OPERATOR’S MANUAL 1

This manual has been prepared for and is considered part of -

TMS800E
Crane Model Number

2
This Manual is divided into the following sections:

SECTION 1 INTRODUCTION
SECTION 2 SAFETY INFORMATION
SECTION 3 OPERATING CONTROLS AND PROCEDURES
SECTION 4 SET-UP AND INSTALLATION
SECTION 5 LUBRICATION
SECTION 6 MAINTENANCE CHECKLIST
3
NOTICE

The crane serial number is the only method your distributor or the factory
has of providing you with correct parts and service information.

The crane serial number is identified on the builder’s decal attached to the
operator’s cab. Always furnish crane serial number when ordering parts
or communicating service problems with your distributor or the factory.

To prevent death or serious injury:

• Avoid unsafe operation and maintenance.
• This crane must be operated and maintained by trained and 5
experienced personnel. Manitowoc is not responsible for qualifying
these personnel.
• Do not operate or work on this crane without first reading and
understanding Operator’s Manual and Rating Plate supplied with
crane.
• Store Operator’s Manual in holder provided on crane.
• Attach laminated Capacity Charts supplied with crane to chain in
operator’s cab.
• If Operator’s Manual or Capacity Charts are missing from cab,
contact your distributor for new ones. 6
© 2005 Manitowoc Crane Group
Published 08-11-2006 Control # 030-04
 To Contact Us:

Manitowoc Cranes, Inc.

2401 South 30th Street
Manitowoc, WI 54220
(920) 684-6621
(920) 683-6277 (fax)

Grove Worldwide
1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)

National Crane Corporation

1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)

Grove Worldwide
1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)

Technical Field Parts Factory Training

Publications Service Service
TMS800E OPERATOR’S MANUAL OPERATORS MANUAL

Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Assembly Of Boom Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Auxiliary Single Sheave Boom Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Battery Posts, Terminals, and Related Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Boom Extension (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Boom Extension Erecting and Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Boom Extension/Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . . 5-8
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Checklists For Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Checklists For Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Crushing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Description Of Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Diesel Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Hook Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Installing Cable On The Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Load Moment Indicating (LMI) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Maintenance Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Malfunction When Working With Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Operation With The Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Raising And Setting Down The Main Boom With Rigged Lattice Extension . . . . . . . . . 4-29
Removable Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Superstructure Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Superstructure Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Telescoping With Rigged Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Transporting The Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
OPERATORS MANUAL TMS800E OPERATOR’S MANUAL
 SECTION 1
INTRODUCTION 1
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-i
INTRODUCTION TMS800E OPERATOR’S MANUAL

1-ii
TMS800E OPERATOR’S MANUAL INTRODUCTION

SECTION 1
INTRODUCTION 1
GENERAL The superstructure is capable of 360° rotation in either
dir ecti on. A ll cr ane fu nctio ns, with the exc epti on of
This Handbook provides important information for the counterweight removal, are controlled from the fully-
operator of the TMS800E Series Grove Crane. enclosed cab mounted on the superstructure. The crane is
Before placing the crane in service, take time to thoroughly equipped with a four-section boom. Additional reach is
familiarize yourself with the contents of this manual. After all obtained by utilizing an optional bi-fold boom extension.
sections have been read and understood, retain the manual Lifting is provided by a main hoist and an optional auxiliary
for future reference in a readily accessible location. hoist. For basic crane component locations, (see Figure 1-1).

T h e G r o ve c r an e h as b e en d e si g ne d f o r m a x im u m
performance with minimum maintenance. With proper care, 2
years of trouble-free service can be expected.
Constant improvement and engineering progress makes it
necessary that we reserve the right to make specification
and equipment changes without notice.
1
Gro ve a nd o ur Deale r Ne twor k want to en sure you r 1
satisfaction with our products and customer support. Your
local dealer is the best equipped and most knowledgeable to
assist you for parts, service and warranty issues. They have
the facilities, parts, factory trained personnel, and the
information to assist you in a timely manner. We request that
you first contact them for assistance. If you feel you need
fa cto ry ass ista nce , ple ase as k t he de ale r’s se rvi ce
management to coordinate the contact on your behalf.
Engine operating procedures and routine maintenance 3
procedures are supplied in a separate manual with each
crane, and should be referred to for detailed information.
NOTE: Throughout this handbook, reference is made to
left, right, front, and rear when describing locations.
These reference locations are to be considered as
those viewed from the operator’s seat with the
superstructure facing forward over the front of the
carrier frame.
6561-3
5 5
The mobile crane carrier incorporates an all welded steel 4
frame. The 8x4x4 carrier utilizes two drive axles and two Rear View
steer axles. Steering is provided by a power steering pump, FIGURE 1-1
gearbox and control valve. The engine is mounted in the
front of the carrier and provides power through a 10 speed Item Description
forward and 2 speed reverse UltraShift™ transmission.
1 Rear View Mirror
Hydraulic, two stage double box telescopic beams with
2 Crane Cab
inverted stabilizer (jack) cylinder outriggers are integral with
the carrier frame. The outriggers are utilized in three 3 Counterweight
position; fully extended, intermediate (50%) extended, and
4 Outrigger Float
fully retracted. The carrier is also equipped with a center
front stabilizer that has a permanently stowed pad. 5 Outrigger Jack Cylinder

1-1
INTRODUCTION TMS800E OPERATOR’S MANUAL

6 8
7 9 11
12

6561-2
19 14 9
9

14 12
7 16 13
17 11

10
18
6561-1
28
19 26 24 9
20 9 25
27

Left Side View

FIGURE 1-1 continued

1-2
TMS800E OPERATOR’S MANUAL INTRODUCTION

1
12
13 7
11
6 15 16
17

10

18

22 9 25 28
22 21
9 20 19
23 6561-4

Right Side View

FIGURE 1-1 continued

Item Description Item Description

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

1-3
INTRODUCTION TMS800E OPERATOR’S MANUAL

THIS PAGE BLANK

1-4
 SECTION 2
SAFETY INFORMATION
TABLE OF CONTENTS
Diesel Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Battery Posts, Terminals, and Related Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2
Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Load Moment Indicating (LMI) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Two-Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Special Operating Conditions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Crushing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Job Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Hand Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Transporting The Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Boom Extension/Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

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SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

2-ii
TMS800E OPERATOR’S MANUAL SAFETY INFORMATION

SECTION 2
SAFETY INFORMATION
DIESEL ENGINE EXHAUST Signal Words

CALIFORNIA DANGER
PROPOSITION 65 WARNING Identifies immediate hazards that will result in death or
Diesel engine exhaust and some of its constituents are serious injury if the message is ignored.
known to the State of California to cause cancer, birth
defects, and other reproductive harm. 2
BATTERY POSTS, TERMINALS, AND WARNING
Identifies potential hazards that could result in death or
RELATED ACCESSORIES
serious injury if the message is ignored.

CALIFORNIA CAUTION
PROPOSITION 65 WARNING Identifies potential hazards that could result in minor or
The battery posts, terminals, and related accessories moderate injury if the message is ignored.
contains chemical lead and lead compounds, chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm. Wash hands after CAUTION
handling. Without the safety alert symbol, identifies potential
hazards that could result in property damage if the
SAFETY MESSAGES message is ignored.

General NOTE: Highlights operation or maintenance procedures.

The importance of safe operation and maintenance cannot
be over emphasized. Carelessness or neglect on the part of GENERAL
operators, job supervisors and planners, rigging personnel, NOTE: Illustrations have been included in this section to
and job site workers can result in their death or injury and emphasize certain proper and improper points;
costly damage to the crane and property. READ AND FOLLOW PRINTED INSTRUCTIONS.
To alert personnel to hazardous operating practices and It is impossible to compile a list of safety precautions
maintenance procedures, safety messages are used covering all situations. However, there are basic principles
throughout the manual. Each safety message contains a that MUST be followed during your daily routine. Safety is
safety alert symbol and a signal word to identify the hazard’s YOUR PRIMARY RESPONSIBILITY, since any piece of
degree of seriousness. equipment is only as safe AS THE PERS ON AT THE
CONTROLS.
Safety Alert Symbol
With this thought in mind, this information has been provided
to assist you, the operator, in promoting a safe working
atmosphere for yourself and those around you. It is not
meant to cover every conceivable circumstance which could
This safety alert symbol means ATTENTION!
arise. It is intended to present basic safety precautions that
Become alert — your safety is involved! Obey all safety
should be followed in daily operation.
messages that follow this symbol to avoid possible death
or injury. Because you, the operator, are the only part of the crane that
can think and reason, your responsibility is not lessened by
the addition of operational aids or warning devices. Indeed,
you must guard against acquiring a false sense of security

2-1
SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

when using them. They are there to assist, not direct the Allow No One other than the operator to be on the crane
operation. Operational aids or warning devices can be while the crane is functioning or moving, unless they are
mechanical, electrical, electronic, or a combination thereof. seated in a two-man cab.
They are subject to failure or misuse and should not be relied
upon in place of good operating practices. OPERATIONAL AIDS
You, the operator, are the only one who can be relied upon to Grove remains committed to providing reliable products that
assure the safety of yourself and those around you. Be a enable users and operators to safely lift and position loads.
PROFESSIONAL and follow the RULES of SAFETY. Grove has been an industry leader in the incorporation of
REMEMBER, failure to follow just one safety precaution operational aids into the design of its cranes. Federal law
could cause an accident that results in death or serious injury requires that cranes be properly maintained and kept in good
to personnel or damage to equipment. You are responsible working condition. The manuals that Grove provides that are
for the safety of yourself and those around you. specific for each crane and the manufacturer’s manuals for
the operational aids shall be followed. If an operational aid
IMMEDIATELY report all accidents, malfunctions, and should fail to work properly, the crane user or owner must
equipment damages to your local Gr ove distributo r. assure that repair or recalibration is accomplished as soon
Following any accident or damage to equipment, the local as is reasonably possible. If immediate repair or recalibration
Grove distributor must be immediately advised of the of an op e r at io n al ai d i s no t p o ss ib le a n d t he r e a r e
incident and consulted on necessary inspections and exceptional circumstances which justify continued short-
repairs. Should the distributor not be immediately available, term use of the crane when operational aids are inoperative
co n ta c t s ho u ld be ma d e d i re c tl y wi th M an i to wo c or malfunctioning, the following requirements shall apply for
CraneCARE. The crane must not be returned to service until continued use or shutdown of the crane:
it is thoroughly inspected for any evidence of damage. All
damaged parts must be repaired or replaced as authorized 1. Steps shall be taken to schedule repairs and
by yo ur local Gro ve d istrib uto r a nd/o r M anitowoc recalibration immediately. The operational aids shall be
CraneCARE. put back into service as soon as replacement parts, if
required, are available and the repairs and recalibration
can be carried out. Every reasonable effort must be
OPERATOR’S INFORMATION
made to expedite repairs and recalibration.
You must READ and UNDERSTAND the Operator’s and
2. When a load indicator, rated capacity indicator, or
Safety Handbook and the Load Chart before operating the
rated capacity limiter is inoperative or malfunctioning,
crane. You must also VIEW and UNDERSTAND the safety
the designated person responsible for supervising the
video titled “The Real Key to Crane Safety” supplied with
lifting operations shall establish procedures for
your new Grove product. The handbook and Load Chart
determining load weights and shall ascertain that the
must be readily available to the operator at all times and
weight of the load does not exceed the crane ratings at
must remain in the cab while the crane is in use.
the radius where the load is to be handled.
Ensure that all personnel working around the crane are
thoroughly familiar with safe operating practices. You must 3. When a boom angle or radius indicator is inoperative
be thoroughly familiar with the location and content of all or malfunctioning, the radius or boom angle shall be
placards and decals on the crane. Decals provide important determined by measurement.
instructions and warnings and must be read prior to any
4. When an anti-block device, two-blocking damage
operational or maintenance function.
prevention or two-block warning device is inoperative
You must be familiar with the regulations and standards or malfunctioning, the designated person responsible for
governing cranes and their operation. Work practice supervising the lifting operations shall establish
requirements may vary slightly between government procedures, such as assigning an additional signal
regulations, industry standards, and employer policies so a person to furnish equivalent protection. This does not
thorough knowledge of all such relevant work rules is apply when lifting personnel in load-line supported
necessary. personnel platforms. Personnel shall not be lifted when
anti-two block devices are not functioning properly.
DO NOT REMOVE the Load Chart, this Operator’s and
Safety Handbook, or any decal from this crane. 5. When a boom length indicator is inoperative or
Inspect the crane every day (before the start of each shift). malfunctioning, the designated person responsible for
Ensure that routine maintenance and lubrication are being supervising the lifting operations shall establish the
dutifully performed. Don’t operate a damaged or poorly boom lengths at which the lift will be made by actual
maintained crane. You risk lives when operating faulty measurements or marking on the boom.
machinery - including your own.

2-2
TMS800E OPERATOR’S MANUAL SAFETY INFORMATION

6. When a level indicator is inoperative or malfunctioning, • You read, understand, and follow the safety and
other means shall be used to level the crane. operating recom mendations c ontained in the
manufacturer’s manuals, your employer’s work rules,
OPERATOR’S QUALIFICATIONS and applicable government regulations.
• You are sure the machine is operating properly and has
been inspected and maintained in accordance with the
manufacturer’s manuals.
• You are sure that all safety signs, guards, and other
safety features are in place and in proper condition.
Do not attempt to operate the crane unless you are trained
and thoroughly familiar with all operational functions.
Controls and design may vary from crane to crane, therefore,
it is important that you have specific training on the particular
2
crane you will be operating.
Training is ESSENTIAL for proper crane operation. Never
jeo par dize you r o wn wel l-be ing or th at of oth ers by
attempting to operate a crane on which you have not been
An untrained operator subjects himself and others to death trained.
or serious injury.
You must be mentally and physically fit to operate a crane.
YOU MUST NOT OPERATE THIS MACHINE UNLESS: Never attempt to operate a crane while under the influence
• You have been trained in the safe operation of this of medication, narcotics, or alcohol. Any type of drug could
machine. impair physical, visual and mental reactions, and
capabilities.

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SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

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

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

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TMS800E OPERATOR’S MANUAL SAFETY INFORMATION

Work Site If you should encounter a tipping condition, immediately

lower the load with the hoist line and retract or elevate the
Prior to any operation, you must inspect the ENTIRE work boom to decrease the load radius. Never lower or extend the
site, (including ground conditions) where the crane will travel boom, this will aggravate the condition.
and operate. Be sure that the surfaces will support a load
greater than the crane’s weight and maximum capacity. Be sure the load is properly rigged and attached. Always
determine the weight of the load before you attempt to lift it
Barricade the area where the crane is working and keep all and remember that all rigging (slings, etc.) and lifting devices
unnecessary personnel out of that area. (hook block, jib, etc.) must be considered part of the load.
Use caution when operating in the vicinity of overhanging Measure the load radius before making a lift and stay within
banks and edges. approved lifting areas based on the range diagrams and
Be aware of all conditions that could adversely affect the working area diagrams on the crane’s load chart.
stability of the crane.
Wind can have a significant affect on loads that may be lifted
Verify the crane’s capacity by checking the Load Chart
against the weight of the load. Then, lift the load slightly at
2
by a crane. Wind forces act differently on a crane depending first to ensure stability before proceeding with the lift.
upon the direction from which the wind is blowing (e.g., wind Always keep the load as near to the crane and as close to
on the rear of the boom can result in decreased forward the ground as possible.
stability, wind on the underside of the boom can result in
decreased backward stability, wind on the side of the boom The crane can tip over or fail structurally if:
can result in structural damages, etc.). To assist you in • The load and crane’s configuration is not within the
determining prevailing wind conditions, refer to the Wind capacity as shown on the applicable load rating chart
Velocity Chart (Table 2-1). and notes.

