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Manitowoc Grove TMS800E13, Operator'S Manual

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TMS800E13 OPERATOR MANUAL

TABLE OF CONTENTS

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See end of this Manual for Alphabetical Index

SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction

General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
New Owner  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator’s Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operational Aids  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Rated Capacity Limiter (RCL) Systems (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . 2-4
Anti-Two-Blocking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Work Area Definition System (WADS) (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

Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Electrical Contact  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Special Operating Conditions and Equipment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Lubrication  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Tires  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Sheaves  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Transporting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Travel Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Personal Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Job Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Lifting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Hand Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Parking and Securing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Cold Weather Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Temperature Effects on Hook Blocks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Reference Only

Summary of Contents for Grove TMS800E13

Page 1: ...onnel You read understand and follow the safety and operating recommendations contained in the crane manufacturer s manuals and load charts your employer s work rules and applicable government regulations You are sure that all safety signs guards and other safety features are in place and in proper condition The Operator Manual and Load Chart are in the holder provided on crane DANGER 2014 Manitow...

Page 2: ...SECTION CONTENTS Crane Warm up Procedures 1 Engine 1 Transmission 1 Hoist 1 Swing Drive and Turntable Bearing 1 Axles 2 Hydraulic Oil System 2 R e f e r e n c e O n l y ...

Page 3: ...king brake and apply the service brake 2 Shift the transmission into the highest gear and increase the engine RPM to 1500 for 15 seconds then allow the engine RPM to return to idle 3 Repeat Step 2 until the temperature of the transmission sump reaches normal operating temperature Alternate Warm up Procedures for Rough Terrain RT Truck Mount TM TMS and Industrial Cranes 1 Setup the crane on outrigg...

Page 4: ...m Operating Limits and Warm up Procedures From 4 C to 10 C 40 F to 15 F Crane operation without a load is allowed with medium engine RPM and medium function speed joystick position until the fluid reaches at least 10 C 50 F It is then recommended that all crane functions be cycled to remove cold fluid from all components and cylinders of the hydraulic system If there is any unusual sound coming fr...

Page 5: ...Operator Manual Grove TMS800E13 R e f e r e n c e O n l y ...

Page 6: ...R e f e r e n c e O n l y ...

Page 7: ...er when ordering parts or communicating service problems with your distributor or the factory 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 c...

Page 8: ...e 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 R e f e r e n c e O n l y ...

Page 9: ...es 2 6 Lifting Operations 2 7 Counterweight 2 8 Outrigger Lift Off 2 8 Multiple Crane Lifts 2 8 Electrocution Hazard 2 9 Set Up and Operation 2 10 Electrocution Hazard Devices 2 10 Electrical Contact 2 11 Special Operating Conditions and Equipment 2 11 Personnel Handling 2 11 Environmental Protection 2 12 Maintenance 2 13 Service and Repairs 2 13 Lubrication 2 14 Tires 2 14 Wire Rope 2 14 Sheaves ...

Page 10: ...gine Operation 3 42 General Crane Operation 3 44 Using Your Load Chart 3 45 Crane Functions 3 46 Operational Aids 3 52 Crane Travel Operation 3 53 Clutch Operation 3 54 Shifting Gears 3 54 Differential Control Switches 3 57 Traveling with Jib and or Inserts Erected 3 57 Rear Tandem Inter Axle Cross Axle Locks 3 58 Service Parking Brakes 3 58 Engine Braking 3 59 Trailing Boom Optional 3 59 Travel C...

Page 11: ...Traveling with Manually Offsettable Jib and or Inserts Erected 4 32 Auxiliary Single Sheave Boom Nose Additional Equipment 4 32 Identification 4 32 Installing Removing Auxiliary Single Sheave Boom Nose 4 32 Removing the Auxiliary Single Sheave Boom Nose 4 33 Rigging the Auxiliary Single Sheave Boom Nose 4 33 Rigging in Transport Position 4 33 Rigging in Working Position 4 34 Attaching and Removing...

Page 12: ...TABLE OF CONTENTS TMS800E13 OPERATOR MANUAL 4 Instructions 6 1 Alphabetical Index APL 1 R e f e r e n c e O n l y ...

Page 13: ...s and routine maintenance procedures are supplied in a separate manual with each crane and should be referred to for detailed information NOTE Throughout this manual reference is made to left right front and rear when describing locations These reference locations are to be considered as those viewed from the operator s seat with the superstructure facing forward over the front of the carrier fram...

Page 14: ... with Manitowoc Crane Care so we have the ability to contact you if the need arises Go to www manitowoccranes com MCG_CARE Includes EN changeOfOwnership cfm and complete the form 6561 3 FIGURE 1 1 1 5 2 3 4 5 1 Rear View Item Description 1 Rear View Mirror 2 Crane Cab 3 Counterweight 4 Outrigger Float 5 Outrigger Jack Cylinder R e f e r e n c e O n l y ...

Page 15: ...TMS800E13 OPERATOR MANUAL INTRODUCTION 1 Published 02 06 2014 Control 495 00 17 7 16 14 12 11 10 9 27 25 26 24 6 7 8 9 12 11 13 9 20 19 18 FIGURE1 1continued 9 14 19 9 Left Side View 28 R e f e r e n c e O n l y ...

Page 16: ...r Stabilizer Cylinder 10 Removable Counterweights 11 Auxiliary Hoist 12 Main Hoist 13 Boom Pivot 14 Superstructure Cab 15 Lift Cylinder 16 Exhaust System 17 Boom Nose Sheaves Item Description 18 Auxiliary Boom Nose 19 Carrier Cab 20 Center Front Stabilizer 21 Front Axles 22 Outrigger Beam 23 Outrigger 24 Hydraulic Oil Cooler 25 Rear Axles 26 Fuel Tank 27 Outrigger Float 28 Carrier Outrigger Contro...

Page 17: ...ves 2 16 Batteries 2 16 Engine 2 16 Transporting the Crane 2 17 Travel Operation 2 17 Work Practices 2 18 Personal Considerations 2 18 Crane Access 2 18 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...

Page 18: ...ealer must be immediately advised of the incident and consulted on necessary inspections and 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 authorized by you...

Page 19: ...t instructions and warnings and must be read prior to any operational or maintenance function Refer to the Parts Manual for this crane for the locations of all safety decals You must be familiar with the regulations and standards governing cranes and their operation Work practice requirements may vary slightly between government regulations industry standards and employer policies so a thorough kn...

Page 20: ...hen an Anti Two Blocking Device Two Blocking Damage Prevention Device or Two Block Warning Device is inoperative or malfunctioning the designated person responsible for supervising the lifting operations shall establish procedures such as assigning an additional signal person to furnish equivalent protection This does not apply when lifting personnel in load line supported personnel platforms Pers...

Page 21: ...nt factor in preventing this condition An Anti Two Block System is intended to assist the operator in preventing dangerous two block conditions It is not a replacement for operator awareness and competence Never interfere with the proper functioning of operational aids or warning devices Work Area Definition System WADS If Equipped If your crane is equipped with a WADS you must read and understand...

Page 22: ...ber capacities outrigger beams and jack cylinders plus center front stabilizer if equipped must be properly extended and set to provide precise leveling of the crane Tires must be clear of the ground before lifting on outriggers KEEP THE BOOM SHORT Swinging loads with a long line can create an unstable condition and possible structural failure of the boom Load Charts Load Charts represent the abso...

