
their readings. Other lubrication requirements must be made
create a crushing and/or pinching hazard. Failure to
on a time basis, i.e. weekly, monthly, etc.
observe this warning could result in death or serious
All oil levels are to be checked with the crane parked on a injury.
level surface in transport position, and while the oil is cold,
unless otherwise specified.

Steering and Suspension

Lube Point Figure Approved Lube
Item Lube Interval Application
Description No. Lubricant Capacity
EP-MPG
Extreme
Until
Steer Cylinder Pressure
1 Figure 5-1 grease 500 hours or 3 months 8 grease fittings
Pivot Pins Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Upper and Lower Pressure
King Pins Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Fifth Wheel Pressure
Pivots Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Lockout Cylinder Pressure
Pivot Pins Multipurpose
extrudes
Grease
6829003477

8046-1
5
4 6818-2
1
2 1 3 6818-1
FIGURE 5-1


Axles
• Check level every
GL-5 500 hours or 3
Extended months Fill to bottom of hole
Axle Tech As seen in 20.8 l
6 Service Interval in housing on the
Differentials Figure 5-2 (44 pt) • Drain and fill every
Gear Lubricant steer cylinder side
6829012964 4000 hours or 2
years
NOTE: Lube level close enough to the hole to be seen or touched is not sufficient. It must be level with the hole.
When checking lube level, also check and clean housing breathers.
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.
CAUTION: If the makeup amount is substantially more than 0.23 liter (0.5 pint), check for leaks.
• Check level every
GL-5 500 hours or 3 Fill to the bottom of
Axle Tech
Extended months the level hole in the
Planetary Hubs As seen in 3.1 l
9 Service Interval housing with the fill
and Wheel Figure 5-2 (6.5pt) • Drain and fill every
Gear Lubricant plug and the oil level
Bearings 4000 hours or 2
6829012964 mark horizontal.
years
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.

8046-1
9 6818-3
5
6 6818-45
FIGURE 5-2


Drive Train
EO-15W/40 • Check level
Engine Oil • Check level every 10
through dipstick.
13a a. Engine SAE 15W-40 hours or daily
17.5 l • Fill engine oil
Crankcase Figure 5-3 T3 Engine - • Drain, fill and replace
(18.5 qt) through fill cap on
13b b. Filter 6829003483 filter every 500 hours
T4 Engine - engine valve
or 6 months
6829104182 cover.
• Check level every 10

hours or daily
• Drain and refill every
a. Transmission, 1000 hours or 6
14a HYDO Through fill pipe to
Torque 23.6 l months
Figure 5-3 Hydraulic Oil FULL mark on
Converter (25 qt) • Change transmission
14b 6829006444 dipstick
b. Filter filter after first 50 and
100 hours of service,
then every 500 hours
thereafter
NOTE:
• Check fluid level with engine running at 750 rpm idle and the oil at 82 to 93° C (180 to 200 ° F). Do not attempt an oil level check
with cold oil. To bring the oil temperature to this range, it is necessary to either work the crane or stall the converter. Converter
stall should be accomplished by engaging shift lever in forward high range with the brakes applied and then accelerating the
engine to half or three-quarter throttle. Hold the stall until the required converter temperature is reached and stabilized.
Do not operate the converter at stall condition for longer than 30 seconds at one time. Shift to neutral for 15 seconds and repeat
the procedure until the desired temperature is reached. Excessive temperature, i.e, 120° C (250° F) maximum will cause damage
to transmission clutches, fluid, converter and seals.
• Drain and fill with the oil at 65 to 93° C (150 to 200° F).
• Transmission filters are located on the outside left hand frame in the area of the hydraulic oil cooler.
• To add fluid:
a. Fill to FULL mark on dipstick
b. Run engine at 750 rpm to prime torque converter and lines
c. Check oil level with engine running at 750 rpm and oil at 82 to 93° C (180 to 200° F). Add oil to bring oil level to
FULL mark on dipstick.
AFC 50/50 • Check coolant level
50/50 Blended every 10 hours or
Fully daily
Engine Cooling Formulated
Antifreeze 28.4 l • Check SCA levels
15 System and SCA Figure 5-3 See Service Manual
Coolant (30 qt) every 500 hours
Levels
6829101130 • Check coolant for
SCA contamination every
6829012858 1000 hours
Change strainer screen

after first 100 hours and Close shutoff valves.
Coolant Strainer
16 Figure 5-3 --- --- every 2000 hours or 12 Unscrew hex plug to
(Cab Heater)
months intervals clean filter.
thereafter.