Lifting Operations • The ground is soft and/or the surface conditions are
poor.
If the boom extension, jib, or auxiliary boom nose is to be
used, ensure the electrical cable and the weight for the anti- • Outriggers are not properly extended and set. On
two-block switch are properly installed and the LMI is models equipped with outriggers that can be pinned at
programmed for the crane configuration. Refer to the LMI the mid-extend position, the outriggers must also be
handbook supplied with the crane. pinned when operating from the mid-extend position.

Before lifting, position the crane on a firm surface, properly • Cribbing under the outrigger pads is inadequate.
extend and set the outriggers, and level the crane. • The crane is improperly operated.
If the boom extension or auxiliary boom nose is to be used, Wind forces can exert extreme dynamic loads. Grove
you must ensure that the cable for the LMI system is properly recommends that a lift not be made if the wind can
connected at the junction box located on the boom nose. cause a loss of control in handling the load. Grove
Depend ing on the natur e of the suppor ting surfa ce, recommends if the wind speed (velocity) is between 32 km/h
adequate cribbing may be required to obtain a larger bearing (20 mph) to 48 km/h (30 mph), that the load capacities shall
surface. be reduced to account for the size and shape of the load and
the wind direction in relation to the machine for all boom,
DO NOT OVERLOAD THE CRANE by exceeding the boom extension, and jib lengths. Further, operation of the
capacities shown on the appropriate Load Chart. Death or crane in wind velocities over 48 km/h (30 mph) is not
serious injury could result from the crane tipping over or recommended. To assist you in determining prevailing wind
failing structurally from overload. conditions, refer to the Wind Velocity Chart (Table 2-1).
Do not rely on the crane’s tipping to determine your lifting
capacity.

Table 2-1
Wind Velocity Chart

Wind Force
Wind Velocity Visible Indicator
Beauford km/h (mph) Effects of wind as observed on land
Designation
Scale
Zero (0) Calm <2 (<1) No wind: smoke rises vertically
1 Light Air 2-5 (1-3) Wind direction seen by smoke but not by wind vanes

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SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

Wind Force
Wind Velocity Visible Indicator
Beauford km/h (mph) Effects of wind as observed on land
Designation
Scale
2 Light Breeze 6-11 (4-7) Wind felt on face: leaves rustle: wind vane moves slightly
3 Gentle Breeze 13-19 (8-12) Leaves/small twigs in constant motion: wind extends flag
Moderate
4 21-29 (13-18) Raises dust & loose paper: moves small branches
Breeze
Reduce crane load ratings and operating parameters at 32 km/h (20 mph)
Small trees in leaf begin to sway: on ponds, crested wavelets
5 Fresh Breeze 31-39 (19-24)
form
Large branches in motion: telegraph wires whistle: umbrellas
6 Strong Breeze 40-50 (25-31)
used with difficulty
Cease all craning operations at 48 km/h (30 mph); lower & retract boom
7 Moderate Gale 52-61 (32-38) Whole trees in motion: walking against wind is inconvenient

The crane cab is equipped with a sight level bubble that Counterweight
should be used to determine whether the crane is level. The
load line can also be used to estimate the levelness of the On cranes equipped with removable counterweights, ensure
crane by checking to be sure it is in-line with the center of the the appropriate counterweight sections are properly installed
boom at all points on the swing circle. for the lift being considered.

Use tag lines when ever po ssible to help control the To reduce the crushing hazard and to prevent death or
movement of the load. se r io u s i nj u ry , a l wa ys c le a r a l l pe r s on n el fr o m t h e
counterweight and superstructure area before moving the
When lifting loads, the crane will lean toward the boom and counterweight or rotating the superstructure.
the load will swing out, increasing the load radius. Ensure the
load capacity chart is not exceeded when this occurs. Do not add material to the counterweight to increase
capacity.
Be sure the hoist line is vertical before lifting. Do not subject
the crane to side loading. A side load can tip the crane or Federal law prohibits modification or additions which affect
cause it to fail structurally. the capacity or safe operation of the equipment without the
manufacturer’s written approval. [29CFR 1926.550]
Do not strike any obstruction with the boom. If the boom
should accidentally contact an object, stop immediately. MULTIPLE CRANE LIFTS
Inspect the boom. Remove the crane from service if the
boom is damaged. Multiple crane lifts are not recommended.
Never push or pull with the crane boom. Any lift that requires more that one crane must be precisely
Avoid sudden starts and stops when moving the load. The planned and coordinated by a qualified engineer.
inertia and an increased load radius could tip the crane over If it is necessary to perform a multi-crane lift, the operator
or cause it to fail structurally. shall be responsible for assuring that the following minimum
Load Chart capacities are based on freely suspended loads. safety precautions are taken.
Do not pull posts, pilings, or submerged articles. Be sure the 1. Secure the services of a qualified engineer to direct the
load is not frozen or otherwise attached to the ground before operation.
lifting.
2. Use one qualified signal person.
Use only one hoist at a time when lifting loads.
3. Coordinate lifting plans with the operator, engineer, and
Always use enough parts-of-line to accommodate the load to signal person prior to beginning the lift.
be lifted. Lifting with too few parts-of-line can result in failure
of the wire rope. 4. Communication between all parties must be maintained
throughout the entire operation. If possible, provide
Never operate the crane with less than two wraps of wire approved radio equipment for voice communication
rope on the hoist drum. between all parties engaged in the lift.

2-6
TMS800E OPERATOR’S MANUAL SAFETY INFORMATION

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

Two-Blocking
Two-blocking occurs when the load block (hook block,
headache ball, rigging, etc.) comes into physical contact with
the boom (boom nose, sheaves, jib, etc.). Two-blocking can
cause hoist lines (wire rope) rigging, reeving, and other
components to become highly stressed and overloaded in
which case the wire rope may fail allowing the load, block,
etc. to free fall.
Two-blocking is more likely to occur when both the main and
auxiliary hoist lines are reeved over the main boom nose and
boo m e xte nsio n/jib no se res pect ively . A n ope ra tor ,
concentrating on the specific line being used, may telescope To avoid death or serious injury, keep all parts of this
or lower the boom allowing the other hoist line attachment to machine, the rigging, and materials being lifted at least 6 m
contact the boom or boom extension/jib nose, thus causing (20 ft) away from all electrical power lines and equipment.
damage to the sheaves, or causing the wire rope to fail,
Keep all personnel away from this machine if it is being
operated near electrical power lines or equipment.

2-7
SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

Before operating this crane in the vicinity of electrical power Set-Up and Operation
lines or equipment, notify the power utility company. Obtain
positive and absolute assurance that the power has been During crane use, assume that every line is energized (“hot”
turned off. or “live”) and take the necessary precautions.

This machine is NOT INSULATED. Always consider all parts Set up the crane in a position such that the load, boom, or
of the load and the crane, including the wire rope, hoist any part of the crane and its attachments cannot be moved
cable, pendant cables, and tag lines, as conductors. to within 6 m (20 ft) of electrical power lines or equipment.
This includes the crane boom (fully extended to maximum
Most overhead power lines ARE NOT insulated. Treat all height, radius, and length) and all attachments (jibs, boom
overhead power lines as being energized unless you have extensions, rigging, loads, etc.). Overhead lines tend to blow
reliable information to the contrary from the utility company in the wind so allow for lines’ movement when determining
or owner. safe operating distance.
The rules in this handbook must be followed at all times, A suitable barricade should be erected to physically restrain
even if the electrical power lines or equipment have been de- the crane and all attachments (including the load) from
energized. entering into an unsafe distance from electrical power lines
Crane operation is dangerous when close to an energized or equipment.
electrical power source. Exercise extreme caution and
prudent judgement. Operate slowly and cautiously when in
the vicinity of power lines.
If the load, wire rope, crane boom, or any portion of the crane
contacts or comes too close to an electrical power source,
everyone in, on, and around the crane can be seriously
injured or killed.
The safest way to avoid electrocution is to stay away from
electrical power lines and electrical power sources.
You, the operator, are responsible for alerting all personnel
of dangers associated with electrical power lines and
equipment. The crane is not insulated. Do not allow
unnecessary personnel in the vicinity of the crane while
operating. Permit no one to lean against or touch the crane.
Permit no one, including riggers and load handlers, to hold
the load, load lines, tag lines, or rigging gear. Plan ahead and always plan a safe route before traveling
under power lines. Rider poles should be erected on each
Even if the crane operator is not affected by an electrical
sid e of a cro ss ing t o as su re s uf fic ie nt cl ea ra nc e is
contact, others in the area may become seriously injured or
maintained.
killed.
Appoint a reliable and qualified signal person, equipped with
It is not always necessary to contact a power line or power
a loud signal whistle or horn and voice communication
source to become electrocuted. Electricity, depending on
equipment, to warn the operator when any part of the crane
magnitude, can arc or jump to any part of the load, load line,
or load moves near a power source. This person should
or crane boom if it comes too close to an electrical power
have no other duties while the crane is working.
source. Low voltages can also be dangerous.
Tag lines should always be made of non-conductive
Thoroughly read, understand, and abide by all applicable
materials. Any tag line that is wet or dirty can conduct
federal, state, and local regulations.
electricity.
Federal law prohibits the use of cranes closer than 3 m (10 ft)
DO NOT store materials under power lines or close to
to power sources up to 50,000 volts and greater distances
electrical power sources.
for higher voltages [29CFR1910.180 and 29CFR1926.550].
Manitowoc/Grove recommends keeping cranes twice the
minimum distance [e.g., 6 m (20 ft)] as specified by US
Electrocution Hazard Devices
Department of Labor - Occupational Safety and Health The use of insulated links, insulated boom cages/guards,
Administration (OSHA) standards. proximity warning devices, or mechanical limit stops does
not assure that electrical contact will not occur. Even if codes
or regulations require the use of such devices, failure to
follow the rules listed here may result in serious injury or

2-8
TMS800E OPERATOR’S MANUAL SAFETY INFORMATION

death. You should be aware that such devices have of the voltage and current present, and numerous other
limitations and you should follow the rules and precautions factors.
outlined in this handbook at all times even if the crane is
equipped with these devices. Electrical Contact
Insulating links installed into the load line afford limited If the crane should come in contact with an energized power
protection from electrocution hazards. Links are limited in source, you must:
their lifting abilities, insulating properties, and other
1. Stay in the crane cab. DON’T PANIC.
properties that affect their performance. Moisture, dust, dirt,
oils, and other contaminants can cause a link to conduct 2. Immediately warn personnel in the vicinity to stay away.
electricity. Due to their capacity ratings, some links are not
3. Attempt to move the crane away from the contacted
effective for large cranes and/or high voltages/currents.
power source using the crane’s controls which are likely
The only protection that may be afforded by an insulated link
is below the link (electrically downstream), provided the link
4.
to remain functional.
Stay in the crane until the power company has been
2
has been kept clean, free of contamination, has not been
contacted and the power source has been de-energized.
scratched or damaged, and is periodically tested (just before
NO ONE must attempt to come close to the crane or
use) for its dielectric integrity.
load until the power has been turned off.
Boom cages and boom guards afford limited protection from
Only as a last resort should an operator attempt to leave the
electrocution hazards. They are designed to cover only the
crane upon contacting a power source. If it is absolutely
boom nose and a small portion of the boom. Performance of
neces s ary to leav e the operator s tation, J U MP
boom cages and boom guards is limited by their physical
COMPLETELY CLEAR OF THE CRANE. DO NOT STEP
size, insulating characteristics, and operating environment
OFF. Hop away with both feet together. DO NOT walk or run.
(e.g. dust, dirt, moisture, etc.). The insulating characteristics
of these devices can be compromised if not kept clean, free Following any contact with an energized electrical source,
of contamination, and undamaged. the local, authorized, Manitowoc/Grove distributor must be
immediately advised of the incident and consulted on
Proximity sensing and warning devices are available in
necessary inspections and repairs. Thoroughly inspect the
different types. Some use boom nose (localized) sensors
wire rope and all points of contact on the crane. Should the
and others use full boom length sensors. No warning may be
distributor not be immediately available, contact Manitowoc
given for components, cables, loads, and other attachments
CraneCARE. The crane must not be returned to service until
located outside of the sensing area. Much reliance is placed
it is thoroughly inspected for any evidence of damage and all
upon you, the operator, in selecting and properly setting the
damaged parts are repaired or replaced as authorized by
sensitivity of these devices.
Manitowoc/Grove CraneCARE or your local Manitowoc/
Never rely solely on a device to protect you and your fellow Grove distributor.
workers from danger.
Special Operating Conditions and
Some variables you must know and understand are:
Equipment
• Proximity devices are supposed to detect the existence
of electricity and not its quantity or magnitude. Never operate the crane during an electrical thunderstorm.

• Some proximity devices will detect only alternating Working in the vicinity of radio frequency transmission
current (AC) and not direct current (DC). towers and other transmission sources may cause a crane to
become “electrically charged.”
• Some proximity devices detect radio frequency (RF)
energy and others do not. When operating cranes equipped with electromagnets you
must take additional precautions. Permit no one to touch the
• Most proximity devices simply provide a signal (audible, magnet or load. Alert personnel by sounding a warning
visual, or both) for the operator and this signal must not signal when moving a load. Do not allow the cover of the
be ignored. electromagnet power supply to be open during operation or
• Sometimes the sensing portion of the proximity devices at any time the electrical system is activated. Shut down the
becomes confused by complex or differing arrays of crane completely and open the magnet controls switch prior
power lines and power sources. to connecting or disconnecting magnet leads. Use only a
non-conductive device when positioning a load. Lower the
DO NOT depend on grounding. Grounding of a crane affords magnet to the stowing area and shut off power before
li t t le o r n o p r o te c t io n fr o m e le c tr i c a l h a za r d s. T h e leaving the operator’s cab.
effectiveness of grounding is limited by the size of the (wire)
conductor used, the condition of the ground, the magnitude

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SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

CRUSHING HAZARDS

All four outrigger beam lock pins must be engaged before

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

Barricade the entire area where the crane is working and

PERSONNEL HANDLING
keep all unnecessary personnel out of the work area.
The American Society of Mechanical Engineers issued a
Ne ve r allow anyone t o stand or wo rk on or near the
new American National Standard entitled, Personnel Lifting
superstructure while the crane is in operation.
Systems, ASME B30.23-1998. This standard provides,
Always barricade the tail- sw ing of the rotating "lifting and lowering of personnel using ASME B30 Standard
superstructure. hoisting equipment shall be undertaken only in
circumstances when it is not possible to accomplish the task
Before actuating swing or any other crane function, sound
by less hazardous means. Unless all of the applicable
the horn and verify that all personnel are clear of rotating and
requirements of this volume are met, the lifting or lowering of
moving parts.
pe r son n el us in g A S ME B 30 S t an da r d eq ui pm en t is
Watch the path of the boom and load when swinging. Avoid prohibited." This new standard is consistent with the U.S.
lowering or swinging the boom and load into ground Department of Labor, Occupational Safety and Health
personnel, equipment, or other objects. Administration (OSHA) regulations for Construction that
state, in 29CFRI926.550(g)(2): "General requirements. The
Always be aware of your working environment during
use of a crane or derrick to hoist employees on a personnel
operation of the crane. Avoid contacting any part of the crane
platform is prohibited, except when the erection, use, and
with external objects.
dismantling of conventional means of reaching the worksite,
You must always be aware of everything around the crane such as a personnel hoist, ladder, stairway, aerial lift,
while lifting or traveling. If you are unable to clearly see in the ele va tin g wo r k p lat fo rm or s caf fo ld, wo uld b e m or e
direction of motion, you must post a look out or signal person hazardous or is not possible because of structural design or
before moving the crane or making a lift. Sound the horn to worksite conditions." Additional requirements for crane
warn personnel. o p er at i o n s a r e s t a t ed i n A S M E B 30 . 5 , M o b il e A n d
Locom otiv e C ranes, and in O SH A regulations
Clear all personnel from the outrigger area before extending 29CFRI910.180 for General Industry and 29CFRI926.550
or retracting the outriggers. for Construction.