Page 23: ...ity by checking the Load Chart against the weight of the load Then lift the load slightly at first to ensure stability before proceeding with the lift Be sure the load is properly rigged and attached Always determine the weight of the load before you attempt to lift it and remember that all rigging slings etc and lifting devices hook block boom extension etc must be considered part of the load Mea...

Page 24: ...f the equipment without the manufacturer s written approval 29CFR 1926 1434 Outrigger Lift Off Regarding lifting of an outrigger pad during craning activities be advised that the rated loads for these cranes as indicated on the crane s Load Chart do not exceed 85 of the tipping load on outriggers as determined by SAE J765 OCT90 Cranes Stability Test Code An outrigger pad may lift off the ground du...

Page 25: ... grounded before performing any work If contact is ever accidentally made with a power line and any part of this crane its rigging or load never touch the crane or even approach or come near the crane Electrocution can occur even without direct contact with the crane Crane operation is dangerous when close to an energized electrical power source Exercise extreme caution and prudent judgement Opera...

Page 26: ...te before traveling under power lines Rider poles should be erected on each side of a crossing to assure sufficient clearance is maintained United States OSHA regulations require a flagman when operating in close proximity to energized power lines Appoint a reliable and qualified signal person equipped with a loud signal whistle or horn and voice communication equipment to warn the operator when a...

Page 27: ... until the power has been turned off Only as a last resort should an operator attempt to leave the crane upon contacting a power source If it is absolutely necessary to leave the operator s station jump completely clear of the crane Do not step off Hop away with both feet together Do not walk or run Following any contact with an energized electrical source the Manitowoc distributor must be immedia...

Page 28: ...of personnel platform lifts The crane is in proper working order The crane must be equipped with a boom angle indicator that is visible to the crane operator The crane s Load Chart is affixed at the operator s station and readily accessible to the operator The total weight of the loaded personnel platform and related rigging shall not exceed 50 percent of the rated capacity for the radius and conf...

Page 29: ...and Repairs Service and repairs to the crane must only be performed by a qualified person All service and repairs must be performed in accordance with manufacturer s recommendations this manual and the service manual for this machine If there is any question regarding maintenance procedures or specifications contact your Manitowoc distributor for assistance Qualified person is defined as one who b...

Page 30: ...he following precautions must be taken when servicing the hydraulic system Follow the manufacturer s recommendations when adding oil to the system Mixing the wrong fluids could destroy seals causing component failure Be certain all lines components and fittings are tight before resuming operation Tires Inspect the tires for nicks cuts embedded material and abnormal wear Ensure all lug nuts are pro...

Page 31: ...odically Refer to the Service Manual for more information In the U S A regular inspections of the wire rope and keeping of permanent records signed by a qualified person are required by OSHA for almost every wire rope application The purpose of the inspection is to determine whether or not a wire rope may continue to be safely used on the application Inspection criteria including number and locati...

Page 32: ...ed that a retirement criteria should be established based upon the user s experience and the demands of his application Batteries Battery electrolyte must not be allowed to contact the skin or eyes If this occurs flush the contacted area with water and consult a doctor immediately When checking and maintaining batteries exercise the following procedures and precautions Wear safety glasses when ser...

Page 33: ... restrictions in the Load Chart for pick and carry operations RT and Shuttlelift cranes are manufactured with no axle suspension system Traveling at high speeds especially on rough ground may create a bouncing affect that can result in loss of control If bouncing occurs reduce travel speed Death or serious injury could result from being crushed by revolving tires Stunt driving and horse play are s...

Page 34: ...an might slip off a control pedal during operation Do not allow ground personnel to store their personal belongings clothing lunch boxes water coolers and the like on the crane This practice will prevent ground personnel from being crushed or electrocuted when they attempt to access personal belongings stored on the crane Job Preparation Before crane use Barricade the entire area where the crane i...

Page 35: ...ion you must post a look out or signal person before moving the crane or making a lift Sound the horn to warn personnel Operate the crane only from the operator s seat Do not reach in a window or door to operate any controls Operate the crane slowly and cautiously looking carefully in the direction of movement A good practice is to make a dry run without a load before making the first lift Become ...

Page 36: ...al setup may have been checked situations do change Never swing or lower the boom into the carrier cab if applicable Never push or pull loads with the crane s boom never drag a load Do not subject crane to side loading A side load can tip the crane or cause it to fail structurally If the boom should contact an object stop immediately and inspect the boom Remove the crane from service if the boom i...

Page 37: ...GROVE 2 21 TMS800E13 OPERATOR MANUAL SAFETY INFORMATION 2 Published 02 06 2014 Control 495 00 R e f e r e n c e O n l y ...

Page 38: ...owed values 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 In high winds the boom and boom extensions should be lowered or secured Changing weather conditions including but not limited to wind ice accumulation precipitation flooding lightning etc should be considered wh...

Page 39: ...uld only retract approximately 1 1 2 in The rate at which the oil cools depends on many factors and will be more noticeable with a larger difference in oil temperature verses the ambient temperature Thermal contraction coupled with improper lubrication or improper wear pad adjustments may under certain conditions cause a stick slip condition in the boom This stick slip condition could result in th...

Page 40: ...0 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 Length change in inches Stroke Ft X Temperature Change F X Coeff in 3 in 3 F X 12 in ft Coeff 0 000774 1 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...

Page 41: ...ections apply only to overloads up to 50 For overloads of 50 or higher crane operation must be stopped immediately and Crane Care must be contacted for corrective action NOTE If your crane is equipped with CraneSTAR an overload warning will be posted to the web site for review by the crane owner Overload warnings do NOT indicate real time events Warnings could be sent 24 hours or more after the ac...

Page 42: ...SAFETY INFORMATION TMS800E13 OPERATOR MANUAL 2 26 Published 02 06 2014 Control 495 00 Boom Inspection 1 3 4 1 2 1 5 6 1 7 8 9 10 9 10 R e f e r e n c e O n l y ...

Page 43: ...ism Cylinder Inspect for damage leaks 3 Collar wear pads Inspect all for damage 4 Collar welds Inspect all for cracks 5 Telescopic Sections Inspect for bent or twisted sections Check the boom for straightness 6 Lift Cylinder Head Area Inspect for bends or cracked welds 7 Turret Base Section Inspect for cracked welds 8 Locking Area Pin Booms Inspect for elongated holes 9 Welds Inspect for cracks 10...

Page 44: ...SAFETY INFORMATION TMS800E13 OPERATOR MANUAL 2 28 Published 02 06 2014 Control 495 00 Superstructure Inspection 1 6 3 4 5 2 7 8 9 10 R e f e r e n c e O n l y ...

Page 45: ...king 2 Turntable Bearing Check bolts for proper torque See topic in Swing section of Service Manual 3 Wire Rope Inspect all for damage See topic in Introduction section of Service Manual 4 Hoist Drums Inspect each for damage 5 Hoist Brakes Brakes must hold rated line pull 6 Bearing Main Boom Pivot Pin Inspect for deformation cracked welds 7 Lift Cylinder lower mount Inspect pin and welds 8 Turntab...