14b 8054
Dipstick 13a 8542
16 6813-7
8046-1
Opposite Side
13b 6818-37
8048
15 8045
14a
FIGURE 5-3


Drive Train (continued)
EP-MPG
Extreme
Until
Driveline - Slip Pressure
Joints Multipurpose
extrudes
Grease
6829003477
• Replace/Clean filter
element when
indicator shows red
(25” H20). Remove panel
52 Air Cleaner Filter Figure 5-4 --- --- • View indicator behind ladder to
through grill from rear access air filter.
of crane.
• Refer to Service
Manual
• Change filter every • Fuel filter is
a. Fuel Filter 500 hours or 6 located on the
53a months. intake manifold of
Figure 5-4 --- --- engine.
b. Water • Drain water trap
53b
Separator every 10 hours or • Strainer is located
daily. near battery box.

Oil Cap Access
53a 14b 8542 52 8527
8046-1
Opposite Side
5
53b 8052
17 6818-8
17 6818-43
FIGURE 5-4


Outriggers
EP-MPG
Extreme
Brush lubricant on
Outrigger Beams Pressure
18 Figure 5-5 --- 50 hours or 1 week bottom of outrigger
(Outside) Multipurpose
beams
Grease
6829003477
EP-MPG Brush lubricant on
Extreme OD of jack cylinder
Jack Cylinder Pressure barrel and wear
19 Figure 5-5 --- 50 hours or 1 week
Support Tubes Multipurpose band before
Grease installing jack
6829003477 cylinders
EP-MPG Brush lubricant on
Extreme OD of jack cylinder
Jack Cylinder Pressure support tubes (4)
51 Figure 5-5 --- 50 hours or 1 week
Barrels Multipurpose places before
Grease installing jack
6829003477 cylinders
Brush lubricant on
EP-MPG
inside bottom of
Extreme
outrigger beams
Outrigger Beams Pressure
54 Figure 5-5 --- 50 hours or 1 week where beam
(Inside) Multipurpose
extension cylinder
Grease
guide supports
6829003477
travel

8046-1
18
19
51
54
7961
6818-9
5
FIGURE 5-5


Turntable
• Check and fill every
GL-5 50 hours
Extended Use dipstick. If no
Turntable Gear 4.0 l • Drain and fill after
20 Figure 5-6 Service Interval dipstick, fill to top of
Box (4.25 qt) first 250 hours and
Gear Lubricant case.
6829012964 every 500 hours or
12 months thereafter.
EP-OGL
Turntable Gear Open Gear Coat all
21 Figure 5-6 500 hours or 6 months Spray on
and Drive Pinion Lubricant teeth
6829102971
Until
EP-MPG
grease
Extreme
extrudes 2 grease fittings at
Turntable Pressure
22 Figure 5-6 the whole 500 hours or 6 months the front of the
Bearing Multipurpose
circumfer- turntable
Grease
ence of the
6829003477
bearing
NOTE: Rotate the turntable 90° and apply grease to fittings. Continue rotating 90° and grease the fittings until the whole
bearing is greased.

20
22 6818-11
6818-10
Dipstick
8046-1
21 6818-44
FIGURE 5-6


Boom
EP-MPG
Extreme Pressure Until
Upper Lift
25 Figure 5-7 Multipurpose grease 500 hours or 3 months 1 grease fittings
Cylinder Pin Grease extrudes
6829003477
EP-MPG Extreme
Pressure Until
Hook Block
29 Figure 5-7 Multipurpose grease 250 hours or 3 months 1 grease fitting
Swivel Bearing Grease extrudes
6829003477
EP-MPG Extreme 4 grease fittings - 35
Pressure Until
Hook Block Tons
30 Figure 5-7 Multipurpose grease 250 hours or 3 months
Sheaves Grease
3 grease fittings - 35
extrudes
6829003477 Tons
EP-MPG Extreme 2 places by brush
Telescope Pressure
Thoroughly Every boom teardown Extend boom for
31 Cylinder Wear Figure 5-7 Multipurpose
Grease coat or 125 hours/3 months access through
Pads
6829003477 holes
EP-MPG Extreme Thoroughly