Carefully follow the procedures in this handbook when Use of a Grove crane to handle personnel is acceptable
extending or retracting the outriggers. Death or serious injury provided:
could result from improper crane set up on outriggers. • The requirements of the applicable national, state and
Be sure the outriggers are properly extended, set and the local regulations and safety codes are met.
crane is level for operation on outriggers. • A determination has been made that use of a crane to
All four outrigger beams must be equally extended to the mid handle personnel is the least hazardous means to
position vertical stripe or fully extended position before perform the work.
beginning operation.

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TMS800E OPERATOR’S MANUAL SAFETY INFORMATION

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

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SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

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

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TMS800E OPERATOR’S MANUAL SAFETY INFORMATION

TIRES When installing and inspecting wire ropes and attachments,

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

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SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

breaks may prove inadequate in predicting rope Never exit or enter the crane cab or deck by any other means
failure. The user of cast nylon sheaves is therefore than the access system(s) provided (i.e., steps and grab
cautioned that a retirement criteria should be handles).
established based upon the user’s experience and
If necessary, use a ladder or aerial work platform to access
the demands of his application.
the boom nose.

BATTERIES Do not step on surfaces on the crane that are not approved
or suitable for walking and working. All walking and working
Battery electrolyte must not be allowed to contact the skin or surfaces on the crane should be clean, dry, slip-resistant,
eyes. If this occurs, flush the contacted area with water and and have adequate supporting capacity. Do not walk on a
consult a doctor immediately. surface if slip-resistant material is missing or excessively
When checking and maintaining batteries exercise the worn.
following procedures and precautions: Do not use the top of the boom as a walkway.
• Disconnect the batteries. Do not step on the outrigger beams or outrigger pads (floats)
• Wear safety glasses when servicing batteries. to enter or exit the crane.

• Do not short across the battery posts to check charge. Wear shoes with a highly slip-resistant sole material. Clean
Short circuit, spark, or flame could cause battery any mud or debris from shoes before entering the crane cab
explosion. or climbing onto the crane superstructure. Excessive dirt and
debris on the hand-holds, access steps, or walking/working
• Maintain battery electrolyte at the proper level. Check surfaces could cause a slipping accident. A shoe that is not
the electrolyte with a flashlight. clean might slip off a control pedal during operation.
• If applicable to your crane, check battery test indicator Do not make modifications or additions to the crane’s access
on maintenance-free batteries. system that have not been evaluated and approved by
• Do not break a live circuit at the battery terminal. Manitowoc CraneCARE.
Disconnect the ground battery cable first when removing
a battery and connect it last when installing a battery. Job Preparation
• Check battery condition only with proper test equipment. You must inspect the crane prior to your work shift - checking
Batteries shall not be charged except in an open, well- for cracked welds, damaged components, and evidence of
ventilated area that is free of flame, smoking, sparks, improper maintenance (consult Maintenance-Inspection and
and fire. Service Manual).
You must ensure that the crane is properly equipped
ENGINE including access steps, covers, doors, guards, and controls.
Be careful when checking the engine coolant level. The fluid You must ensure that the outriggers are properly extended
may be hot and under pressure. Shut down the engine and and set before performing any lifting operations. On models
allow the radiator time to cool before removing the radiator equipped with outriggers that can be pinned at the mid-
cap. extend position, the outriggers must also be pinned when
operating from the mid-extend position.
Shut down the engine and disconnect the battery before
performing maintenance. If unable to do so for the task W ea r ap pr o p ri at e c lo th i ng a n d p er s on al pr o te ct iv e
required, keep hands clear of the engine fan and other e q u ip m e n t w h e t h er o r n o t r e q u ir e d b y l o ca l o r j o b
moving parts while performing maintenance. regulations. Be prepared for the work day.
Be careful of hot surfaces and hot fluids when performing Before entering the cab, you must be THOROUGHLY
maintenance on or around the engine. familiar with the planned rout e of travel and ar ea of
operation, including surface conditions and the presence of
WORK PRACTICES overhead obstructions and power lines.
Always keep the crane clean, free of dirt, debris, and grease.
Crane Access
Fuel the crane ONLY with the engine turned off. Do not
You must take every precaution to ensure you do not slip smoke while fueling the crane. Do not store flammable
and/or fall off the crane. Falling from any elevation could materials on the crane or in the operator’s cab.
result in serious injury or death.
Follow standard safety precautions when refueling. FUEL IT
SAFELY.

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TMS800E OPERATOR’S MANUAL SAFETY INFORMATION

Be familiar with the location and use of the nearest fire LIFT ONE LOA D A T A TIME. Do not lift two or more
extinguisher. separately rigged loads at one time, even if the loads are
within the crane’s rated capacity.
Cold weather requires special starting procedures, use of
built-in starting aids, if provided, and ample time for hydraulic
oil to warm-up. Keep the crane free of ice and snow.

Working
Never operate the crane when darkness, fog, or other
visibility restrictions make operation unsafe. Never operate a
crane in thunderstorms or high winds.
Keep unauthorized personnel clear of the working area
during operation. 2
Operate the crane only from the operator’s seat. Do not
reach in a window or door to operate any controls.
Operate the crane slowly and cautiously, looking carefully in
the direction of movement.
“Stunt” driving and “horse-play” are strictly prohibited. Never
allow anyone to hitch a ride or get on or off a moving crane.
A good practice is to make a “dry run” without a load before
making the first lift. Become familiar with all factors peculiar
to the job site.
Ensure the wire rope is properly routed on the hook block
and boom nose and that all rope guards are in place.
USE ENOUGH PARTS OF LINE FOR ALL LIFTS AND
CHECK ALL LINES, SLINGS, AND CHAINS FOR Never leave the crane with a load suspended. Should it
CORRECT ATTACHMENT. To obtain maximum lifting become necessary to leave the crane, lower the load to the
capacities, the hook block must be set up with enough parts ground and stop the engine before leaving the cab.
of line. NO LESS THAN TWO WRAPS of wire rope should
remain on the hoist drum. When slings, ties, hooks, etc., are Remember - all rigging equipment must be considered as
used, make certain they are correctly positioned and part of the load. Lifting capacities vary with working areas.
secured before raising or lowering the loads. Permissible working areas are posted in the crane cab.
When swinging from one working area to another, ensure
Be sure the rigging is adequate before lifting. Use tag lines load chart capacities are not exceeded. Know your crane!
when possible to position and restrain loads. Personnel
using tag lines should be on the ground. Never swing or lower the boom into the carrier cab.

Be sure good rigging practices are being used. Refuse to Stop the hook block from swinging when unhooking a load.
use any poorly maintained or damaged equipment. Never Swinging rapidly can cause the load to swing out and
wrap the hoist cable around a load. increase the load radius. Swing the load slowly. Swing with
caution and keep the load lines vertical.
Lifting
Look before swinging your crane. Even though the original
Operate the crane at or near governed RPM during all lifting setup may have been checked, situations do change.
operations.
Keep everyone away from suspended loads. Allow no one to
Check the hoist brake by raising the load a few inches, walk under a load. Ensure that all slings, ties, and hooks are
stopping the hoist and holding the load. Be sure the hoist correctly placed and secured before raising or lowering the
brake is working correctly before continuing the lift. load.
When lowering a load always slow down the load’s descent Use tag lines (as appropriate) for positioning and restraining
before stopping the hoist. Do not attempt to change speeds loads. Check the load slings before lifting.
on multiple-speed hoists while the hoist is in motion.
Be sure everyone is clear of the crane and work area before
making any lifts.

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SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

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

TRANSPORTING THE CRANE

When loading or unloading the crane on a trailer or railroad
car, use a ramp capable of supporting the weight of the
crane.
Ensure the crane is adequately secured to the transporting
vehicle.
If it is necessary to take the crane on a road or highway, first
check state and local restrictions and regulations.
Check load limits of bridges on the travel route and ensure
they are greater than the combined weight of the crane and
transporting vehicle.
Always drive the crane carefully, obeying speed limits and
highway regulations. Keep lights on and use traffic warning
flags and signs and front and rear flag vehicles as applicable.

SHUT-DOWN
Never leave the crane with a load suspended. Lower the
load to the ground before shutting down the crane.
Use the following steps when shutting down the crane:
• Engage the parking brake.
• Fully retract and lower the boom.
• Engage the pin swing lock or 360 degree swing lock.
A qualified signal person shall be used at all times when: • Place controls in neutral position.
• Working in the vicinity of power lines. • Shut down the engine and remove the ignition key.
• The crane operator cannot clearly see the load at all • Chock the wheels.
times.
• Lock the operator’s cab and install vandal guards, if
• Moving the crane in an area or direction in which the used.
operator cannot clearly see the path of travel.
In cold weather, never park the crane where the tires can
become frozen to the ground.

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TMS800E OPERATOR’S MANUAL SAFETY INFORMATION

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

TEMPERATURE EFFECTS ON HYDRAULIC

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

2-17
SAFETY INFORMATION TMS800E OPERATOR’S MANUAL

decrease as the lift cylinder(s) retracts causing an increase chart is for dry rod cylinders. If the cylinder rod is filled with
in radius and a decrease in load height. hydraulic oil, the contraction rate is somewhat greater.
This situation will also occur in reverse. If a crane is set up in NOTE: Operators and service personnel must be aware
t he m or n i ng wi t h c o ol o il a n d th e da y t im e a m b ie n t that load movement, as a result of this phenomena,
temperature heats the oil, the cylinders will extend in similar can be easily mistaken as leaking cylinder seals or
proportions. faulty holding valves. If leaking seals or faulty
holding valves are suspected to be the problem,
Table 2-2 has been prepared to assist you in determining the
refer to Service Bulletin 98-036 dealing with testing
approximate amount of retraction/extension that may be
telescope cylinders
expected from a hydraulic cylinder as a result of change in
the temperature of the hydraulic oil inside the cylinder. The

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

3 3
Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74
20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96

3 3
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in /in / °F) X 12 in/ft

2-18
 SECTION 3
OPERATING CONTROLS AND PROCEDURES
TABLE OF CONTENTS
Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Stop/Module Off Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Warning/Electrical System Diagnostic Indicator . . . . . . . . . . . . . . . . . . 3-1
Engine Coolant Temperature/Auxiliary Transmission Low Range Indicator . . . 3-2
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine Brake On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine Brake High/Low Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine Diagnostic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine Wait To Start Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Travel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Dual Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Low Air Pressure/Tire Inflation On Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3
Park Brake Engaged Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cross-Axle Differential Locked Indicator (Optional) . . . . . . . . . . . . . . . . . . . . . 3-3
Cross-Axle Differential Lock Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inter-Axle Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inter-Axle DIfferential Lock Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Transmission Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Transmission Range Control Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Gear Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Trailing Boom Trailer Emergency Brake Control (Optional) . . . . . . . . . . . . . . . 3-6
Swing Brake Engaged Indicator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Suspension Inflation Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Suspension Deflated Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Auxiliary Transmission Low Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Craning Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Swing Brake Engaged Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
High Beam/Lamp Malfunction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Heater On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Heater /Air Conditioner Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Air Conditioner Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Windshield Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Headlights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Beacon Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Headlights Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Hazard Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Left Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Right Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-i
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

Steering Column Tilt/Telescope Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Cab Circulating Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Tire Inflation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
12 VDC Accessory Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Cab Dome Light (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Air Horn (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Fuse and Relay Panel (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Carrier Electrical Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Additional Carrier Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Outrigger Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Outrigger Selector Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Center Front Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Daytime Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Superstructure Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Engine Stop/Module Off Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Engine Warning/Electrical System Diagnostic Indicator . . . . . . . . . . . . . . . . 3-11
Engine Wait To Start Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Foot Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Craning Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Telescope/Auxiliary Hoist/Swing Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Boom Lift/Main Hoist Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Swing Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Telescope Control Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Main Hoist Speed Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Auxiliary Hoist Speed Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Hoist Rotation Indicators (Main and Auxiliary Hoist) . . . . . . . . . . . . . . . . . . . 3-12
Crane Function Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Outrigger Extend/Retract Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Center Front Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Left Front Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Right Front Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Left Rear Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Right Rear Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Center Front Stabilizer Overloaded Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Bubble Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Swing Brake Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Swing Lock Control (Pin Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
360° Swing Lock Control (Positive Lock Type) (Optional) . . . . . . . . . . . . . . . 3-17
Swing Brake Engaged Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Swing Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Cab Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Accessory Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Boom Lights Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-ii
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

Cab Circulating Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Windshield Wiper/Washer Switch and Motor . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Skylight Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Heater On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Heater /Air Conditioner Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Air Conditioner Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Beacon Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Crane’s Electrical System Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . 3-18
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Breaking-In A New Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Pre-Starting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Hydraulic Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Hook Block and Headache Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Seats and Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Signal and Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 3
Service and Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Operation Below -40°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Operation Below -40°F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Idling The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Racing The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
General Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Control Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Preload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Using Your Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Crane Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Using the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Setting The Outriggers (From Ground Outrigger Control Panels) . . . . . . . . . . 3-24
Stowing The Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Setting The Center Front Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Stowing The Center Front Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Setting The Outriggers (From Superstructure Cab Controls) . . . . . . . . . . . . . 3-27
Swinging The Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Elevating And Lowering The Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Telescoping The Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Lowering And Raising The Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Load Moment Indicator (LMI) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Control Lever Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-iii
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

Crane Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Active Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Traveling - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
UltraShift™ Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Gear Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Start-up and Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Proper Starting Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Skip Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Optimal Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Skid Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Load Based Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Coast Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Clutch Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Reverse Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Drive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Low Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Transmission Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Auxiliary Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Rear Tandem Inter-Axle/Cross-Axle Locks . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Service/Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Crane Shutdown Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-iv
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