Page 46: ...SAFETY INFORMATION TMS800E13 OPERATOR MANUAL 2 30 Published 02 06 2014 Control 495 00 Carrier Inspection 5 6 3 1 1 1 2 2 2 3 3 4 4 R e f e r e n c e O n l y ...

Page 47: ...cracked welds Overload from 25 to 49 1 Stabilizer Cylinders Inspect for leaking 2 Outrigger Pads Inspect for deformation and cracked welds 3 Outrigger Beams Inspect for deformation and cracked welds 4 Outrigger Boxes Inspect for deformation and cracked welds 5 Welds Inspect for cracks 6 Paint Inspect for cracked paint which could indicate twisted stretched or compressed members R e f e r e n c e O...

Page 48: ...SAFETY INFORMATION TMS800E13 OPERATOR MANUAL 2 32 Published 02 06 2014 Control 495 00 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 49: ...operations Both cabs utilize international symbols and English text to label the various controls For detailed information on either cab refer to either Carrier Cab on page 3 1 or Superstructure Cab on page 3 13 in this Section NOTE The following paragraphs describe all the available standard and optional controls and indicators located in the cab Some machines may not be equipped with the optiona...

Page 50: ...d by the crane s electronic operating system based on a J1939 message received from the engine ECM It will illuminate to notify the operator that a non critical engine system error occurred or that an engine or aftertreatment maintenance event occurred This engine issue should be corrected as soon as safely possible It can also be used to flash out active fault codes while the key is ON and the en...

Page 51: ... crane is equipped with a hydraulic pump engage clutch and the hydraulic pump engage switch is in the engaged position throttle will be limited to idle Regen Initiate Inhibit Switch The switch 60 is a three position switch located on the left side of the carrier cab front console and is used to initiate or inhibit an active exhaust regeneration The top portion of the switch is momentary Pushing an...

Page 52: ... all these conditions are met the crane may then be started which should provide enough hydraulic pressure to fully engage the pump The hydraulic pump may be disengaged at any time by pushing the bottom of the switch to the disengage position Pump Engage Indicator ISX Engine The Pump Engage Indictor 63 has three states Off On Solid and On Flashing Off This indicator shall be off when the pump swit...

Page 53: ...tor 29 is located at the top of the front console The indicator illuminates red when the crane parking brakes are applied It is illuminated by a pressure switch on the parking brake valve The bottom of the indicator if equipped with a trailing boom illuminates red to warn the operator that the swing brake release pressure is not enough to hold the swing brake disengaged during trailing boom operat...

Page 54: ...URES TMS800E13 OPERATOR MANUAL 3 6 Published 02 06 2014 Control 495 00 FIGURE 3 1 48 46 55 47 56 50 37 39 51 53 40 38 View B 10 8 7 52 9 See View A See View B 42 43 54 49 6562 6560 45 53 41 34 18 33 63 62 R e f e r e n c e O n l y ...

Page 55: ...ferential Lock Switch 16 Odometer 17 Cross Axle Differential Lock Switch Optional 18 Tire Inflation Switch 19 Beacon Light Switch Optional Item Description 20 Engine Brake High Low Switch 21 Headlights Switch 22 Engine Brake On Off Switch 23 Engine Stop Module Off Line Indicator 24 Engine Warning Electrical Diagnostic Indicator 25 Alternator Charge Indicator 26 Cross Axle Differential Locked Indic...

Page 56: ...lease the brakes on the trailing boom trailer Pull the control knob out to apply and push control knob in to release the trailing boom trailer brakes If the air brake system pressure becomes low the Emergency Brake Control knob will automatically return to the Emergency Brake ON position control knob out Traveling without Optional Trailing Boom Trailer If Equipped Traveling without the optional tr...

Page 57: ... a lamp malfunction Heater On Off Switch The heater on off switch 7 is located on the right side console Press the right side of the switch to ON for heat Press the left side of the switch to turn the heater off Heater Control Switch The heater control switch 52 is located on the right side console Push the switch to the right to OPEN the valve for heat Push the switch to the left to CLOSE the val...

Page 58: ...he turn signal lever is pushed up or the hazard switch is activated Steering Column Tilt Telescope Lever The steering column tilt telescope lever 56 is located on the steering column behind the turn signal lever Pulling back on the lever allows the steering column to be tilted and pushing forward on the lever allows the steering column to be telescoped in and out Horn Button The horn button 46 is ...

Page 59: ...aptop computer with appropriate cable and engine or electrical system software are required Malfunction Indicator Lamp The Malfunction Indicator Lamp 64 illuminates amber when there is an emission related system error When this indicator illuminates have the crane serviced as soon as possible R e f e r e n c e O n l y ...

Page 60: ...6 2014 Control 495 00 Item Description 1 Outrigger Control Panel 2 Outrigger Beam Selector Switch 3 Extend Retract Switch 4 Center Front Stabilizer Switch 5 Stabilizer Selector Switch 6 Bubble Level 7 Emergency Stop Switch 6563 FIGURE 3 2 1 2 3 4 5 5 6 7 R e f e r e n c e O n l y ...

Page 61: ... to either position a signal is sent to the engine ECM to increase engine speed above idle for operation of the outriggers Center Front Stabilizer Switch The center front stabilizer switch 4 is located in the center of the outrigger control panel It must be used in conjunction with the extend retract switch to control the operation of the center front stabilizer The center front stabilizer will re...

Page 62: ... Indicator 8 Hydraulic Oil Temperature and High Oil Temperature Indicator 9 Engine Stop Indicator 10 Engine Warning Indicator 11 Engine MIL Malfunction Indicator Lamp 12 High Exhaust System Temperature Indicator 13 Engine Regen Needed Indicator Item Description 14 Engine Regen Inhibit Indicator 15 Park Brake Indicator 16 Swing Brake Engaged Indicator 17 Emergency Stop E Stop Indicator 18 Menu Sele...

Page 63: ...n a warning buzzer will also sound Engine Warning Indicator 10 Controlled by the Engine ECM and turns amber when there is an engine problem which must be corrected Engine MIL Malfunction Indicator Lamp 11 For the ISX Engine Only Not present otherwise Controlled by the Engine ECM and turns amber when there is an emission related system error When this indicator illuminates have the crane serviced a...

Page 64: ...ntrol Status Indicators 25 The crane control status indicators located along the right hand side have three possible states function disabled gray function inactive blue and function active orange The functions listed from top to bottom are Swing Tele Lift Main Hoist and Aux Hoist only visible if the Aux Hoist is enabled in the crane control EEPROMs If the crane function enable switch is inactive ...

Page 65: ...output parameters for the crane functions swing tele lift and hoist to be changed per the operators preference for joystick control and hydraulic function performance The presets will be defined in more detail in the modify presets screen Modify Operator Presets 2 Selection of this icon which is only possible once a preset is loaded otherwise the icon is disabled and selection of this icon is not ...

Page 66: ... modified from this icon The brightness change only remains in effect while the ignition key is on Once the key is cycled to off the brightness level returns to its default state 80 When the brightness icon sun is highlighted then selected the icon turns green and the operator can now select whether to increase or decrease the brightness units by pressing either the left or right directional keys ...