Pressure coat all 12 places by brush;
32 Side Wear Pads Figure 5-7 Multipurpose areas the 250 hours or 3 months with boom in
Grease wear pad extended position
6829003477 moves on
EP-MPG Extreme Thoroughly 6 places by brush;

Boom Section Pressure coat all with boom in
33 Upper Wear Figure 5-7 Multipurpose areas the 50 hours or 1 week extended position
Pads Grease wear pad through access
6829003477 moves on holes
EP-MPG Extreme Thoroughly

Boom Section Pressure coat all 3 places by brush;
34 Lower Wear Figure 5-7 Multipurpose areas the 50 hours or 1 week with boom in
Pads Grease wear pad extended position
6829003477 moves on
EP-MPG Extreme 3 grease fittings
Pressure Until
Extend Cable Extend boom for
35 Figure 5-7 Multipurpose grease 250 hours or 3 months
Sheaves Grease access through
extrudes
6829003477 holes
EP-MPG Extreme
Pressure Until
Retract Cable
36 Figure 5-7 Multipurpose grease 250 hours or 3 months 4 grease fittings
Sheaves Grease extrudes
6829003477
NOTE: Lubricate items more frequently than interval indicated in table if environmental conditions and/or operating
conditions necessitate.

33 33
32
32
34
34
34
34
34
35 31
36 7181-1
7181-2
8046-1
30
6818-21
29
5
25 6818-42
6818-13
6818-26
31
FIGURE 5-7


Boom (continued)
EP-MPG
Extreme
Until
Pressure
37 Boom Pivot Shaft Figure 5-8 grease 250 hours or 3 months 2 grease fittings
Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Boom Extension Pressure
38 Figure 5-8 grease 250 hours or 3 months 1 grease fitting
Sheave Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Boom Extension Pressure
Roller Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Upper Boom Pressure
Nose Sheave Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Lower Boom Pressure
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Auxiliary Boom Pressure
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Pressure
43 Mast Sheave Figure 5-8 grease 500 hours or 12 months 1 grease fitting
Multipurpose
extrudes
Grease
6829003477

40
41
42
37 6818-17 6818-41
8046-1
38
39
43
6818-31
6818-30
FIGURE 5-8


Hoist
AGMA • Check and fill every
Extreme 50 hours or weekly Oil level must be
5.2 l
45 Main Hoist Figure 5-9 Pressure Gear • Drain and fill every visible in the sight
(5.5 qt)
Lubricant 1000 hours or 12 glass
6829100213 months
AGMA • Check and fill every
Extreme 50 hours or weekly Oil level must be
5.2 l
46 Auxiliary Hoist Figure 5-9 Pressure Gear • Drain and fill every visible in the sight
(5.5 qt)
Lubricant 1000 hours or 12 glass
6829100213 months
NOTE: Line up the Fill/Drain Plug with the upper cutout hole (A). Let hoist sit idle for 20 minutes for an accurate reading.
Ensure hoist is level and oil temperature is 21°C ±11°C (70°F ±20°F). If oil level is not visible in sight glass, the
hoist may be under filled. Oil escaping from vent plug is an indication the hoist may be over filled. If hoist is over
filled, move the Fill/Drain Plug to the lower cutout hole (B) and drain until oil level falls within the sight glass.
EP-MPG
Extreme
Cable Follower Pressure Thoroughly
47 Figure 5-9 250 hours or 3 months Spray on
(Arms) Multipurpose coat
Grease
6829003477
NOTE: Lubricate more frequently than interval indicated in table if environmental conditions and/or operating conditions
necessitate.