SECTION 3
OPERATING CONTROLS AND PROCEDURES
The crane is equipped with two cabs, a carrier cab and a engine coolant temperature on a scale calibrated from 100 to
superstructure cab. The carrier cab (see Figure 3-1) contains 240° F. The gauge receives a signal from the crane’s
all controls and indicators necessary for crane traveling and electronic operating system which receives the signal from
parking. The superstructure cab (see Figure 3-3) contains all the engine ECM via J1939.
controls and indicators necessary to perform all craning
Fuel Quantity Gauge
operations. Both cabs utilize international symbols and
English text to label the various controls. For detailed The fuel quantity (FUEL) gauge is located on the upper left of
information on either cab, refer to either CARRIER CAB or the gauge cluster. The gauge indicates the quantity of fuel in
SUPERSTRUCTURE CAB in this Section. the tank and has a scale calibrated from empty (E) to full (F).
The fuel quantity gauge receives a signal from the crane’s
NOTE: The following paragraphs describe all the available
electronic operating system which monitors a sending unit in
(standard and optional) controls and indicators
the fuel tank.
located in the cab. Some machines may not be
equipped with the optional controls shown. The Engine Stop/Module Off Line Indicator
numbers in ( ) represent the index number from
(Figures 3-1 through 3-3). The engine stop/module off line indicator (23) is located on
the top left side of the front console. The top portion of the
NOTE: All rocker switches contain one or two LED’s in the switch is the stop indicator. It illuminates red when energized
switch for illumination. by a signal from the engine ECM that signifies a serious
NOTE: All indicators on the top row of the consoles will engine problem that requires the vehicle and the engine to
illuminate solid, all at the same time for
approximately two seconds as a diagnostic test
be stopped as soon as safely possible. In addition, a warning
buzzer will also sound.
3
when the ignition switch is positioned to on. If any In addition to alerting the operator of system faults, the stop
indicator fails to illuminate, replace it immediately. light, in conjunction with the warning light, is used in the
diagnostic operation of the engine control system. The
CARRIER CAB diagnostic mode begins when the ignition and engine
diagnostic switch is on and the engine is not running. The
Engine Controls and Indicators amb er li ght flashe s at the begin ning of a fa ult co de
sequence, the red light flashes the three-digit or four-digit
Gauge Cluster code for the active and the amber light flashes again to
The gauge cluster (5) is located in the center of the front separate the previous red light sequence from the next one.
console assembly and contains a voltmeter, oil pressure Each code will be flashed twice before moving to the next
gauge, water temperature gauge, and a fuel quantity gauge. code. When all codes have been flashed, the sequence will
begin again. If no codes are present, both the warning and
Voltmeter stop lights will remain on.
The voltmeter (VOLTS) is located on the lower right of the The bottom portion is the module off line indicator. This
gauge cluster. With the ignition switch in the run (between indicator will come on solid and a buzze r will sound
vertical and far right) position and before starting the engine, whenever communication with one of the crane’s electronics
the voltmeter indicates the condition of the batteries. With modules is lost. The vehicle should be stopped as soon as
the engine running, the voltmeter indicates output voltage of safely possible. The crane must be restored to proper
the alternator. The voltmeter scale is from 10 to 16 volts. condition before operating again.
Engine Oil Pressure Gauge Engine Warning/Electrical System Diagnostic
The engine oil pressure (OIL) gauge is located on the upper Indicator
right of the gauge cluster. The gauge indicates the engine oil
The engine warning/electrical system diagnostic indicator
pressure on a scale calibrated from zero (0) to 80 psi. It
(24) is located at the top left side of the front console. The top
receives a signal from the crane’s electronic operating
portion is the warning indicator. It illuminates amber when
system which receives the signal from the engine ECM via
energized by a signal from the engine ECM that signals the
J1939.
operator of an engine problem which must be corrected.
Water Temperature Gauge In addition to alerting the operator of system faults, the
The engine coolant temperature (TEMP) gauge is located on warning light, in conjunction with the stop light, is used in the
the lower left of the gauge cluster. The gauge indicates the diagnostic operation of the engine control system. The

3-1
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

diagnostic mode begins when the ignition and engine Ignition Switch
diagnostic switch is on and the engine is not running. The
The ignition switch (14) is located on the right side of the
ambe r lig ht f lashe s at the begin ning of a fau lt co de
front console. The switch is key operated with four positions:
sequence, the red light flashes the three-digit or four-digit
accessory (left position), off (vertical position), run (position
code for the active fault and the amber light flashes again to
between vertical and right), and start (right position).
separate the previous red light sequence from the next one.
Each code will be flashed twice before moving to the next With ignition switches in both cabs in the off position, all
code. When all codes have been flashed, the sequence will electrical power is off except for the headlights, marker
begin again. If no codes are present, both the warning and ligh ts, gaug e lig hts, tu rn and sto p lig ht, car rier a nd
stop lights will remain on. superstructure cab dome lights, carrier and superstructure
cab 12V accessory outlets, superstructure cab work lights,
The bottom portion of the switch is the electrical system
and superstructure horn.
diagnostic indicator. There are three conditions for this
indicator as follows: The accessory position energizes all electrical components
except the engine ECM. The run position is the same as
a. On solid with buzzer sounding - There is an
accessory except the engine ECM is energized. The start
interruption of communication over the main canbus
position energizes the starter relay which in turn energizes
control line between the crane’s electronic control
the cranking motor solenoid and cranks the engine for
modules. Proper crane operating condition shall be
starting. The switch will return to run when the switch is
restored as quickly as possible.
released after the engine is started. Turn the switch to off to
b. Flashing with buzzer sounding - An undesirable shut down the engine.
condition with the crane’s joysticks has been
detected. Proper crane operating condition shall be Throttle Pedal
restored before performing any hydraulic function. The THROTTLE pedal (38) is the right most pedal on the cab
c. Flashing without buzzer - An undesirable floor. It is used to control engine speed. The foot pedal
component or electrical system condition has modulates engine speed proportionately to the foot pressure
occurred. applied. The pedal is angled for increased operator comfort.
The foot pedal is monitored by the crane’s electronic
Engine Coolant Temperature/Auxiliary Transmission operating system which sends the information to the engine
Low Range Indicator ECM via J1939.
The engine coolant temperature/auxiliary transmission low Engine Diagnostic Switches
range indicator (25) is located at the top left side of the front
console. It illuminates amber to indicate high engine coolant Two engine diagnostic switches are located on the left front
temperature or transmission low range. side of the front console.
Engine Idle/Diagnostic Switch
Tachometer
The engine idle/diagnostic switch (36) located on the left side
The tachometer (2) is located on the right side of the front
of the front console is used when servicing the engines
console. The tachometer is calibrated in RPM x 100 with a
electronic control system.
range of zero (0) to 35. It receives a signal from the crane’s
electronic operating system which receives the signal from It is a two position on/off switch used to activate the testing
the engine ECM via J1939. mode (fault codes). When the switch is in the diagnostic
po siti on an d i s u sed in co nju nct ion wit h t he en gin e
Engine Brake On/Off Switch increment/decrement (+/-) switch, access will be gained to
The engine brake on/off switch is located on the left center toggle up and down through the fault codes.
side of the front console. The two position (on/off) switch (22) Engine Increment/Decrement Switch
energizes the engine brake. When the top of the switch is
pushed, the switch is in the on position. The engine increment/decrement switch (35) located on the
left side of the front console is used when servicing the
Engine Brake High/Low Switch engines electronic control system.
The two position engine brake high/low switch (20) controls It is a two-position (+/-) momentary switch that provides idle-
the amount of engine braking. control inputs that increases and decreases the engine idle
When the top of the switch is pushed, the switch is in the high when the idle/diagnostic switch is n the idle position.
position. Pushing the top of the switch increases (+) engine RPM or
pushing the bottom of the switch decreases (-) engine RPM.

3-2
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

Engine Wait To Start Indicator crane parking brakes are applied. It is illuminated by a
pressure switch on the parking brake valve.
The engine wait to start indicator (30) is located on the top
left side of the front console. It illuminates amber for a period The bottom of the indicator illuminates red to warn the
of time when the ignition switch is turned to the on position. operator that the swing brake release pressure is not enough
The engine should not be cranked until the wait to start to hold the swing brake disengaged during trailing boom
indicator turns off and a solid “N” is visible in the transmission operation. In addition to illuminating the indicator, a warning
gear display (see item 57). buzzer will sound.

Travel Controls and Indicators Cross-Axle Differential Locked Indicator (Optional)

The cross-axle differential locked indicator (26) is located at
Dual Air Pressure Gauge
the left center side of the front console. The amber indicator
The dual air pressure gauge (1) is located on the right side of illuminates to show that the cross axle differential is locked.
the front console. The gauge is a direct reading pressure
gauge with two indicating pointers, red for the primary
system and green for the secondary system. The gauge has CAUTION
a dual scale calibrated from 100 to 1000 kPa and 0 to Do not operate the cross axle differential lock or the inter-
150 psi. The gauge is connected to each air system axle differential lock on dry roads.
separately through tubing.

Low Air Pressure/Tire Inflation On Indicator Cross-Axle Differential Lock Switch (Optional)

The low air pressure/tire inflation on indicator (27) is located The cross-axle differential lock switch (17) is located on the
on the top left side of the front console. The indicator left center side of the front console and is used to lock the
illuminates red when the pressure in either or both air
systems is below 517 kPa (75 psi). The indicator is controlled
right and left wheels in a tandem set. The cross-axle
differential lock increases traction on slippery roads. It is a 3
by two pressure switches electrically connected in parallel. two position lock/unlock switch. Press top of switch for the
To determine which system pressure is low, observe the lock position or bottom of switch for the unlock position.
dual air pressure gauge. In addition to illuminating the
indicator, a warning buzzer will sound.
CAUTION
The bottom of the indicator illuminates amber when the Do not operate cross-axle differential lock while crane
pressure switch in the tire inflation system is activated. In wheels are spinning or at speeds over approximately 16
addition to illuminating the indicator, a warning buzzer will km/h (10 mph). Release the throttle when locking or
sound. unlocking.
Speedometer
Inter-Axle Differential Lock Switch
The speedometer (4) is located in the center of the front
console above the steering wheel. The speedometer The inter-axle differential lock switch (15) is located on the
indicates road speed in both km/h (kilometers per hour) and left center side of the front console. In the lock (press top of
mph (miles per hour). switch) position, both rear axles are locked together and
turning at the same speed. In the unlocked (press bottom of
Odometer switch) position, the axles operate independently of each
other.
There is an odometer (16) located at the bottom of the
speedometer and shows total distance traveled.

Parking Brake Control CAUTION

Do not operate inter-axle differential lock switch while
NOTE: The park brake must be set before the outrigger
crane wheels are spinning or at speeds over
controls will operate.
approximately 16 km/h (10 mph). Release the throttle
The parking brake control (12) is located on the right side of when locking or unlocking.
the front console. The control is a push-pull type air valve
used to apply and release the parking brakes on all four rear Inter-Axle DIfferential Lock Indicator
wheels.
The inter-axle differential lock indicator (32) is located on the
Park Brake Engaged Indicator left center side of the front console. The amber indicator
illuminates when the inter-axle differential lock is engaged.
The park brake engaged indicator (29) is located at the top of
the front console. The indicator illuminates red when the

3-3
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

53 51
53

See View A
39

50
37

49
38

56
40
55
47
34
46
33
See View B
45

59

18

48
10

43
7

42
54
52
6562

6560
View B

FIGURE 3-1

3-4
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

24 58 28 3
25 30 29
23 27 6
5 11
4 2 1

22

36
35 16
20 15
32 26
17
12

View A 6558
21 19 57 14
31 13

FIGURE 3-1 continued 3

Item Description Item Description
1 Dual Air Pressure Gauge 20 Engine Brake High-Low Switch
2 Tachometer 21 Headlights Switch
3 Left Turn Signal Indicator 22 Engine Brake On/Off Switch
4 Speedometer 23 Engine Stop/Module Off Line Indicator
5 Gauge Cluster 24 Engine Warning/Electrical Diagnostic Indicator
6 Right Turn Signal Indicator Engine Coolant Temperature/Auxiliary
25
Transmission Low Indicator
7 Heater On/Off Switch
Cross-Axle Differential Locked Indicator
8 Heater/Air Conditioner Fan Switch 26
(Optional)
9 12 Volt Accessory Outlet 27 Low Air Pressure/Tire Inflation On Indicator
10 Air Conditioner Switch (Optional) 28 High Beam/Lamp Malfunction Indicator
Trailing Boom Trailer Emergency Brake Control Park Brake Engaged/Swing Brake Engaged
11 29
(Optional) Indicator
12 Parking Brake Control 30 Engine Wait To Start indicator
13 Windshield Wiper/Washer Switch 31 Dimmer Switch
14 Ignition Switch 32 Inter-Axle Differential Lock Indicator
15 Inter-Axle Differential Lock Switch 33 Suspension Deflated Indicator
16 Odometer 34 Suspension Inflation Control Switch
17 Cross-Axle Differential Lock Switch (Optional) 35 Engine Increment/Decrement Switch
18 Tire Inflation Switch 36 Engine Idle/Diagnostic Switch
19 Beacon Light Switch (Optional) 37 Brake Pedal

3-5
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

side of the front console. The control is used to set and

release the brakes on the trailing boom trailer.
Item Description
38 Throttle Pedal Swing Brake Engaged Indicator (Optional)
39 Carrier Electrical Diagnostic Connector The swing brake engaged indicator (58) is located on the top
left side of the front console. The indicator illuminates when
40 Transmission Shift Lever
the re is suff icien t pre ssur e t o hold th e swi ng bra ke
41 Ash Tray (Not Shown) disengaged during trailing boom operation. In addition to
illuminating the indicator, a warning buzzer will sound.
42 Beacon Light (Optional)
43 Fire Extinguisher Suspension Inflation Control Switch
44 Cab Dome Light (Not Shown) The suspension inflation control switch (34) is located on the
right side console. When positioned to the right to inflate, the
45 Steering Wheel
suspension air bags are inflated. When positioned to the left
46 Horn Button to deflate, the suspension air bags are deflated.
Headlight Dimmer/Turn Signal Lever/Cruise NOTE: The suspension air bags should be inflated at all
47
Control times except when on outriggers or in a pick and
48 Seat carry mode.
49 Sun Visor Suspension Deflated Indicator
50 Cab Circulating Fan The SUSPENSION DEFLATED indicator (33) is located on
51 Windshield Defroster Air Outlet the right side console. The amber indicator illuminates when
the air is removed from the suspension air bags. It is
52 Heater Control Switch controlled by four pressure switches connected in series.
53 Cab Marker Lights
Auxiliary Transmission Low Range Switch
54 Fuse and Relay Panel (Not Shown)
The auxiliary transmission low range switch (59) is located
55 Hazard Light Switch on the right side console. Push the switch to the right to
56 Steering Column Tilt/Telescope Lever engage low range.
57 Gear Display Craning Controls and Indicators
58 Swing Brake Engaged Indicator (Optional)
Swing Brake Engaged Indicator
59 Auxiliary Transmission Low Range Switch
The swing brake engaged indicator (29) is located at the top
Brake Pedal of the front console. The top of the indicator illuminates red
when the crane parking brakes are applied. Illumination is
The brake pedal (37) is located on the cab floor, to the left of
determined by a pressure switch on the parking brake valve.
the foot throttle and is used to apply the service brakes.
The park brake must be set before the outrigger controls will
Transmission Shift Lever operate.