Page 67: ...fault s System Fault Active Indicator 2 This indicator will become visible whenever there is an active system fault The operator should return to the fault screen to view the active fault s Current Visible Preset Selection 3 Displays the name of the presets shown on screen Values can be Preset 1 Preset 2 Preset 3 or No Preset Display Next Preset Button 4 Pressing this button cycles through the pre...

Page 68: ...ould return to the fault screen to view the active fault s Currently Loaded Preset 3 The loaded presets that can be modified Crane Function Threshold Offset 4 The threshold value is the point in joystick pedal movement where the crane function starts moving The range of this preset is from 50 to 50 with 0 being the default A more negative number will result in the threshold value being achieved wi...

Page 69: ... Loaded Presets 7 The operator will now be able to select a preset value s to modify The screen will transition to Modify Presets Screen 2 Reset Currently Loaded Presets 8 The preset values will be set back to the default values 0 for threshold 100 for max and a flat line for the curve response The operator will need to press the save button in order for the reset to be completed Save Currently Lo...

Page 70: ...ready to be edited will be highlighted orange Only one parameter at a time will be active and able to be edited In this navigation mode all parameters threshold max and curve response can be edited Edit Currently Highlighted Parameter 5 The operator will now be able modify the preset value The screen will transition to Modify Presets Screen 3 ESC 6 Pressing the escape button at this point will ret...

Page 71: ...r can modify the preset using the up and down arrow buttons Pressing and holding either of these buttons will increase the rate the parameter value changes Set Currently Highlighted Parameter 5 The modified parameter will be temporarily stored and the screen will transition back to Modify Presets Screen 2 The operator will be able to continue modifying parameters in this fashion until finished Can...

Page 72: ...an be modified Save Modified Parameters 4 Once the operator has pressed the save button when on Modify Presets Screen 1 all modified parameters will be saved to their respective EEPROM locations and the button will turn green to indicate the save is complete The operator now has the options to edit the parameters again reset the parameters or escape back to the menu screen ESC 5 Pressing the escap...

Page 73: ... engine ECM Active Crane System Fault 4 The currently visible fault and the total number of faults will be displayed here in this case the operator is looking at fault 2 of 2 total faults Active Crane System Fault Information 5 The active fault is displayed as a four number combination that will be used to look up the fault information in a table The four numbers are as follows from left to right ...

Page 74: ...o the preceding fault or to the last fault in the list if on the first fault Examples for the engine faults the viewable active fault will change from 1 to 7 for the system faults from 2 to 1 Cycle Down Through Active Faults 8 If more than one fault is active the display will go to the next fault or the first fault if at the end of the list Examples for the engine faults the viewable active fault ...

Page 75: ... Cab Outrigger Control Module CL202 100 Firmware 5 Super Cab Display Module CL705 111 Firmware 6 Turntable Module GB278 100 Firmware 7 Power Control Module GB 231 100 Firmware 8 Swing Control Module GB232 100 Firmware 9 Counterweight Removal Panel CK006 100 Firmware 10 Control System Software Version 11 Engine Fault Active Indicator 12 FIGURE 3 12 Item Description 1 Master Module 2 Carrier Cab Con...

Page 76: ... is displayed on this screen Swing Function Time 1 Figure 3 13 Telescope Function Time 2 Lift Function Time 3 Main Hoist Function Time 4 Aux Hoist Function Time 5 NOTE only visible if the Aux Hoist is enabled in the crane control EEPROMs Engine Fault Active Indicator 6 This indicator will become visible whenever there is an active engine fault The operator should return to the fault screen to view...

Page 77: ...is in an error state One is the communication loss screen and the other is the timestamp mismatch screen Communication Lost Screen Figure 3 14 The communication loss screen will be present whenever the operator display loses communication with the master control module The display will return to normal functionality once communications are restored FIGURE 3 14 R e f e r e n c e O n l y ...

Page 78: ...here is a timestamp embedded within the software and the display XML file to ensure compatibility between the display and the master control module This screen is displayed whenever those timestamps do not match The display will return to normal functionality once the correct display software is loaded FIGURE 3 15 R e f e r e n c e O n l y ...

Page 79: ...o control swing and either auxiliary hoist if installed or telescoping if auxiliary hoist is not installed crane functions NOTE If the crane has an auxiliary hoist installed than telescoping will be controlled by a tele pedal mounted on the cab floor Swing Function with Single Axis Joystick The joystick handle 39 closest to the cab door will always be used for the swing function Pushing this handl...

Page 80: ...ake pedal 22 This pedal is only installed when the crane is equipped with an auxiliary hoist Push down on the top of the pedal to extend the boom and push down on the bottom of the pedal to retract the boom NOTE If the crane does not have an auxiliary hoist installed then telescoping will be controlled by the left hand armrest joystick Main Hoist Speed Selector Switch The three position main hoist...

Page 81: ...ng to the pressure from the swing power brake valve Swing Lock Control Pin Type The pin swing lock control handle 6 is located on the right side of the cab The purpose of the pin swing lock is to lock the superstructure in position directly over the front or over the rear When the control handle is pushed in and the superstructure is directly over the front or rear the swing lock pin drops into a ...

Page 82: ...RATING CONTROLS AND PROCEDURES TMS800E13 OPERATOR MANUAL 3 34 Published 02 06 2014 Control 495 00 FIGURE 3 16 25 1 4 5 15 22 2 See View A See View B See View C 6 12 30 20 13 29 3 R e f e r e n c e O n l y ...

Page 83: ... TMS800E13 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 3 Published 02 06 2014 Control 495 00 FIGURE 3 16 continued 24 View A View C 11 10 8 16 17 42 20 35 39 32 27 28 26 9 18 30 18 R e f e r e n c e O n l y ...

Page 84: ...ot Throttle Pedal 5 Bubble Level Indicator 6 Swing Lock Control Pin Type 7 Seat Adjustment Lever Not Shown 8 Main Hoist Joystick 9 Boom Lift Joystick Item Description 10 Main Hoist Speed Selector Switch 11 Cab Tilt Switch 12 Cab Dome Light 13 Fuse and Relay Panel 14 Beacon Light Not Shown 15 Fire Extinguisher 16 Auxiliary Hoist Speed Selector Switch optional 17 Swing Brake Selector Switch 18 Teles...

Page 85: ...f the cab The light is controlled by an ON OFF switch on the light Fire Extinguisher The fire extinguisher 15 is located at the left rear side of the cab The fire extinguisher is a BC rated dry type fire extinguisher for emergency use Windshield Wiper Washer Switch and Motor The windshield wiper washer toggle switch 38 is located on the right side of the overhead panel The switch is used for remov...

Page 86: ...ontrol motor Crane System Diagnostic Connector The crane system diagnostic connector 43 is an USB connector located on the Fuse and Relay Panel 13 This connector is use to troubleshoot or monitor inputs outputs settings NOTE Never use this connector for downloading software which shall only be done using the carrier cab crane system diagnostic connector Contact CraneCare for necessary tools includ...

Page 87: ... of the controller It must be used in conjunction with the outrigger selector switches to control the operation of the stabilizer and extension cylinders Push the top of the switch to select the extend function or push the bottom of the switch to select the retract function In addition when the switch is positioned to either EXTEND or RETRACT position a signal is sent to the engine ECM to increase...