8046-1
B 45 A 47 46 47
5
6818-17
FIGURE 5-9

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Hydraulic
• Use sight gauge
on side of tank,
with boom down
HYDO and all outrigger
397.4 l Check fluid level every
48 Hydraulic Tank Figure 5-10 Hydraulic Oil cylinders
(105 gal) 10 hours or daily.
6829006444 retracted.
• Drain and refill as
necessary
NOTE: Environmental and other conditions can dramatically affect the condition of hydraulic oil and filters. Therefore,
specific intervals for servicing/changing hydraulic oil, filters and hydraulic tank breathers cannot be set. However,
it is imperative for the continued satisfactory performance of Grove cranes that inspections be performed on the
basis of how and where each crane is used. Air borne and ingested contaminants can significantly reduce the life
of oil and the condition of hydraulic oil filters and tank breathers.
• Under normal operating conditions, it is recommended that hydraulic oil, filters and breathers be inspected
and oils sampled at least every 3 to 6 months and more frequently for severe operating conditions. The
inspections should be for air borne and/or ingested particles and water that deteriorate and contaminate the
oil (e.g., oil appears “milky” or no longer has a transparent clear to amber color). The return filter by-pass
indicator should be observed daily to determine if the contaminants content may be high. If the indicator
reaches the red zone or indicates a by-pass condition, the hydraulic oil must be sampled. The hydraulic tank
breather should also be inspected to assure that it is not restricting air flow into and out of the reservoir.
• To inspect hydraulic oil, fill a small glass container with a sample of reservoir oil and another glass container
with fresh oil. Let the samples stand, undisturbed, for one to two hours and then compare the samples. If the
reservoir oil is heavily contaminated with water the sample will appear "milky" with only a small layer of
transparent oil on top. If the "milky” appearance was due to air foaming, it will dissipate and the oil should
closely match the fresh oil. Should you have any questions, please contact your local authorized Manitowoc
distributor.
• The hydraulic oil shall meet of exceed ISO #4406 class 17/14 cleanliness level.
HYDO
Change filter when the
49 Hydraulic Filter Figure 5-10 Hydraulic Oil --- ---
indicator is red
6829006444

8046-1
49
48 Sight
Gauge
6818-19
8055
5
FIGURE 5-10

THIS PAGE BLANK

RT530E-2 OPERATOR’S MANUAL MAINTENANCE CHECKLIST
SECTION 6
MAINTENANCE CHECKLIST
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Daily or 10 Hour Check List . . . . . . . . . . . . . . . . . . 6-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Weekly or 50 Hour Check List . . . . . . . . . . . . . . . . 6-2
GENERAL INSTRUCTIONS
This section contains a list of daily inspection and Refer to your Service Manual for specific maintenance and
maintenance checks. Performing the checks will help adjustment procedures.
maintain the safety, dependability, and productivity designed
Refer to Section 5 - Lubrication (in this Operator Manual) for
into your crane.
lubrication intervals, types of fluids and lube point locations.
Refer to your Inspection and Lubrication Service Log for
further requirements.
Daily or 10 Hour Check List
1 Operator Manual: Is item properly installed on machine?

2 Signal and Running Lights and Horn: Check for cracked or broken glass. Check for proper working order
3 Backup Alarm: Check for proper operation while operating machine
4 Gauges and Instruments: Check for proper working order. Check for proper reading while operating engine;
Check for proper operation while operating machine
5 Brakes (Swing, Foot and Parking): Check for proper working order. Check for proper operation while operating
machine
6 Boom Angle Indicator: Check for proper operation while operating machine
7 Rated Capacity Limiter: Check for proper operation while operating machine. Check connectors and wiring for
proper alignment and insulation
8 Antitwo-Block (A2B) Electrical and Hydraulic: Check for proper operation while operating machine. Check
connectors and wiring for proper alignment and insulation
9 Brakes and Air System (if equipped): Check for proper working order. Check for proper operation while
operating machine. Drain moisture
10 Tires: Check for proper inflation/pressure. Check for excessive wear. Check for excess dirt, grease or foreign
matter
11 Hydraulic Tank: Check for proper service/level. Check for excess dirt, grease, or foreign matter
12 Hydraulic Oil Filter: Check for proper service/level
13 Wire Rope: Check for damaged, frayed, or broken strands.
14 Hoists: Is item properly installed on machine? Check for excess dirt, grease, or foreign matter. Check for proper
operation while operating machine
15 Boom and Attachments: Is item properly installed on machine? Check for excess dirt, grease, or foreign matter;
Check for proper operation while operating machine
16 Engine: Check for proper service/level. Check for excess dirt, grease, or foreign matter
17 Transmission/Torque Converter: Check for proper service/level
18 Cooling System: Check for proper service/level. Check for cracks or leaks 6
MAINTENANCE CHECKLIST RT530E-2 OPERATOR’S MANUAL
19 Fuel/Water Separator: Drain moisture