The transmission shift lever (40) is located on the right side The bottom of the indicator illuminates red to warn the
of the cab. It is used to select the transmission gears. Refer operator that the swing brake release pressure is not enough
to OPERATING PROCEDURES in this section for complete to hold the swing brake disengaged during trailing boom
transmission operating instructions. operation. In addition, illuminating the indicator, a warning
buzzer will sound.
Gear Display
Accessory Controls and Indicators
The gear display (57) is located on the right side of the front
console. It displays the current transmission gear. This High Beam/Lamp Malfunction Indicator
display is also used to retrieve transmission fault codes.
The headlight high beam/lamp malfunction indicator (28) is
Trailing Boom Trailer Emergency Brake Control located at the top left of the center front console. The
(Optional) indicator is a blue light that illuminates when the headlights
are on high beam or amber when there is a lamp
The TRAILING BOOM (TRAILER EMERGENCY) brake
malfunction.
control (11) is a push-pull type air valve located on the right

3-6
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

Heater On/Off Switch Dimmer Switch

The heater on/off switch (7) is located on the right side The dimmer switch (31) is located on the left bottom side of
console. Press the right side of the switch to ON for heat. the front console. The switch controls the brightness of the
Press the left side of the switch to turn the heater off. gauge lights.

Heater Control Switch NOTE: The headlight switch (21) must be in the center or
top position before gauge lights will illuminate and
The heater control switch (52) is located on the right side the dimmer switch becomes functional.
console. Push the switch to the right to (OPEN) the valve for
heat. Push the switch to the left to (CLOSE) the valve. Headlights Dimmer Switch

Heater /Air Conditioner Fan Switch The headlights dimmer switch (47) is incorporated in the turn
signal switch. It is located on the left side of the steering
The heater/air conditioner fan switch (8) is located on the column. The switch is activated by pulling or pushing the turn
right side console. The switch controls the speed which in signal lever toward you or away from you.
turn regulates the volume of heated air output of the heater
and air conditioner fan by positioning switch to: low (switch Turn Signal Lever
positioned to left), medium (switch centered), and high
The turn signal lever (47) is located on the steering column.
(switch positioned to right).
Positioning the lever down causes the indicator light on the
NOTE: Either air condition or heater switch must be console and the left front and left rear signals to flash.
positioned to “on” before the fan will become Positioning the lever up causes the indicator light on the
operational. console and the right front and right rear signals to flash.

Air Conditioner Switch (Optional) Cruise Control

The air conditioning switch (10) is located on the right side The cruise control (47) is incorporated in the turn signal lever 3
console. The switch controls the operation of the optional air located on the left side of the steering column. Push the
conditioning system in conjunction with the fan switch. Press switch to ON to turn the cruise control on. Accelerate to
the switch to the right to turn air conditioner on. Press the desired speed and push (SET COAST) button on end of
switch to the left to turn the air conditioner off. lever.

Windshield Wiper/Washer Switch If cruise is stopped by braking and switch is still positioned to
ON, the switch can be pushed to (RESUME-ACCEL) to
The windshield wiper/washer toggle switch (13) is located on resume cruise speed. Position switch to OFF to turn the
the lower right side of the front console. The switch is used cruise control off.
for removing moisture from the windshield.The switch has an
off and high position with six intermittent positions between Hazard Light Switch
high and off. Pushing the switch up from the off position
The hazard light switch (55) is located on the steering
energizes the wiper motor. Continue to push switch up for
column. Pulling on the switch (in the direction of the arrow)
each intermittent position and the high position. Push the
causes all the turn signals and the indicator light on the
switch down to off to stop the motor and return the wiper
console to flash.
blade to the parked position.
Push the very top of the switch to activate the washer switch Left Turn Signal Indicator
to spray washer fluid on the windshield. The left turn signal indicator (3) is located on the top left side
of the front console. It is a green indicator light that flashes
Headlights Switch
when the turn signal lever or hazard switch is pulled down.
The headlights switch (21) is a three position switch located
on the bottom left side of the front console. The bottom Right Turn Signal Indicator
position is off. The center position will illuminate marker, The right turn signal indicator (6) is located on the top right
clearance and gauge lights. The top position will turn on the side of the front console. It is a green indicator light that
headlights in addition to the marker, clearance and gauge flashes when the turn signal lever or hazard switch is pushed
lights. up.
Beacon Light Switch (Optional)
The beacon light switch (19) is a two position, on-off switch
located on the left side of the front console that controls the
beacon light (42) on the top of the carrier cab.

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OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

Steering Column Tilt/Telescope Lever Fuse and Relay Panel (Not Shown)
The steering column tilt/telescope lever (56) is located on the The fuse and relay panel (54) is located on the right rear side
steering column behind the turn signal lever. Pulling back on of the cab under a removable cover. It contains 8 fuses and
the lever allows the steering column to be tilted, and pushing various relays that protect and control the various electrical
forward on the lever allows the steering column to be components of the carrier.
telescoped in and out.
Carrier Electrical Diagnostic Connector
Horn Button
The carrier electrical diagnostic connector (39) is located on
The horn button (46) is located in the center of the steering the left side of the cab beneath the front console. It is used
wheel (45). Depressing the horn button energizes the circuit for servicing the engine ECM, transmission ECM or the
sounding the horn. crane’s electrical system.

Fire Extinguisher NOTE: A laptop computer with appropriate cable and

engine or electrical system software are required.
The fire extinguisher (43) is mounted on the left inside rear of
the cab. Additional Carrier Controls and Indicators
Cab Circulating Fan NOTE: The following paragraphs describe the additional
controls and indicators located on the carrier to
The cab circulating fan (50) is mounted on the left front of the
op e ra te th e o utrig ge rs. Th e nu m be rs i n
cab and is controlled by a two speed rocker switch on the
parentheses ( ) represent the index number from
base of the fan.
(Figure 3-2).
Tire Inflation Switch
Outrigger Control Panel
The tire inflation switch (18) is located on the left side of the
There are two outrigger panels located on each side of the
front console. It is a two position switch that activates the tire
crane carrier. Each outrigger control panel contains the
inflation system. Push the top of the switch to activate the tire
control switches for extending and retracting the outrigger
inflation system. An amber indicator will illuminate and the
beams and for raising and lowering the outrigger stabilizer
warning buzzer will sound when the switch is in the on
(jack) cylinders on that side of the crane. Each control panel
position.
also contains a control switch for raising and lowering the
12 VDC Accessory Outlet center front stabilizer. The following paragraphs explain
these controls.
The 12 vdc accessory outlet (9) is located on the right side
console. It provides an outlet for the operator to plug in a 12 NOTE: The outrigger control panels only operate when the
vd c ac ces so ry . T hi s o u tl et s ho ul d be u se d o nl y f o r carrier ignition is on and the parking brake is set.
components requiring 8 amps or less. The right hand control panel only controls the right
side outriggers and the left side controls the left
Cab Dome Light (Not Shown) side outriggers.
The cab dome light (44) is located in the center of the cab Outrigger Selector Switches
roof directly over the seat. It is controlled by a switch on the
light and by a door switch that powers the light when the cab There are (two) two-position, spring centered to off outrigger
door is opened. selector toggle switches (1) on each of the outrigger control
panels. One switch is placarded FRONT EXTENSION;
Air Horn (Not Shown) FRONT STABILIZER and is used to control the extension
cylinder and the stabilizer (jack) cylinders on the front
A set of air horns are mounted on top of the cab and are
outrigger beam. The other switch is placarded REAR
controlled by a valve manually actuated by a cable inside the
EXTENSION; REAR STABILIZER and is used to control the
cab.
extension cylinder and the stabilizer (jack) cylinders on the
rear outrigger beam. Both switches must be used in
conjunction with the outrigger EXTEND/RETRACT switch
(2).

3-8
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

2
3 1

6164-1

6563

Item Description
1 Outrigger Selector Switches
2 Outrigger Extension/Retraction Switch
3 Center Front Stabilizer Switch
FIGURE 3-2

3-9
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

Outrigger Extend/Retract Switch Pushing the top of the switch increases (+) engine RPM or
pushing the bottom of the switch decreases (-) engine RPM.
The OUTRIGGER EXTEND/RETRACT switch (2) is located
Gauge Cluster
near the center of the panel in the outrigger control panel and
has two placarded positions; EXTEND and RETRACT. It The gauge cluster (29) is located on the left side of the
mu st b e u se d in co nju n ct io n wit h t he O UT RI GGE R pedestal mounted console beside the LMI panel and
SE LECTOR switches to co ntrol the o peration of the contains a voltmeter, oil pressure gauge, water temperature
stabilizer and extension cylinders. After positioning the gauge, and a fuel quantity gauge.
desired OUTRIGGER SELECTOR switch, positioning the
outrigger extend/retract switch energizes the control Voltmeter
solenoid to allow hydraulic fluid to flow through the control The voltmeter (VOLTS) is located on the lower right of the
solenoid valve and the individual solenoid valve and move gauge cluster. With the ignition switch in the run (between
the selected component in the desired direction. In addition, vertical and right) position and before starting the engine, the
when the switch is positioned to either position, a signal is voltmeter indicates the condition of the batteries. With the
sent to the engine ECM to increase engine speed above idle engine running, the voltmeter indicates output voltage of the
for operation of the outriggers. alternator. The voltmeter scale is from 10 to 16 volts.
Center Front Stabilizer Switch Engine Oil Pressure Gauge
The CENTER FRONT STABILIZER switch (3) is located The engine oil pressure (OIL) gauge is located on the upper
toward the outside edge of the outrigger control panel and right of the gauge cluster. The gauge indicates the engine oil
has two placarded positions; ACTIVATE and OFF. It must be pressure on a scale calibrated from zero (0) to 80 psi. It
used in conjunction with the outrigger extension/retraction receives a signal from the crane’s electronic operating
switch to control the operation of the center front stabilizer. system which receives the signal from the engine ECM via
The center front stabilizer will retract automatically when any J1939.
of the other four stabilizers are retracted, therefore it must be
reset if lifting is to be continued. Water Temperature Gauge

Daytime Running Lights The engine coolant temperature (TEMP) gauge is located on
the lower left of the gauge cluster. The gauge indicates the
Daytime running lights is a feature in which the headlight low engine coolant temperature on a scale calibrated from 100 to
beams will come on automatically anytime the carrier ignition 240° F. The gauge receives a signal from the crane’s
switch is in the on position, engine is running, and the park electronic operating system which receives the signal from
brake is released regardless of the position of the headlight the engine ECM via J1939.
switch.
Fuel Quantity Gauge
SUPERSTRUCTURE CAB The fuel quantity (FUEL) gauge is located on the upper left of
NOTE: The following paragraphs describe all the available the gauge cluster. The gauge indicates the quantity of fuel in
(standard and optional) controls and indicators the tank and has a scale calibrated from empty (E) to full (F).
located in the cab. Some machines may not be The fuel quantity gauge a signal from the crane’s electronic
equipped with the optional controls shown. The operating system which monitors a sending unit in the fuel
numbers in ( ) represent the index number from tank.
(Figure 3-3).
Ignition Switch
NOTE: All rocker switches contain one or two LED’s in the
The ignition switch (32) is located on the right side console.
switch for illumination.
The switch is key operated with four positions: accessory
(left position), off (vertical position), run (position between
Engine Controls and Indicators
vertical and right), and start (right position). The switch is
Engine Increment/Decrement Switch spring returned from start to run. In the off position, all
electrical power in the superstructure is off except for the
The engine increment/decrement switch (31) located on the boom work lights, cab work lights, panel lights, dome light,
right side console is used when servicing the engines swing horn, and accessory outlet. In the accessory position,
electronic control system. It is a two position (+/-) momentary all electrical components are energized. Placing the switch in
switch that provides idle-control inputs that increases and the start position energizes the starter motor solenoid for
decreases the engine idle. starting the engine. Releasing the switch will allow it to spring
return to the run position. To shut down the engine, turn the
switch to the off position.

3-10
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

Tachometer diagnostic switch is on and the engine is not running. The

amb er li ght flashe s at the begin ning of a fa ult co de
The tachometer (27) is located on the pedestal mounted
sequence, the red light flashes the three-digit or four-digit
console and registers engine RPM. The tachometer is
code for the active fault and the amber light flashes again to
calibrated in rpm x 100 with a range of zero (0) to 35. It
separate the previous red light sequence from the next one.
receives a signal from the crane’s electronic operating
Each code will be flashed twice before moving to the next
system which receives the signal from the engine ECM via
code. When all codes have been flashed, the sequence will
J1939.
begin again. If no codes are present, both the warning and
Hourmeter stop lights will remain on.