Page 88: ...ch used to extend or retract the left rear stabilizer and extension cylinders It must be used in conjunction with the outrigger extend retract switch To extend the left rear outrigger beam push the top of the outrigger extend retract switch and the top of the left rear outrigger switch To retract the left rear outrigger beam push the bottom of the outrigger extend retract switch and the top of the...

Page 89: ... oil level in the crankcase and fill to the FULL mark on the dipstick Do not overfill Engine Coolant Check the coolant level in the radiator and fill to the proper level Do not overfill and ensure the radiator cap is secure Batteries Check the state of charge indicator if applicable with maintenance free batteries or check each cell for the correct fluid level if equipped with standard or low main...

Page 90: ...tors who possess the skill experience and dexterity to ensure smooth operation Shock loading shall be avoided Operation Below 40 C For crane operation below 40 C capacities shall be derated 3 67 of the capacities shown on the load chart for each degree 1 C below 40 C Operation Below 40 F For crane operation below 40 F capacities shall be derated 2 0 of the capacities shown on the load chart for ea...

Page 91: ...rking brake is set and position the transmission in neutral NOTE The engine will not crank unless the transmission shift lever is in neutral 2 Turn the ignition switch to START far right position and release immediately when the engine starts Do not push or hold the throttle down The ECM will automatically provide the proper amount of fuel to start the engine 3 Immediately check the engine instrum...

Page 92: ...can occur while parked or driving Engine speed will increase and possibly reach between 1000 and 1500 rpm Also a reduction in power might be noticed General Crane Operation Pump Drive The No 1 hydraulic pump is driven by an engine PTO ISX engines The No 2 and No 3 pumps are direct engine driven Pump Disconnect ISX Engines The electric pump disconnect system is used to disconnect Pump 1 making it e...

Page 93: ...etracted to fully extended with swingaway extension The number at the intersection of the left column and top row is the total load limit for that load radius and boom length The number in parentheses below the total load limit is the required boom angle in degrees for that load Boom lengths between increments should always be treated as if it were the next longer length For example if the actual ...

Page 94: ...50 ft radius and 19 5 m 64 ft of boom length shows a capacity of 3601 kg 7940 lb on outriggers over front and 2254 kg 4970 lb on outriggers 360 degrees We subtract the load handling weight of 632 lbs 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 degrees We are constricted in making the lif...

Page 95: ...clear of the ground and the crane is level as indicated by the sight level bubble located on the right side of the cab or in each carrier outrigger control panel If it is suspected that the bubble level indicator is out of adjustment verify and adjust the bubble level as described in Bubble Level Adjustment page 3 47 Proper Leveling of the Crane ASME B30 5 specifies that if a crane is not level wi...

Page 96: ...e the most conservative outrigger beam configuration that is if three outriggers are fully extended and one is retracted the RCL will select retracted as the outrigger configuration A confirmation of this outrigger configuration is all that is needed Refer to the Rated Capacity Limiter Operator s Handbook for detailed instructions Engaging the Mid Extend Lock Pin 1 Turn the locking pin Figure 3 20...

Page 97: ...triggers have been fully retracted stow the outrigger floats Figure 3 22 Secure the floats with quick pins and cotter pins Stowing the Mid Extend Lock Pin 1 Retract the outrigger extension retraction cylinder NOTE If the lock pin Figure 3 8 is wedged in the hole in the outrigger beam it may be necessary to jog the outrigger extension retraction switch slightly while pulling upward on the pin 2 Lif...

Page 98: ...ntil the boom reaches the desired elevation CAUTION Never operate center front stabilizer unless boom is retracted and in boom rest and outriggers and stabilizers are extended and set Retract center front stabilizer before stabilizers and outriggers CAUTION Do not try to lift or level the crane with the center front stabilizer CAUTION The center front stabilizer will retract automatically when the...

Page 99: ...desired position Telescope Control Pedal The telescope control pedal is used on cranes equipped with an auxiliary hoist Push on the top of the pedal to extend the boom and push on the bottom of the pedal to retract the boom Lowering and Raising the Hoist Cable NOTE When the load is stopped at the desired height the automatic brake will engage and hold the load as long as the joystick remains in ne...

Page 100: ...c in the crane s working range They are set by defining points along the outer limits of the working area with the tip of the boom Once the working area has been defined the system will provide a visual and an audible warning if the boom approaches a virtual wall An Anti Two Block Device is also incorporated into the system to prevent the hook block or headache ball from coming into contact with t...

Page 101: ...ane until the superstructure has been secured as outlined below 1 To ensure the axles and or suspension are not overloaded adhere to the following a For highway travel with 8170 kg 18 000 lb of counterweight install 3630 kg 8000 lb of counterweight on the carrier Check that front axle load does not exceed 22 300 kg 49 200 lb and rear axle load does not exceed 27 200 kg 60 000 lb b For highway trav...

Page 102: ...finite resistance to clutch pedal downward movement will be felt at the last 25 mm one inch of travel The clutch brake is particularly useful for initial gear engagement in the lower gears when going uphill when the road speed drops off more quickly than the engine speed requiring rapid shifts The clutch brake MUST NOT BE USED when making a downshift Clutch engagement should always be made smoothl...

Page 103: ... operation use the vehicle brakes and gears in combination to keep crane speed under control and the engine below rated governed engine speed The transmission has 11 forward speeds and three reverse consisting of a five speed front section and a three speed auxiliary section The auxiliary section contains low and high range ratios plus three deep reduction gears The three lowest LL1 LO LL2 gear se...

Page 104: ...ange proceed as follows Move the shift lever double clutching to the next desired gear position 5th to 6th to 7th to 8th Downshifting 1 To shift in HI range proceed as follows Move the shift lever double clutching to the next desired gear position 8th to 7th to 6th to 5th 2 To shift from HI 5th to LO 4th range proceed as follows When in the 5th gear position for HI range and ready for the next dow...

Page 105: ...een the front and rear axles in the tandem set The switch has two positions LOCK and UNLOCK The Cross Axle Control Switch is used to control the locking capability between the right and left wheels in the tandem set The switch has two positions LOCK and UNLOCK Operation of the vehicle with differentials locked increases wear on tires axles drive shafts and the transmission These features should on...

Page 106: ...approaching a stop or going down a long grade On a downgrade use the same transmission gear as would be needed to go up the same grade When necessary to use brakes to reduce crane speed on downgrades use an on and off application to minimize heat and wear Do not hold a continuous brake application or slide the wheels When driving on slippery pavement or under icy conditions alternately and smoothl...

Page 107: ...ush top of switch 2 Position the engine brake switch to either HIGH press top of switch or LOW press bottom of switch position depending on the amount of braking desired 3 Let off the throttle to activate the engine braking system and slow the crane NOTE The engine braking system will automatically deactivate when the throttle is depressed TRAILING BOOM OPTIONAL The trailing boom option allows the...

Page 108: ...support lugs 9 Open the lift cylinder pressure release valve by turning counterclockwise 1 Figure 3 32 10 Open the swing brake release valve 2 by turning counterclockwise 11 Open and close valves FC1 and FC2 as shown in Figure 3 33 FIGURE 3 31 1 For Reference Only Actual Control May be Different FIGURE 3 32 2 1 6144 FIGURE 3 33 6144 1 2 1 Item Description 1 Needle Valve FC1 2 Needle Valve FC2 R e ...