20 Air Cleaner: Check for proper service/level. Check for cracks or leaks
21 Hook Block and Headache Ball Safety Latch: Check for proper working order. Check for cracks and leaks;
Check for excessive wear
22 Lock-out Cylinder and Swing Potentiometer: Check for proper operation while operating machine. Check for
proper adjustment
Weekly or 50 Hour Check List
1 Sheaves: Check for proper operation, excessive wear, and damage.

RT530E-2 OPERATOR’S MANUAL
Alphabetical Index
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Cab Overhead Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Control Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Crane Control System (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Dead-end Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Erecting And Stowing The Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Foot Pedal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Installing Cable On The Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Miscellaneous Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Model Specific Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Noise/Vibration Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Operator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Overload Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Parking and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Pile Driving and Extracting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Rated Capacity Limiter (RCL) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Surface Protection For Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Temperature Effects on Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Transporting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
GROVE APL 1
OPERATOR’S MANUAL RT530E-2
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APL 2

Rt530e-2 t4f Ccs Om Ctrl583-00

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Grove RT530 I

This Manual is divided into the following sections: 2

The original language of this publication is English.

See back of this manual for Alphabetical Index

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

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

Diesel Exhaust Fluid (Tier 4 Engines—2014 and Later Only) . . . . . . . . . . . . . . . . . 3-7

Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

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

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

GENERAL NOISE/VIBRATION TEST RESULTS

GROVE Published 6-10-2015, Control # 583-00 1-1

New Owners Gear Ratios

Capacities Swing Gearbox

1-2 Published 6-10-2015, Control # 583-00

Hydraulic Pumps Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

GROVE Published 6-10-2015, Control # 583-00 1-3

SERIAL NUMBER LOCATION

Frame - Left Front

Inside Cab - Lower Right FIGURE 1-2

1-4 Published 6-10-2015, Control # 583-00

Left Side View of Crane FIGURE 1-3

Item Description Item Description

GROVE Published 6-10-2015, Control # 583-00 1-5

Right Side View of Crane

FIGURE 1-3 continued

1-6 Published 6-10-2015, Control # 583-00

FIGURE 1-0 continued

GROVE Published 6-10-2015, Control # 583-00 1-7

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1-8 Published 6-10-2015, Control # 583-00

GROVE Published 6-10-2015, Control # 583-00 2-1

2-2 Published 6-10-2015, Control # 583-00

An untrained operator subjects himself and others to death

GROVE Published 6-10-2015, Control # 583-00 2-3

2-4 Published 6-10-2015, Control # 583-00

GROVE Published 6-10-2015, Control # 583-00 2-5

outriggers must also be pinned when operating from the mid-

KEEP THE BOOM SHORT. Swinging loads with a long line

2-6 Published 6-10-2015, Control # 583-00

Table 2-1 Beaufort Wind Scale

GROVE Published 6-10-2015, Control # 583-00 2-7

2-8 Published 6-10-2015, Control # 583-00

GROVE Published 6-10-2015, Control # 583-00 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

2-10 Published 6-10-2015, Control # 583-00

GROVE Published 6-10-2015, Control # 583-00 2-11

2-12 Published 6-10-2015, Control # 583-00

GROVE Published 6-10-2015, Control # 583-00 2-13

2-14 Published 6-10-2015, Control # 583-00

WARNING • In standing ropes, more than three (3) breaks in one

GROVE Published 6-10-2015, Control # 583-00 2-15

- Wire ropes are damaged by knots. Wire rope with Sheaves

2-16 Published 6-10-2015, Control # 583-00

GROVE Published 6-10-2015, Control # 583-00 2-17

Stunt driving and horse-play are strictly prohibited. Never

2-18 Published 6-10-2015, Control # 583-00

WORK PRACTICES or walking/working surfaces could cause a slipping accident.

GROVE Published 6-10-2015, Control # 583-00 2-19

Sparks from the crane’s electrical system and/or engine