T he ho u rm e te r ( 2 8 ) is lo ca te d a t t h e b ot t om of th e The bottom portion of the switch is the electrical system

tachometer and registers the total hours that the engine has diagnostic indicator. There are three conditions for this
run. The hourmeter receives an electrical signal from the indicator as follows:
tachometer. a. On solid with buzzer sounding - There is an
interruption of communication over the main canbus
Engine Stop/Module Off Line Indicator
control line between the crane’s electronic control
The engine stop/module off line indicator (48) is located on modules. Proper crane operating condition shall be
the top left side of the pedestal mounted console. The top restored as quickly as possible.
portion of the switch is the stop indicator. It illuminates red
b. Flashing with buzzer sounding - An undesirable
when energized by a signal from the engine ECM that
condition with the crane’s joysticks has been
signifies a serious engine problem that requires the vehicle
detected. Proper crane operating condition shall be
and the engine to be stopped as soon as safely possible. In
restored before performing any hydraulic function.
addition, a warning buzzer will also sound.
In addition to alerting the operator of system faults, the stop
light, in conjunction with the warning light, is used in the
c. Flashing without buzzer - An undesirable
component or electrical system condition has
3
occurred.
diagnostic operation of the engine control system. The
diagnostic mode begins when the ignition and engine Engine Wait To Start Indicator
diagnostic switch is on and the engine is not running. The
ambe r lig ht f lashe s at the begin ning of a fau lt co de The engine wait to start indicator (9) is located on the left
sequence, the red light flashes the three-digit or four-digit side of the pedestal mounted console. It illuminates amber
code for the active and the amber light flashes again to for a period of time when the ignition switch is turned to the
separate the previous red light sequence from the next one. ON position. The engine should not be cranked until the wait
Each code will be flashed twice before moving to the next to start indicator turns off.
code. When all codes have been flashed, the sequence will
Foot Throttle Pedal
begin again. If no codes are present, both the warning and
stop lights will remain on. The foot throttle pedal (4) is located on the right side of the
cab floor. The pedal is used to control engine RPM. The
The bottom portion is the module off line indicator. This
pedal modulates engine speed proportionately to the foot
indicator will come on solid a nd a buzzer will sound
pressure applied.
whenever communication with one of the crane’s electronics
modules is lost. The vehicle should be stopped as soon as
Craning Controls and Indicators
safely possible. The crane must be restored to proper
condition before operating again. Telescope/Auxiliary Hoist/Swing Controller
Engine Warning/Electrical System Diagnostic The telescope or auxiliary hoist/swing controller (18) is
Indicator located on the left armrest. The controller controls the
telescope functions when the crane is not equipped with an
The engine warning/electrical system diagnostic indicator
auxiliary hoist. Pushing the controller forward actuates the
(24) is located at the top left side of the pedestal mounted
control valve to telescope the boom out and pulling the
console. The top portio n is th e warnin g indicat or. It
controller back telescopes the boom in.
illuminates amber when energized by a signal from the
engine ECM that signals the operator of an engine problem When equipped with an auxiliary hoist, the controller controls
which must be corrected. auxiliary hoist functions and telescope functions through a
foot pedal (3). Pushing the controller forward actuates the
In addition to alerting the operator of system faults, the
control valve to let out the hoist cable and pulling the
warning light, in conjunction with the stop light, is used in the
controller back reels the cable in.
diagnostic operation of the engine control system. The
diagnostic mode begins when the ignition and engine

3-11
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

When used for swing, the controller, when pushed to the power from the crane functions controlled by the controllers
right (rotates the turntable clockwise) or left (rotates the on the armrests.
turntable counterclockwise), actuates a control valve to
Push the top of the switch to energize the pilot supply
provide 360 degree continuous rotation in the desired
solenoid to allow functions controlled by the controllers on
direction.
the armrests to be performed.
Boom Lift/Main Hoist Controller Positioning the switch to OFF prevents inadvertent operation
The boom lift/main hoist controller (8) is located on the right of functions due to bumping the controllers while roading or
armrest. The controller, when pushed to the right (lowers the any other operation.
boom) or left (raises the boom), actuates the control valve to
Outrigger Extend/Retract Switch
raise or lower the boom.
NOTE: The park brake in the carrier cab must be set
When used for main hoist, the controller, when pushed
before the outrigger controls will operate.
forward (lowers the cable) or back (raises the cable),
actuates the control valve to raise or lower the main hoist NOTE: Be sure the outriggers plus the center front
cable. stabilizer are properly extended and set, and the
crane is level for operation on outriggers. The
Swing Horn Button center front stabilizer outrigger is a vital factor in
The swing horn button (20) is located on the right side of the the stability of the crane.
swing controller and is used by the operator to provide a All four outrigger beams plus the center front
warning that the superstructure is rotating. Press in on the stabilizer outrigger must be equally extended to the
button to sound the swing horn. mid position vertical stripe or fully extended
position before beginning operation.
Telescope Control Pedal
The outrigger extend/retract momentary switch (44) is
The telescope control foot pedal (3), supplied when the
located on the right side console. It must be used in
crane is equipped with an auxiliary hoist, is located on the
conjunction with the outrigger selector switches to control the
right side of the cab floor. Pushing forward on the top of the
operation of the stabilizer and extension cylinders.
pedal will extend the boom and pushing down on the bottom
of the pedal will retract the boom. Push the top of the switch to select the extend function or
push the bottom of the switch to select the retract function. In
Main Hoist Speed Selector Switch addition, when the switch is positioned to either extend or
The three-position main hoist speed selector switch (10) is retract position, a signal is sent to the engine ECM to
located on the right armrest. Select the top of the switch for increase engine speed above idle for operation of the
high speed or the bottom of the switch for low speed. outriggers.
Position the switch in the center position to “off” to disable
Center Front Stabilizer Switch
main hoist functions.
A center front stabilizer switch (45) is located on the right
Auxiliary Hoist Speed Selector Switch side console. To extend the center front stabilizer, push the
The three-position auxiliary hoist speed selector switch (16) top of the outrigger extend/retract switch, then push the top
is located on the left armrest. Select the top of the switch for of the center front stabilizer switch.
high speed and the bottom of the switch for low speed. To retract the center front stabilizer, push the bottom of the
Position the switch in the center to “off” to disable auxiliary outrigger extend/retract switch, then push the bottom of the
hoist functions. center front stabilizer switch.
Hoist Rotation Indicators (Main and Auxiliary Hoist) NOTE: The center front stabilizer will retract anytime the
The hoist rotation indicators (51) are located on the top of the extend/retract switch is positioned to the retract
main and auxiliary hoist controllers. The indicator is position.
electronically driven by a sensor attached to the main hoist. Left Front Outrigger Switch
A pulsating signal is sensed by the operator’s thumb during
hoist operation. The left front outrigger switch (11) is located on the right side
console. It is a three-position switch used to extend or retract
Crane Function Power Switch the left front stabilizer and extension cylinders. It must be
The crane function power switch (37) is located on the right used in conjunction with the outrigger extend/retract switch.
side console. Push the bottom of the switch to disconnect

3-12
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

To extend the left front outrigger beam, push the top of the To extend the left rear stabilizer, push the top of the outrigger
outrigger extend/retract switch (44) and the top of the left extend/retract switch (44) and the bottom of the left rear
front outrigger switch. outrigger switch.
To retract the left front outrigger beam, push the bottom of To retract the left rear stabilizer, push the bottom of the
the outrigger extend/retract switch (44) and the top of the left outrigger extend/retract switch (44) and the bottom of the left
front outrigger switch. rear outrigger switch.
To extend the left front stabilizer, push the top of the Right Rear Outrigger Switch
outrigger extend/retract switch (44) and the bottom of the left
front outrigger switch. The right rear outrigger switch (42) is located on the right
side console. It is a three-position switch used to extend or
To retract the left front stabilizer, push the bottom of the retract the right rear stabilizer and extension cylinders. It
outrigger extend/retract switch (44) and the bottom of the left must be used in conjunction with the outrigger extend/retract
front outrigger switch. switch.
Right Front Outrigger Switch To extend the right rear outrigger beam, push the top of the
outrigger extend/retract switch (44) and the top of the right
The right front outrigger switch (19) is located on the right
rear outrigger switch.
side console. It is a three-position switch used to extend or
retract the right front stabilizer and extension cylinders. It To retract the right rear outrigger beam, push the bottom of
must be used in conjunction with the outrigger extend/retract the outrigger extend/retract switch (44) and the top of the
switch. right rear outrigger switch.
To extend the right front outrigger beam, push the top of the To extend the right rear stabilizer, push the top of the
outrigger extend/retract switch (44) and the top of the right outrigger extend/retract switch (44) and the bottom of the
front outrigger switch. right rear outrigger switch. 3
To retract the right front outrigger beam, push the bottom of To retract the right rear stabilizer, push the bottom of the
the outrigger extend/retract switch (44) and the top of the outrigger extend/retract switch (44) and the bottom of the
right front outrigger switch. right rear outrigger switch.
To extend the right front stabilizer, push the top of the Center Front Stabilizer Overloaded Indicator
outrigger extend/retract switch (44) and the bottom of the
right front outrigger switch. The center front stabilizer overloaded indicator (26) is
located on the pedestal mounted console. The indicator is a
To retract the right front stabilizer, push the bottom of the red light that will illuminate when the pressure switch in the
outrigger extend/retract switch (44) and the bottom of the front stabilizer circuit senses over-pressurization indicating
right front outrigger switch. an overload condition. In addition to the indicator light, a
buzzer will sound.
Left Rear Outrigger Switch
The left rear outrigger switch (43) is located on the right side Bubble Level Indicator
console. It is a three-position switch used to extend or retract The bubble level indicator (5) is located on a bracket on the
the left rear stabilizer and extension cylinders. It must be right side of the cab. The indicator provides the operator with
used in conjunction with the outrigger extend/retract switch. a visual indication for determining the levelness of the
To extend the left rear outrigger beam, push the top of the machine.
outrigger extend/retract switch (44) and the top of the left
Swing Brake Selector Switch
rear outrigger switch.
The swing brake selector switch (17) is located on the left
To retract the left rear outrigger beam, push the bottom of the
armrest. This two-position switch (on/off) is used to control a
outrigger extend/retract switch (44) and the top of the left
hydraulic valve that directs a regulated flow of pressure to
rear outrigger switch.
and from the swing brake. Push the top of the switch to ON to
apply the swing brake and push the bottom of the switch to
OFF to release the swing brake.

3-13
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

30
2
1

23

See View A

See View B

4 See View C

5 35

22 6
25
3

20 12

See View D

15

13

FIGURE 3-3

3-14
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

48 24 26 49 30
9

29
27
28 6565-1
3
View A

47

10
51

50

17
18
6566-1
51
20
View D
16
FIGURE 3-3 continued

3-15
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

37 38 21

40
39

41
31

33 46

11

42
19

43 36
34

44
45

View C 6564-2

6564-1
32 View B
FIGURE 3-3 continued

Item Description Item Description

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

3-16
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

Item Description brake to slow or stop swing motion. Braking is proportional to

pedal depression.
20 Swing Horn Button
With the pedal not depressed and the swing brake control
21 Skylight Wiper Switch valve disengaged, hydraulic pressure is applied to the brake,
22 Swing Brake Pedal overcoming spring pressure and releasing the brake.
23 Cab Circulating Fan Depressing the pedal actuates a swing power brake valve to
apply pressure to the brake assembly. This pressure aids the
Engine Warning/Electrical System Diagnostic
24 spring pressure to overcome the hydraulic pressure being
Indicator
applied to the brake release circuit and applies the spring
25 360° Swing Lock Control (Positive Lock Type) brake according to the pressure from the swing power brake
26 Center Front Stabilizer Overloaded Indicator valve.

27 Tachometer Swing Lock Control (Pin Type)

28 Hourmeter The pin swing lock control handle (6) is located on the right
29 Gauge Cluster side of the cab. The purpose of the pin swing lock is to lock
the superstructure in position directly over the front or over
30 LMI Panel the rear. When the control handle is pushed down and
31 Engine Increment/Decrement Switch turned clockwise, the superstructure is directly over the front
or rear, the swing lock pin drops into a socket on the carrier
32 Ignition Switch frame, locking the superstructure in place. When the control
33 Air Conditioner Switch (Optional) handle is pulled up and turned clockwise, the pin is pulled out
of the socket, unlocking the superstructure.
34
35
Heater Control Switch
Crane’s Electrical System Diagnostic Connector 360° Swing Lock Control (Positive Lock Type)
3
(Optional)
36 Heater/Air Conditioner Fan Switch
The 360 degree swing lock control lever (25) is located on
37 Crane Function Power Switch
the right side of the operator’s seat next to the control
38 Windshield Wiper/Washer Switch armrest. The purpose of the swing lock is to secure the
superstructure in position in 2.7 degree increments in its 360
39 Dimmer Switch
degree of rotation. The lock is engaged when the control
40 Work Lights Switch lever is pushed down and disengaged when the control lever
41 Boom Lights Switch (Optional) is pulled up.

42 Right Rear Outrigger Switch Swing Brake Engaged Indicator

43 Left Rear Outrigger Switch The swing brake engaged indicator (49) is located on the
44 Outrigger Extend/Retract Switch pedestal mounted console.

45 Center Front Stabilizer Switch The indicator illuminates red to warn the operator that the
swing brake release pressure is not enough to hold the
46 Heater On/Off Switch swing brake disengaged.
47 Cab Tilt Switch
Swing Speed Switch
48 Engine Stop/Module Off Line Indicator
The swing speed switch (50) is a two-position switch located
49 Swing Brake Engaged Indicator on the left armrest. Push the top of the switch for high swing
50 Swing Speed Switch speed or the bottom of the switch for low swing speed.
51 Hoist Rotation Indicator (Main and Aux Hoist) Cab Tilt Switch
Swing Brake Pedal The cab tilt switch (47) is located on the right armrest. It is a
three position, momentary spring centered to off rocker
The swing brake pedal (22) is located on the left side of the switch. The switch allows the cab to be tilted either up or
cab floor. The swing brake pedal is used to actuate the swing down.

3-17
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

Accessory Controls and Indicators Skylight Wiper Switch

Dimmer Switch The skylight wiper switch (21) is installed on the right side
console. The wiper is used to remove moisture from the
The dimmer switch (39) is located on the right side console. skylight. The switch has an off and high position with six
The switch controls the brightness of the panel and gauge intermittent positions between high and off. Pushing the
lights. switch up from the off position energizes the wiper motor.
Continue to push switch up for each intermittent position and
Work Lights Switch the high position. Push the switch down to off to stop the
The work lights switch (40) is a two position on/off switch motor and return the wiper blade to the parked position.
located on the right side console controls the crane’s work
Heater On/Off Switch
lights (1) mounted on the bottom front of the superstructure
cab. Press the top of the switch to the on position to The heater (on/off) switch (46) is located on the lower right
illuminate the work lights. Press the bottom of the switch to side console. Press the top of the switch to on for heat. Press
turn the work lights off. the bottom of the switch to turn heater off.
Boom Lights Switch (Optional) Heater Control Switch
The boom lights switch (41) is a two position on/off switch The heater control switch (34) is located on the lower right
located on the right side console. The switch controls the side console. Push the top of the switch to (OPEN) the valve
flood lights located on the boom base section. Press the top for heat. Push the bottom of the switch to (CLOSE) the valve.
of the switch to the on position to illuminate the flood lights.
The amber indicator in the switch will illuminate. Press the Heater /Air Conditioner Fan Switch
bottom of the switch to turn the flood lights off. The heater/air conditioner fan switch (36) is located on the
Cab Circulating Fan lower right side console. The switch controls the speed
which in turn regulates the volume of heated air output of the
The cab circulating fan (23) is located on the right side of the heater and air conditioner fan by positioning switch to: low
cab. A swivel allows the fan to be positioned in any direction (press bottom of switch), medium (switch centered), and
and a high-off-low switch on the base controls the fan. high (press top of switch).

Cab Dome Light Air Conditioner Switch (Optional)

The cab dome light (12) is located on the right rear corner of The air conditioning switch (33) is located on the lower right
the cab roof and provides illumination of the cab. The light is side console. The switch controls the operation of the
controlled by a on/off switch on the light. optional air conditioning system in conjunction with the FAN
switch. Press the top of the switch to turn air conditioner on.
Fire Extinguisher Press the bottom of the switch to turn the air conditioner off.
The fire extinguisher (15) is located at the left rear side of the
Beacon Light
cab. The fire extinguisher is a BC rated dry type fire
extinguisher for emergency use. The beacon light (14) is located on a bracket on the left rear
side of the machine beside the hoists. It is operational
Windshield Wiper/Washer Switch and Motor anytime the ignition switch is in the ACC or RUN position.
The windshield wiper/washer toggle switch (38) is located on
Crane’s Electrical System Diagnostic Connector
the right side of the front console. The switch is used for
removing moisture from the windshield.The switch has an off This connector (35) is mounted on the side of the right side
and high position with six intermittent positions between high console by the operator’s right leg. It is used for servicing the
and off. Pushing the switch up from the off position energizes engine ECM, transmission ECM or crane’s electrical system.
the wiper motor (2). Continue to push switch up for each
intermittent position and the high position. Push the switch NOTE: A laptop computer with appropriate cable and
down to off to stop the motor and return the wiper blade to electrical system software are required.
the parked position. Fuse Panel
Push the very top of the switch to activate the washer switch The fuse panel (13) is located under the cover panel on the
to spray washer fluid on the windshield. back wall of the cab behind the seat. It contains 16 fuses and
4 relays that protect and control various circuits of the
superstructure.