Page 109: ...ssible precautionary measures shall be taken to prevent shock loads or vibration from being imposed on crane components either directly through the hoist cable or indirectly from ground borne vibration The operator and other personnel associated with the pile driving and pile extraction operation shall have read and understood all safety standards applicable to crane operations as well as being th...

Page 110: ...if necessary chock the wheels 4 Position all controls to neutral or off 5 Shut down the engine using the proper procedures as specified by this manual and the engine manual 6 Perform any other specified procedures required at the end of the workday that is drain water from the fuel filter water separator refueling etc 7 Close all windows 8 Remove the keys from the crane 9 Lock the crane Install va...

Page 111: ...ification and Slinging Points 4 27 Assembly Of Jibs 4 28 Electrical Connection at the Jib 4 29 Unfolding Folding the Deflection Sheave on the 4 9 m 16 ft Section 4 30 Positioning Removing the Hoist Cable 4 31 Traveling with Manually Offsettable Jib and or Inserts Erected 4 32 Auxiliary Single Sheave Boom Nose Additional Equipment 4 32 Identification 4 32 Installing Removing Auxiliary Single Sheave...

Page 112: ...LE REEVING NOTE There are two types of cable wire rope available on this crane 6 x 36 WS and 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 Figure 4 6 and Figure 4 7 This re...

Page 113: ...heir advice should be sought for each specific type of wire rope a crane user intends to install on a mobile crane When assembly is complete raise the boom to a working position with a load suspended to firmly seat the wedge and rope into the socket before the crane is used operationally When anchoring the socket to the boom ensure the flat face of the socket is in position as shown away from the ...

Page 114: ...0 rope diameters but not less than 15 2 cm 6 in for rotation resistant wire ropes When using method A place a wire rope clip around the dead end by clamping a short extra piece of rope to the rope dead end DO NOT CLAMP THE LIVE END The U bolt should bear against the dead end The saddle of the clip should bear against the short extra piece Torque the U bolts according to the figures listed in the c...

Page 115: ...14 Control 495 00 FIGURE 4 7 6453 9 PARTS LINE Hookblock Dead End Lower Boom Nose Sheaves To Main Hoist Upper Boom Nose Sheaves Auxiliary Nose Hookblock Sheaves One Part Line Using Jib Shown at 20 Offset 6453 3 One Part Line Using Jib Shown at 40 Offset R e f e r e n c e O n l y ...

Page 116: ...INSTALLATION TMS800E13 OPERATOR MANUAL 6 Published 02 06 2014 Control 495 00 FIGURE4 7continued 6453 1 33 Ft 10 m FIXED JIB SHOWN AT 0 o OFFSET 56 Ft 17 m BI FOLD JIB SHOWN AT 0 o OFFSET R e f e r e n c e O n l y ...

Page 117: ...13 OPERATOR MANUAL SET UP AND INSTALLATION 4 Published 02 06 2014 Control 495 00 FIGURE4 7continued 6453 2 76 Ft 23 m BI FOLDJIB SHOWN AT 0 o OFFSET 96 Ft 29 m BI FOLDJIB SHOWN AT 0 o OFFSET R e f e r e n c e O n l y ...

Page 118: ...ction switch must be OFF before using the counterweight switch panel 3 Using the counterweight switch panel Figure 4 8 lower the counterweight cylinders by pushing on a power enable button while pushing the appropriate cylinder lower button Pin the cylinders to the counterweight using the attach pins in the cylinders Insert the retaining pins in the attach pins 4 Push in turn and remove the long a...

Page 119: ...wer the counterweight onto the carrier stowage area 7 Insert the long pins through the carrier lugs and counterweight Push in and turn to lock pin in the notch 8 Remove the attach pins from the counterweight lugs and cylinder ends Raise the cylinders and stow the attach pins in cylinder and insert retainer clip pins 9 The carrier is now ready for highway travel with the counterweight stowed FIGURE...

Page 120: ...on whether the lattice extension is folded up at the side of the main boom for transportation or is completely removed for transportation You must check transport condition After stowing the lattice extension before you drive the crane with the lattice extension folded at the side or work with the main boom Before installation and before erecting the lattice extension Item Description 1 Counterwei...

Page 121: ...on is locked at the front mount 2 on the main boom Figure 4 11 The pins 4 are inserted on the pivot point between the 7 m 23 ft section and the 10 1 m 33 ft section Figure 4 11 The connection 8 in the middle area is between the 7 m 23 ft section 10 1 m 33 ft section Figure 4 11 The connection 8 between 7 m 23 ft section and main boom in the rear area is established Figure 4 11 If the 7 m 23 ft Sec...

Page 122: ...trol 495 00 FIGURE 4 11 6510 3 10 11 12 6510 8 8 1 2 Item Description 1 Stinger 2 Front Mount 3 Upper Hangar 4 Lower Support 5 Rear Hangar 6 Carrier 6510 7 8 3 4 5 6 7 9 6916 1 Item Description 7 Bumper Pad 8 Holding Plate 9 Jib 10 Pin 11 Pin 12 Bracket R e f e r e n c e O n l y ...

Page 123: ...y retracted Securing Lattice Extension with Tag Line Rope The lattice extension may swing out on its own accord when the jib is removed from its stowage brackets You must therefore secure the lattice extension before you begin with the erection procedure Secure the lattice extension as follows Attach a tag line rope at the front of the lattice extension Guide the tag line rope underneath the latti...

Page 124: ...ceed to step 6 4 If not using the bi fold 7m 23 ft section remove pin 1 Figure 4 14 photo 6642 8 from the locking bar 2 Move locking bar 2 photo 6642 9 to the base section attachment bar 1 and install pin 3 Secure with retaining pin 5 If not using the bi fold 7m 23 ft section remove the retainer clip and bi fold stowage pin 1 Figure 4 15 at the base section connection Stow pin on bi fold Leave the...

Page 125: ...the jib stowage controller 1 Figure 4 19 from behind the seat in the superstructure cab and connect it to the electrical plug 2 near the boom nose 10 Use the controller to pivot the jib so that lugs 1 Figure 4 20 on jib align with the holes in the lugs 2 on the boom nose 11 Remove pins 1 Figure 4 21 stowed in extension and install in holes right side of boom nose and secure with retainer clips 2 6...

Page 126: ...during erecting procedure NOTE If erecting the 7 m 23 ft section with the 10 1 m 33 ft section perform steps 18 and 19 If erecting the 10 1 m 33 ft section without the 7 m 23 ft section proceed to step 17 15 Using the tag line rope pull the extension away from the boom Figure 4 24 16 While maintaining control of the extension with the tag line swing extension into position on boom nose Figure 4 24...

Page 127: ...ut When establishing or disconnecting the connections proceed as follows Lower the lattice extension until it is on the ground Figure 4 26 1 If necessary override the lifting limit switch Continue to lower carefully until the connecting points align or until the load has been removed from the pins 1 Connect RCL cables a Remove RCL cable end connector 1 Figure 4 27 from extension and route through ...

Page 128: ...e bi fold stinger swing stinger into erected position NOTE Do not lower boom until stinger has been completely swung in front of the 10 1 m 33 ft section 5 Lower the boom 6 Remove pin 1 Figure 4 34 from swingaway Install pin in stinger and retain with clip pin 7 Connect RCL connector 1 Figure 4 35 to RCL connection box The cable is stowed in the 7m 23 ft section 6642 22 FIGURE 4 30 1 6642 23 FIGUR...