3-18
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

OPERATING PROCEDURES Engine Coolant

Check the coolant level in the radiator and fill to the proper
Breaking-In A New Carrier level. Do not overfill and ensure the radiator cap is secure.
Your new Grove carrier has been thoroughly tested,
adjusted, lubricated, and inspected prior to delivery.
However, as road shock and crane operation occur, moving
parts wear in, or gasket and hose connections take seat, an DANGER
occasional oil, air, or coolant leak may develop. Immediate
Do not loosen radiator cap on a hot engine. Steam or hot
corrective action should be taken to avoid major repairs later.
coolant will cause severe burns.
For detailed engine break-in, refer to the applicable engine
manual.
Batteries
The guidelines below will aid in getting a long service life out
of the crane. Check the state-of-charge indicator if applicable with
maintenance free batteries or check each cell for the correct
1. Operate as much as possible in the half to three- fluid level if equipped with standard or low maintenance
quarters throttle or load range. batteries. Use only clean distilled water and do not overfill.
On all types of batteries, make sure the cables and clamps
2. Avoid long periods of operation with the engine at idle or
are tight and not corroded.
continuous maximum horsepower levels.
3. Observe instruments often and shut down at the first Hydraulic Reservoir and Filter
indication of an abnormal reading. Check the hydraulic level sight gauge and filter condition
4. Operate to a power requirement that allows acceleration indicator on the hydraulic tank. Hydraulic fluid should be at
to governed speed when conditions require more power. normal operating temperature and the boom and outriggers
in a retracted position.
3
5. Check all components frequently for proper operation,
unusual noises, and excessive heating. Check breather for cleanliness and security.

6. Check the engine oil and coolant levels frequently. Wire Rope
These guidelines should not be considered limitations but Inspect the wire rope in accordance with applicable Federal
rather as a guide for familiarization of the machine and Regulations. Sheaves, guards, guides, drums, flanges, and
development of good operating habits. any other surfaces that come in contact with the rope should
be inspected for any condition that could cause possible
Pre-Starting Checks damage to the rope.
A complete walk-around visual inspection of the crane Hook Block and Headache Ball
should always be made with special attention to structural
damage, loose equipment, leaks, or other conditions that Inspect for nicks, gouges, cracks, and evidence of any other
would require immediate correction for safe operation. Refer damage. Replace a hook that has cracks or shows evidence
to Section 6 - Maintenance Checklist. The following checklist of excessive deformation of the hook opening (including
items are suggested to ensure the crane is prepared for twist). Be sure the safety latch is free and aligned.
starting the day’s work.
Seats and Mirrors
Fuel Supply Adjust seat and mirrors for clear vision and safe driving.
Fill the fuel tank and ensure the cap is on tight.
Seat Belts
Engine Oil Seat Belt Maintenance
Seat belt assemblies are maintenance-free; however, they
CAUTION should be periodically inspected to ensure that they are not
Do not overfill. damaged and are in proper operating condition, especially if
they have been subjected to severe stress.
Check the oil level in the crankcase and fill to the FULL mark Cleaning Seat Belt Webbing
on the dipstick. Do not overfill.
Wash the seat belt webbing with any mild soap or detergent.
Do not use commercial solvents. Also, bleaching or re-

3-19
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

dyeing the webbing is not recommended because of Operation Below -40°C

possible loss of webbing strength.
For crane operation below -40°C, capacities shall be derated
Signal and Running Lights 3.67% of the capacities shown on the load chart for each
degree (1°C) below -40°C.
Check all signal and running lights for proper operation.
Replace burned out lamps with those of the same number, or Operation Below -40°F
equivalent.
For crane operation below -40°F, capacities shall be derated
Service and Parking Brakes 2.0% of the capacities shown on the load chart for each
degree (1°F) below -40°F.
Check for proper operation.

Tires
Engine Operation
Start-up and shutdown procedures for most diesel engines
Check the pressure and condition of all tires before traveling.
are generally the same. Therefore, the following procedures
NOTE: For tire inflation pressures, refer to the Tire Inflation can be applied, except where specific differences are noted.
Decal on the crane. (Refer to the applicable engine manufacturer’s manual for
detailed procedures).
Wheels
Start-Up Procedure
Maintain proper torque on wheel lugs and check for proper
wheel mounting. If equipped with steel or aluminum wheels, Make an under-the-hood inspection for fuel, oil, and coolant
the wheels should be retorqued 80 to 160 km (50 to 100 leaks, worn drive belts, and trash build-up.
miles) after initial installation or after any time the tires and
wheels are removed. Doing this will reseat the lug nuts.
Recheck the lug nuts for proper torque every (800 km) 500
miles thereafter.
DANGER
Safety Equipment Diesel engine exhaust can be harmful to your health. Only
operate the engine in a well ventilated area or vent
Check all lights, windshield wipers, washers, washer liquid exhaust outside.
supply, horn, instruments, signaling devices, etc.

Daily Lubrication
Ensure all components requiring daily lubrication have been CAUTION
serviced. (Refer to Section 5, Lubrication). Never crank engine for more than 30 seconds during an
attempted start. If engine does not start after 30 seconds,
Cold Weather Operation allow starter motor to cool for about two minutes before
T h e f o l l o wi n g r e c o m m e n d a t i o n s a r e f o r o p e r a t i n g attempting another start.
Ma ni to woc /Gr o ve cr a ne s i n ve ry lo w (i .e . fr ee zi ng )
temperatures.
Use particular care to ensure that cranes being operated in CAUTION
very cold temperatures are operated and maintained in If engine does not start after four attempts, correct
accordance with the procedures as provided by Manitowoc malfunction before attempting another start.
Crane Group. Cranes should have appropriate hydraulic oil,
lubricants, and other auxiliary items required for operation in Use the correct grade of oil for the prevailing temperature in
sub-zero temperatures. Individual crane functions should be the crankcase to prevent hard cranking. Diesel fuel should
operated to ensure they are sufficiently warmed prior to have a pour point of 5°C (10°F) less than the lowest
performing a lift. expected temperature. In case of an emergency, white
Operation of cranes at full rated capacities in temperatures kerosene can be added to the fuel to bring the pour point
between 0°C and -40°C (+32°F and -40°F) or lower shall be down to the required temperature. This will prevent clogging
accomplished only by competent operators who possess the of filters and small passages by wax crystals. The addition of
skill, experience, and dexterity to ensure smooth operation. kerosene is NOT recommended for general use.
Shock loading shall be avoided. For crane operation below -
Warm Engine
40°C (-40°F), capacities shall be derated 3.6% for each °C
below -40°C and 2% for each °F below -40 °F of the rated The engine warning and engine stop indicators will illuminate
load shown on the capacity charts. and go off in sequence after about two seconds (as a check)

3-20
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

when the key is first turned on. If an indicator comes on and below. It is recommended that no other type of cold starting
continues to blink after initial start-up, there is a problem that aid be used with this engine. An engine block heater is also
needs to be corrected. Position the ENGINE DIAGNOSTIC provided.
IDLE switch to ON for code retrieval and check the engine
manufacture’s service manual for code identification.
1. Ensure the parking brake is set and position the CAUTION
transmission in neutral. T h e o p t i o n a l e n g i n e c o l d s t a r t sy s t e m o p e r a t e s
automatically when the engine temperature is 13°C
NOTE: The engine will not crank unless the transmission (55°F) or below. If the engine does not start immediately,
shift is in neutral. avoid overloading the air box with highly volatile fluid
2. Turn the ignition switch to start (far right position) and which could result in a minor explosion.
release immediately when the engine starts. Do not
push or hold the throttle down. The ECM will 1. Ensure the parking brake is set and position the
automatically provide the proper amount of fuel to start transmission in neutral.
the engine. NOTE: The engine will not crank unless the transmission
3. Immediately check the engine instruments for proper shift is in neutral.
indication after starting. Shut down the engine if the oil 2. Turn the ignition switch to start (far right position) and
pressure gauge does not reach the proper reading release immediately when the engine starts. Do not
within 15 seconds. push or hold the throttle down. The ECM will
automatically provide the proper amount of fuel to start
the engine.

DANGER
Bo th air system pr essur es must be in t he n orm al
3. Immediately check the engine instruments for proper
indication after starting. Shut down the engine if the oil 3
pressure gauge does not reach the proper reading
operating range prior to disengaging the park brake. within 15 seconds.

CAUTION
DANGER
If oil pressure and/or temperature indicator(s) do not
Bo th air syste m pr essu res must be in t he nor mal
display the proper readings, shut down engine and
operating range prior to disengaging the park brake.
correct malfunction.

4. Allow the engine to warm up for about five minutes

before applying a load. Do not race the engine for a
faster warm up.
CAUTION
If oil pressure and/or temperature indicator(s) do not
Cold Engine display the proper readings, shut down engine and
correct malfunction.

CAUTION 4. Allow the engine to warm up for about five minutes

Always start a cold engine from the carrier cab. before applying a load. Do not race the engine for a
faster warm up.
The engine warning and engine stop indicators will illuminate
and go off in sequence after about two seconds (as a check) Idling The Engine
when the key is first turned on. If an indicator comes on and Idling the engine unnecessarily for long periods of time
continues to blink after initial start-up, there is a problem that wastes fuel and fouls injector nozzles. Unburned fuel causes
needs to be corrected. Position the ENGINE DIAGNOSTIC carbon formation; oil dilution; formation of lacquer or gummy
IDLE switch to on for code retrieval and check the engine deposits on the valves, pistons and rings; and rapid
manufacture’s service manual for code identification. accumulation of sludge in the engine.
The engine can be equipped with an optional automatic cold NOTE: When prolonged engine idling is necessary,
starting system that provides a metered flow of starting fluid maintain at least 800 rpm.
to the engine when the engine temperature is 13 °C (55°F) or

3-21
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

Racing The Engine Using Your Load Chart

DO NOT race the engine during the warm-up period or NOTE: One of the most important tools of every Grove
operate the engine beyond governed speed (as might occur Manitowoc crane is the load chart found in the
in downhill operation or downshifting). Engine bearings, crane operator’s cab.
pistons, and valves may be damaged if these precautions
are not taken. NOTE: Refer to (Figure 3-4) for terms to know in
determining lifting capacities.
Shutdown Procedure
The load chart contains the lifting capacities of the crane in
1. Allow the engine to run at fast idle speed for about five all allowable lifting configurations, and must be thoroughly
minutes to avoid high internal heat rise and allow for understood by the operator.
heat dissipation.
The load chart is divided into capabilities limited by crane
2. Position the ignition switch to off (vertical position). structural strength and stability which is shown by a bold line
across the chart. Structural strength limits are above the line
3. Drain the fuel filter-water separator.
and stability limits are below the line.
General Crane Operation The left column is the load radius, which is the distance from
the axis of the crane rotation to the load center of gravity.
Pump Drive The top row lists various boom lengths from fully retracted to
The main #1 hydraulic pump is driven by an engine PTO. fully extended (with swingaway extension). The number at
The two section #2 hydraulic pump is direct engine driven. the intersection of the left column and top row is the total load
limit for that load radius and boom length. The number in
Control Lever Operation parentheses below the total load limit is the required boom
angle (in degrees) for that load. Boom lengths between
T h e co n t r o l l e ve r o p e r a t i o n f o r c r a n e f u n c t i o n s i s
increments should always be treated as if it were the next
proportional, i.e., the closer the lever is to neutral (center),
longer length. For example, if the actual boom length is 15.2
the slower the system responds. Return the control lever to
m (50 ft) and the chart shows boom lengths of 14.6 - 16.4 m
neutral to hold the load. Do not feather the hoist control to
(48 - 54 ft), use the load capacity shown in the 16.4 m (54 ft)
hold the load.
column.
NOTE: Always operate the control levers with slow, even
Another important section is the range diagram. The range
pressure.
diagram shows the operating radius and tip height that can
Preload Check be achieved at a given boom length and angle. If the
operator knows the radius and tip height required for a
After the crane has been readied for service, an operational specific lift, the angle and boom length can quickly be
check of all crane functions (with no load applied) should be determined from the range diagram. Or if he knows the boom
performed. Preload check is as follows: length and angle, he can quickly determine the tip height and
• Extend and set the outriggers and level the crane. operating radius.

• Raise, lower, and swing the boom right and left at least A lifting diagram is included for over-side, over-rear, and
45 degrees. over-front lifting areas. The lifting area diagram shows that
the locations of the outrigger stabilizer cylinders in the full
• Telescope the boom out and back in, ensuring all extended position are used to mark the boundaries of the
sections extend and retract properly. lifting areas.
• Raise and lower the cable a few times at various boom Another section contains notes for lifting capacities. Be sure
lengths. Make sure there are no kinks and that the cable to r ea d an d un de r sta nd a ll no te s con ce rn in g lif tin g
is spooling on the hoist properly. capacities.
The load chart also gives weight reductions for Manitowoc/
CAUTION Grove load handling devices such as hookblocks, overhaul
ball s, b oom exte nsion sect ions , et c, wh ich m ust be
Run the engine at or near the governed RPM during
considered as part of the load. The weight of any other load
operation of all crane functions.
handling devices such as chains, slings, or spreader bars
must also be added to the weight of the load.
NOTE: Carefully read and become familiar with all crane
operating instructions before and operating the
crane.

3-22
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

MA
IN
BO
O M
LE
NG AXIS OF ROTATION
TH

BOOM ANGLE

HORIZONTAL

4605
OPERATING RADIUS

TERMS TO KNOW
3
FIGURE 3-4

NOTE: The information in the following paragraph is an weight of 632 lbs from the load capacity of 3601 kg (7940
example of how to compute a lift. The numbers lbs) and 2254 kg (4970 lbs). The result is a weight capacity of
used in the example may not coincide with the load 3315 kg (7308 lbs) over-the-front and 1968 kg (4338 lbs) for
chart in the crane cab. 360 degrees. We are constricted in making the lift over-front
only and the boom angle will be about 29 degrees.
Problem: A concrete beam weighing 2268 kg (5000 lbs)
needs to be lifted to a height of 9.1 m (30 ft) at a radius of Crane Functions
15.2 m (50 ft) (maximum). The range diagram indicates the
boom must be extended to 18.9 m (62 ft) in order to reach a Using the Outriggers
height of 9.1 m (30 ft) at a radius of 15.2 m (50 ft).
The carrier is equipped with remote mounted outrigger
First we need to check the crane for load handling devices. panels on each side of the carrier to allow the outriggers to
In our example, the crane is equipped with a auxiliary boom be operated from the ground.
nose (rooster sheave) and a five ton overhaul ball. The
rooster sheave is 50 kg (110 lbs), and the overhaul ball is 78 The outriggers can also be operated from the superstructure
kg (172 lbs) for a total of 128 kg (282 lbs). The lift requires cab.
slings and spreader bars weighing 159 kg (350 lbs) which
makes the total weight for the load handling devices 286 kg
(632 lbs).
A check of the load chart for a 15.2 m (50 ft) radius and
DANGER
19.5 m (64 ft) of boom length shows a capacity of 3601 kg Death or serious injury could result from improper crane
(794 0 lbs) on ou trigg ers ove r-f ront and 4 970 lbs on setup on outriggers.
outriggers 360 degrees. We subtract the load handling

3-23
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

outrigger selector switch to FRONT EXTENSION or

REAR EXTENSION and position the outrigger
extension/retraction switch to EXTEND. The appropriate
WARNING outrigger should begin to extend. Refer to Engaging the
Be sure the outriggers plus the center front stabilizer are Mid-Extend Lock Pin if the crane is to be operated at the
properly extended and set, and the crane is level for mid-extend position.
operation on outriggers. The center front stabilizer
outrigger is a vital factor in the stability of the crane.
All four outrigger beams plus the center front stabilizer
outrigger must be equally extended to the mid position
DANGER
vertical stripe or fully extended position before beginning All four outrigger beams must be equally extended to the
operation. mid position vertical stripe or fully extended position
before beginning operation.