Page 129: ...n 4 Remove retainer clip and remove the left side stinger retaining pin 1 Figure 4 38 Place pin in holder 5 Raise boom to slightly above horizontal 6 Using tag line to control movement of stinger swing stinger into stowed position Figure 4 39 7 Raise boom slightly above horizontal 8 Connect stowage link 1 Figure 4 40 to stinger using pin 2 and retainer clip 3 9 Remove tag line from stinger WARNING...

Page 130: ...ve two pins attaching the jib to the left side of boom nose 2 Figure 4 45 Stow the pins in the jib pin holders 1 and install the retainer clips 4 Completely retract boom 5 Extend boom approximately 60 9 cm 2 feet 6 Raise boom above horizontal NOTE Step 7 is stowing with the 7 m 23 ft section and 10 1 m 33 ft section together If the 7 m 23 ft section remained on the boom proceed to step 9 7 Use the...

Page 131: ...use controller to pivot jib in towards boom so that the lugs on 10 1 m 33 ft section align with 7 m 23 ft section 6645 5 FIGURE 4 46 6642 47 FIGURE 4 47 2 1 DANGER If the 10 1 m 33 ft lattice extension 1 Figure 4 47 does not engage the ramp 2 Figure 4 47 correctly or does not align with the front stowage bracket 2 Figure 4 48 correctly STOP DO NOT continue to stow the jibs until they are properly ...

Page 132: ... If the bi fold 7m 23 ft section was not used remove bi fold stowage pin 1 Figure 4 51 from bi fold and install at the lattice bi fold connection Install retainer clip to pin NOTE Step 16 applies when the 7m 23 ft section was erected with the 10 1 m 33 ft section 16 Install rear stowage pin 1 Figure 4 52 and retainer clip 2 17 Lower boom 18 Remove tag line Reeve the hoist cable as described in thi...

Page 133: ...during operation with the lattice extension by the lifting switch on the lattice extension and are switched off when the lifting limit switch is actuated NOTE The same lifting limit switch is used for lattice extension and main boom Overriding Connection on Main Boom For operation with the lattice extension you must remove the lifting limit switch on the main boom and override the connection Inser...

Page 134: ...ion sheave at the rear 1 Figure 4 55 Fold out the deflection sheave if the jib offset angle is 20 or 40 NOTE For zero 0 degree offset leave the mast assembly in the stowed position The sheave must be folded out for operation with the swingaway lattice extension for operation with the 17 1 m 56 ft two stage swingaway lattice extension For transportation the mast sheave must be folded in Folding Rea...

Page 135: ...eaves 3 and place it onto the ground on the left side Setting the Folding Swingaway Extension Offset 1 Extend and set the outriggers and swing the boom to over the front Position the boom to above horizontal Figure 4 58 2 Block up under the tip of the extension assembly section 3 To set the offset from a lesser degree to higher degree perform the following procedures CAUTION Risk of accidents due ...

Page 136: ...does not move off of the blocking until the offset links take the full weight of the extension d Reeve the hoist cable as described under normal erecting procedures REMOVING THE BI FOLD MANUAL JIB 1 Before removing the jib make sure the crane is set up on outriggers using normal setup procedures Refer to Operating Controls and Procedures page 3 1 NOTE An auxiliary crane with sling is required to r...

Page 137: ...pins in the holders at the foot of the 4 9 m 16 ft sections Figure 4 60 Using an auxiliary crane with sling lift the 4 9 m 16 ft section with support roller in front of the main boom head so that the bearing points 2 and 3 align on both sides Insert the securing pins into the bearing points 2 and 3 on both sides Secure all pins with retaining pins Install the second 4 9 m 16 ft section in front of...

Page 138: ...e slightly offset on each side Figure 4 61 NOTE For electrical connections at the 4 9 m 16 ft sections refer to Electrical Connections at the Jib in this section ASSEMBLY OF JIBS NOTE The lengths of 22 0 m 72 ft and 27 1 m 89 ft respectively equal the distance between the center of the locking pin on the main boom head and the front edge of the head sheave CAUTION Operate the crane only with those...

Page 139: ...es the electrical connections at the 4 9 m 16 ft sections Establish the electrical connection at the bi fold swingaway lattice extension per the following procedures Transport Condition of the Connection For transport bring the electrical connections into the following condition There is a cable with a plug 3 at the rear of the 4 9 m 16 ft sections Figure 4 62 For transport the cable is wound arou...

Page 140: ...6 ft section to the socket of the first 4 9 m 16 ft section at the front Connect the cable of the first 4 9 m 16 ft section to the socket at the main boom head Disconnecting Detach the electrical connection between the 10 1 m 33 ft and front 4 9 m 16 ft section Detach the electrical connection between the two 4 9 m 16 ft sections Detach the electrical connection between the rear 4 9 m 16 ft sectio...

Page 141: ...ining pins Attach the overhaul ball Install the A2B weight assembly Removing Hoist Cable Unpin the overhaul ball Remove the hoist rope holding rollers and rods 1 Figure 4 66 Take the hoist cable off the head sheave 2 and the deflection sheaves 3 and place it onto the ground on the left side Put all hoist cable holding rollers and rods back in place and secure them with retaining pins CAUTION Risk ...

Page 142: ...SHEAVE BOOM NOSE ADDITIONAL EQUIPMENT Identification The auxiliary single sheave boom nose is designed for the crane it was delivered with If you wish to use the auxiliary single sheave boom nose on several Manitowoc Grove cranes it needs to be adapted to the corresponding crane and marked with all the serial numbers The serial number 1 is on a plate in the front on the auxiliary single sheave boo...

Page 143: ...hree pins 1 Figure 4 69 In the transport position the auxiliary single sheave boom nose is positioned to the side of the main boom head and is fastened with two pins 1 Attach an auxiliary crane to the connection eyes of the boom nose 2 Remove the retaining pins and remove all the pins out of the bores and bearing points 3 Lift the auxiliary single sheave boom nose from the head of the main boom 4 ...

Page 144: ...xiliary single sheave boom nose to the bearing point 2 Figure 4 73 6 Secure the pin with a retaining pin 7 The auxiliary single sheave boom nose is now in transport position Rigging in Working Position On the left side of the main boom head there is a holding device In working position the auxiliary single sheave boom nose is attached to the main boom head at both bore holes Figure 4 74 1 Release ...

Page 145: ... the corresponding retaining pins 4 Fasten the cable end clamp on the headache ball or the hook block Reverse the sequence of operations to remove the hoist cable before rotating the auxiliary boom nose into transport position Possible Reeving Methods on the Auxiliary Single Sheave Boom Nose NOTE The hoist cable may only be simply reeved single drop Maximum load bearing capacity for single reeving...

Page 146: ... extension Procedure if the Permissible Wind Speed is Exceeded Strong winds can overstrain the crane Therefore closely observe the instructions in Table 4 2 If the maximum permissible wind speed according to the lifting capacity table is exceeded during the main boom operation proceed per the following table Table 4 2 NOTE The information in Table 4 3 applies to malfunctions during operation with ...

Page 147: ...t the lifting limit switch Electrical connection between the boom head and lattice extension and between 10 1 m 33 ft section and 7 m 23 ft section is not established Establish electrical connection Lifting limit switch on the main boom head not overridden Override the lifting limit switch on the main boom head When operating with a 17 1 m 56 ft lattice extension or jib the short circuit plug is n...

Page 148: ...SET UP AND INSTALLATION TMS800E13 OPERATOR MANUAL 38 Published 02 06 2014 Control 495 00 R e f e r e n c e O n l y ...

Page 149: ... waste fluids onto the ground down any drain or into any source of water Always drain waste fluids into leak proof containers that are clearly marked with what they contain Always fill or add fluids with a funnel or a filling pump Immediately clean up any spills Hydraulic Oil Inspection Environmental and other conditions can dramatically affect the condition of hydraulic oil and filters Therefore ...

Page 150: ... operator needs to follow the guide lines as stated in the operator s manual We assume that the customer has taken steps for use of an appropriate engine antifreeze coolant taken care of the fuel fuel system and starting system and has done whatever they feel necessary to add insulation for under hood temperatures and meet the engine manufacture s intake air temperature requirements Other lubrican...

Page 151: ...BP Eldoran UTH Trak Tran 9 10W20 BP Blend 7367 10W20 Exxon Mobil 424 10W 30 Hoist Spec 6829100213 AGMA No 4 EP Extreme Pressure Gear Lube Mobil Mobilfluid 629 Texaco Meropa 150 Grease Spec 6829003477 Citgo Lithoplex MP 2 Texaco Starplex Moly 2 Phillips 66 Philube M Grease Mobil Mobilgrese XHP 222 Special 53055 0 Chemtool Inc Lube A Boom Grease Open Gear Lube bearing swingdrive teeth Spec 682910297...

Page 152: ... used cycle the components and relubricate to ensure complete lubrication of the entire wear area Surface Protection for Cylinder Rods Steel cylinder rods include a thin layer of chrome plating on their surfaces to protect them from corroding However chrome plating inherently has cracks in its structure which can allow moisture to corrode the underlying steel At typical ambient temperatures hydrau...

Page 153: ...petcock then fill radiator to bottom of filler neck with mixture of 50 AFC and 50 water Run engine through two 2 thermal cycles Wait 1 minute and recheck coolant level and refill as required Supplemental Coolant Additive SCA Spec 682912858 Lube Interval Change filter and check coolant SCA level every 500 hours or 6 months Check coolant for contamination every 1000 hours or 1 year Lube Amount See S...

Page 154: ...ication 2 grease fittings 9 Front Aluminum Wheel Pilots Lube Type ASC Lube Interval When wheels are removed for service Lube Amount Generously coat the wheel pilot or hub pads with anti seize ASC compound Do not apply anti seize compound to the face of the wheel of the hub Application Brush on 10 Front Axle Hubs Lube Type SSGL 5 Lube Interval Check fluid level every 250 hours and refill as necessa...

Page 155: ...Type SSGL 5 Lube Interval Check lubricant level every 250 hours and refill as necessary Drain refill and clean magnetic drain plug every 80 000 km 50 000 mi or 2 years whichever interval occurs first Lube Amount Capacity 17 5 l 37 pt Normal makeup less than 0 23 l 0 5 pt Application Fill to bottom of fill plug threads 18 Rear Axle Brake Slack Adjusters Lube Type EP MPG Lube Interval 1000 hours Lub...

Page 156: ...00E13 OPERATOR MANUAL 8 Published 02 06 2014 Control 495 00 2 7 13 14 11 22 21 12 1 9 10 13 14 12 15 9 10 21 22 20 24 23 5 18 19 16 11 6 15 18 19 22 20 21 17 26 3 4 8 4 8 FIGURE 5 2 6556 1 27 R e f e r e n c e O n l y ...

Page 157: ...rval can be increased to 3000 hours or 3 years Lube Amount 656 6 l 173 5 gal tank only to the FULL mark on sight gauge Application Fill through filler cap on top of tank When tank is drained clean the magnetic pipe plug Replace breather every 500 hours or 6 months whichever interval occurs first 24 Hydraulic Filter Check filter every 500 hours or 6 months whichever interval occurs first Change the...

Page 158: ... level with the check plug opening 33 Auxiliary Hoist Lube Type AGMA EP 4 Lube Interval Check and fill every 1000 hours or 12 months whichever interval occurs first Drain and fill annually Lube Amount Capacity 14 7 l 15 5 qt Application Fill until level with the check plug opening BOOM JIB AND BOOM ACCESSORIES LUBRICATION NOTE To service the boom at boom lengths longer than 120 ft to access grease...

Page 159: ...8 places with boom in extended position through access holes 40 Boom Section Upper and Lower Wear Pads Lube Type EP MPG Lube Interval 50 hours or 1 week whichever occurs first Lubricate more frequently if environmental conditions and or operating conditions necessitate Lube Amount Thoroughly coat all areas the wear pad moves on Application By brush 12 places with boom in extended position 41 Upper...

Page 160: ...ded periodically throughout the life of a rope to replace factory lubricant which is used or lost NOTE Wire rope may be purchased by contacting the Manitowoc Crane Care Parts Department For more detailed information concerning the lubrication and inspection of wire rope refer to WIRE ROPE in Section 1 INTRODUCTION in the Service Manual Item Description 29 Turntable Gearbox 30 Turntable Gear and Dr...

Page 161: ...TOR MANUAL LUBRICATION 5 Published 02 06 2014 Control 495 00 38 33 32 34 31 42 36 39 39 Left Side View Right Side View 35 40 46 41 47 37 39 45 41 42 48 44 43 29 43 34 33 32 FIGURE 5 3 6556 2 6556 3 30 R e f e r e n c e O n l y ...

Page 162: ...LUBRICATION TMS800E13 OPERATOR MANUAL 14 Published 02 06 2014 Control 495 00 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 163: ...is section contains a list of daily inspection and maintenance checks Performing the checks will help maintain the safety dependability and productivity designed into your crane INSTRUCTIONS See Service Manual for specific maintenance and adjustment procedures See Section 5 in this handbook for lubrication intervals types of fluids and lube point locations R e f e r e n c e O n l y ...

Page 164: ...d levels D 7 Verify Hoists are installed properly with no signs of damage or leaks D 8 Operator s Manual installed properly on machine D 9 Verify that the Operator Aids are working properly Boom Angle Indicator Load Moment Indicator LMI Antitwo Block D 10 Gauges and Instruments are functional D 11 Back up Alarm operates properly when operating machine D 12 Swing Brake operates properly D 13 Verify...

Page 165: ...thly Maintenance Work 4 37 New Owner 1 2 Operating Procedures 3 41 Operating with the Lattice Extension 4 36 Operational Aids 2 4 Operator s Information 2 2 Operator s Qualifications 2 3 Overload Inspection 2 25 Parking and Securing 2 22 Personnel Handling 2 11 Pile Driving and Extraction 3 61 Raising and Setting Down the Main Boom with Rigged Lattice Extension 4 36 Removable Counterweight 4 8 Rem...

Page 166: ...OPERATOR MANUAL TMS800E13 APL 2 R e f e r e n c e O n l y ...

Page 167: ...R e f e r e n c e O n l y ...

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