NOTE: More than one outrigger may be extended at one

time. However, to ensure that each outrigger is fully
extended, each outrigger selector switch should be
WARNING
depressed individually and the outrigger selector
When operating the crane on outriggers, the outriggers switch should be depressed individually and the
should always be fully extended or locked in the mid- outrigger/retraction switch momentarily positioned
extend position. to EXTEND after multi-outrigger extension.
3. After all four outrigger beams plus the center front
stabilizer have been fully extended, position the
appropriate outrigger selector switch to FRONT
WARNING STABILIZER or REAR STABILIZER and position the
outrigger extension/retraction switch to EXTEND.
The center front stabilizer will retract when the outrigger
extend/retract switch is pushed down in the retract 4. Extend each stabilizer, positioning the float as
position. Reset the center front stabilizer if this has necessary, until the locking levers of the float engage
occurred, or if any main outrigger stabilizer has been the stabilizer cylinder rod.
extended after initial set-up.
NOTE: More than one stabilizer may be extended at one
time.
Setting The Outriggers (From Ground Outrigger
Control Panels) 5. With each stabilizer float firmly touching the ground,
position the front outrigger selector switches to FRONT
NOTE: The park brake must be set before the outriggers
STABILIZER and position the extension/retraction
will operate.
switch to EXTEND. Extend the front stabilizers
NOTE: The air suspension system must be deflated when approximately 76 to 102 mm (3 to 4 in).
on outriggers.
6. Position the rear outrigger selector switch to REAR
NOTE: The engine speed is increased to 1000 RPM when STABILIZER and position the extension/retraction
the exte nd/retr act swit ch is placed in eith er switch to EXTEND. Extend the rear stabilizers
position. approximately 76 to 102 mm (3 to 4 in).
1. Position the outrigger floats directly out from each 7. After all floats are on the ground, extend the front
outrigger to where the outriggers will be properly stabilizers about 8 to 10 cm (3 to 4 inches) and then
extended. extend the back stabilizers the same distance. Repeat
until all tires are off the ground.

CAUTION
Always position a switch on the outrigger selector panel
before positioning the outrigger extension/retraction DANGER
switch to extend or retract. All four outrigger beam lock pins must be engaged before
operating from the mid-extend position.
2. Position the CENTER FRONT STABILIZER control
switch to ACTIVATE and position the appropriate

3-24
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

slip into the lug, slowly extend or retract the outrigger

beam, allowing the locking pin to drop into the lug.
2. Slowly extend or retract the outrigger beam, allowing the
DANGER locking pin to drop into the hole in the top of the outrigger
Operator must select proper load chart and LMI program beam, engaging the outrigger beam at the desired
for the outrigger position selected. length.

8. Repeat step 3 until all wheels are clear of the ground Stowing The Outriggers
and the crane is level as indicated by the sight level 1. Position the CENTER FRONT STABILIZER control
bubble located on the right side of the cab. If it is switch to ACTIVATE and position the rear outrigger
suspected that the bubble level indicator is out of selector switches to REAR STABILIZER and position
adjustment, verify and adjust the bubble level as follows: the extension/retraction switch to RETRACT until the
a. Locate the crane on a firm level surface. rear stabilizers have retracted several inches.

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

Lug

4907-1

FIGURE 3-5 4741

NOTE: It may be necessary to jog the outrigger extension/

retraction switch slightly to ensure proper pin
engagement.
1. With the outriggers fully retracted, turn the locking pin FIGURE 3-6
(Figure 3-5) 90° from its stowed position and allow the
pin to slip into the lug on the jack beam. If the pin will not 5. Continue to retract the stabilizers until they are fully
retracted.

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OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

5
4

6612 1
2
1 3
2
1 2 3 FIGURE 3-7

Stowing the Mid-Extend Lock Pin

Item Description
1 Cotter Pin Locking Pin

2 Quick Pin
3 Outrigger Float
4 Rubber Bumper
5 Frame
6. Position the appropriate outrigger selector switches to
FRONT EXTENSION or REAR EXTENSION and
position the extension/retraction switch to RETRACT to
retract each outrigger. Refer to Stowing the Mid-Extend
Lock Pin if the crane was operated at the mid-extend
position.
NOTE: More than one outrigger beam may be retracted at 4907-2
one time.
7. After all outriggers have been fully retracted, stow the FIGURE 3-8
outrigger floats (Figure 3-7).
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.
1. Retract the outrigger extension/retraction cylinder.
2. Lift the lock pin and turn it 90° to its stowed position.

3-26
TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

Setting The Center Front Stabilizer Setting The Outriggers (From Superstructure Cab
Controls)
Use the same procedures for setting the outriggers from the
superstructure cab as setting the outriggers from the ground
WARNING control panels, except use the controls on the right side of
the superstructure cab. Refer to Superstructure Controls in
Be sure the outriggers plus the center front stabilizer are
this section.
properly extended and set, and the crane is level for
operation on outriggers. The center front stabilizer Swinging The Boom
outrigger is a vital factor in the stability of the crane.
All four outrigger beams plus the center front stabilizer
outrigger must be equally extended to the mid position
vertical stripe or fully extended position before beginning DANGER
operation. Death or serious injury could result from being crushed by
moving machinery. Sound swing horn and clear all
personnel from moving parts.

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 DANGER
before stabilizers and outriggers.
Do not elevate or swing boom over side unless outriggers
1. Position the CENTER FRONT STABILIZER control
are properly extended and crane is level.
3
swi tc h t o A CT IV A T E an d p o sit io n t he ou t ri gg e r
extension/retraction switch to EXTEND.

CAUTION DANGER
Do not try to lift or level the crane with the center front Clear boom and tail swing path of all obstructions and
stabilizer. personnel.

2. Continue to extend the stabilizer until the float is firmly

set on the ground.

Stowing The Center Front Stabilizer DANGER

When swinging from over-the-front to over-the-side, refer
to over-the side load chart and make certain the capacity
CAUTION is not exceeded. Traveling with any load over-the-side is
Never operate center front stabilizer unless boom is prohibited.
retracted and in boom rest, and outriggers and stabilizers
are extended and set. Retract center front stabilizer
before stabilizers and outriggers. The center front
stabilizer outrigger is a vital factor in the stability of the CAUTION
crane. Disengage 360° swing lock, pin swing lock, and swing
brake before swinging.
1. Position the CENTER FRONT STABILIZER control
swi tc h t o A CT IV A T E an d p o sit io n t he ou t ri gg e r
extension/retraction switch to RETRACT.
NOTE: Keep feet and hands clear of the float when CAUTION
unlocking it from the stabilizer. Never push or pull swing controller through neutral to the
opposite direction to stop swing motion.
2. Retract the center front stabilizer until the stabilizer is
fully retracted.
To swing the boom, push the controller on the left hand
armrest to the right for right swing or to the left for left swing.

3-27
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

Always operate the controller with a slow, even pressure. Extending The Boom (With Single Hoist) (Optional)
Rotation is stopped utilizing the swing brake foot pedal.
When rotation is stopped, press the top of the swing brake
switch to the on position to prevent further rotation.

Elevating And Lowering The Boom WARNING

When extending the boom, simultaneously let out the
cable to prevent two-blocking the boom nose and hook
block.
DANGER
Clear area above and beneath boom of obstructions and
personnel before elevating or lowering boom.

Elevating the Boom

DANGER
Check the load chart for maximum load at given radius,
To elevate the boom, push the controller on the right hand boom angle, and length before extending boom with a
armrest to the left, and hold until the boom reaches the load.
desired elevation.
Lowering the Boom Push the controller on the left hand armrest to the left, and
hold until the boom reaches the desired length.
To lower the boom, push the controller on the right hand
armrest to the right and hold until the boom is lowered to the Retracting The Boom (With Single Hoist) (Optional)
desired position.

WARNING
WARNING When retracting the boom, the load will lower unless the
Long cantilever booms can create a tipping condition cable is taken in at the same time.
even when unloaded and in an extended and lowered
position. To retract the boom, push the controller on the left hand
armrest to the right and hold until the boom retracts to the
desired position.
Telescope Control Pedal
The telescope control pedal is used on cranes equipped with
DANGER
an auxiliary hoist. Push on the top of the pedal to extend the
Lower boom and let out cable simultaneously to prevent
boom and push on the bottom of the pedal to retract the
two-blocking.
boom.

Lowering And Raising The Hoist Cable

CAUTION
The closer the load is to the boom nose, the more
important it becomes to let out cable as the boom is WARNING
lowered.
Keep the area beneath the load clear of all obstructions
and personnel when lowering or raising the cable (load).
Telescoping The Boom
NOTE: When the crane is equipped with an auxiliary hoist
the telescope function is controlled by a foot pedal.

WARNING
Do not jerk controller when starting or stopping hoist.
Jerking causes load to bounce, which could result in
possible damage to the crane.

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TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

NOTE: When the load is stopped at the desired height, the • Swing Angle Set Limitation
automatic brake will engage and hold the load as
• Work Area Definition
long as the controller remains in neutral.
• Anti-two Block Device
Lowering The Cable
Swing Angle Set Limitation allows left and right swing
Push the main hoist (right hand armrest) or auxiliary hoist angle to be preset. When the preset angle is reached, the
(left hand armrest) controller forward, away from the system will provide an audible warning.
operator, and hold until the hook or load is lowered to the
desired height. Work Area Definition allows the crane operator to describe
the crane’s working area by setting up “virtual walls”. They
Raising the Cable are referred to as virtual walls because they exist in the
system and are not real walls. The virtual walls represent
Pull the main hoist (right hand armrest) or auxiliary hoist (left obstacles (i.e. buildings, towers, poles, etc.) in the crane’s
hand armrest) controller, toward the operator, and hold until working range. They are set by defining points along the
the hook or load is raised to the desired height. outer limits of the working area with the tip of the boom. Once
the working area has been defined, the system will provide a
Hoist Speed Range Selection visual and an audible warning if the boom approaches a
virtual wall.

DANGER CAUTION
Do not change the hoist speed range with the hoist When defining virtual walls (s). always allow a safe
rotating. working distance to any obstacles. Never work outside a

To change the speed range of the hoist(s), press the top

safe working area as defined by common practice,
standards, and manuals.
3
(high speed) or bottom (low speed) of the main hoist speed
switch located on the right hand armrest or auxiliary hoist
speed switch located on the left hand armrest.

Operational Aids WARNING

There are no cut-outs associated with the swing angle set
limitation or the work are definition features.

DANGER An Anti-two Block Device is also incorporated into the

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

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OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

Crane Travel Operation 5. To reduce slack in the belt, pull the belt out as you did in
step 4.a.
Active Restraints
Seat Belts
DANGER
Latch Plate Keep any shoulder belt slack to a minimum, no more than
25 mm (1 inch). Belt slack beyond the specified amount
could significantly reduce the amount of protection in an
accident because the belt is too loose to restrain you as
intended.

6. To unfasten the belt, push in on the button in the center

of the buckle. To store the belt, pull out about 180 mm
(7.1 in) and let go. The belt should retract when the
buckle is unlatched. To help prevent damage to the seat
belt and interior, before closing the door be sure the belt
is fully retracted and the latch plate is out of the way.
Buckle
Traveling - General
Push Button FIGURE 3-9
CAUTION
1. Before fastening a seat belt, always adjust the driver’s Check cold tire pressure prior to extended travel. Refer to
seat to the position in which you will drive. tire inflation decal on crane.
2. Pull the belt across your lap and push the latch plate into
the buckle until it clicks (Figure 3-9).
3. To reduce the risk of sliding under the belt during a CAUTION
collision, position the belt across your lap as low on your
Job site travel with deflated suspension must be limited to
hips as possible and pull it toward the door to a snug fit
8 km/h (5 MPH). Attempting to travel at higher speeds
so the retractor can take up the slack.
may cause drive train component failure.
NOTE: The lap/shoulder belt is designed to lock only
during a sudden stop or impact. At other times is
should move freely.
CAUTION
4. If the shoulder belt is too snug, do the following:
Before job site or off-highway travel or pick and carry,
a. Pull the shoulder belt out (A) at least 130 mm (5 in) select auxiliary transmission LOW range to prevent clutch
so that when it is left go, it returns to your chest damage. Main transmission must be shifted in MANUAL
(Figure 3-10). mode when the auxiliary transmission is in LOW range.
b. Then pull down on the shoulder belt (B) the least
Do not move the crane until the superstructure has been
amount needed to ease pressure but no more than
secured as outlined below.
25 mm (1 inch) and let go.
1. To ensure the axles and/or suspension are not
overloaded, adhere to the following.
a. For highway travel with 8165 kg (18,000 lb) of
cou nte rwe ight, i nsta ll 3 62 9kg (8 000 lb ) o f
counterweight on the carrier. Check that front axle
load does not exceed 22,318 kg (49,200 lb) and rear
axle load does not exceed 27,216 kg (60,000 lb).
b. For highway travel with 6350 kg (14,000 lb) or 5443
kg (12,000 lb) of counterweight, install 1814 kg
FIGURE 3-10 (4000 lb) of counterweight on the carrier. Check that
front axle load does not exceed 22,318 kg (49,200

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TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

lb) and rear axle load does not exceed 27,216 kg 10.1 m (33 ft) extension, the stinger section must be
(60,000 lb). stowed on the boom base section, not on the extension
base section.
c. GVW should never exceed 49,532 kg (109,200 lb).
Also refer to certification label on inside of cab door 2. Jobsite travel only on firm, level surface.
for Gross Axle Weight Ratio (GAWR).
3. Main boom shall be fully retracted.
2. Ensure all boom sections are fully retracted or set to
4. Main boom angle: 3 degrees minimum, 30 degrees
whatever extension is necessary for balance load on the
maximum.
axles.
5. Maximum travel speed: 4 km/h (2.5 mph).
3. Ensure the boom is fully lowered into the boom rest.
6.
4. Engage the swing brake.
a. With the boom over the front, the counterweight
5. Engage the swing lock.
used can be from 0 kg to 8165 kg (18,000 lb).
6. Ensure the swingaway, if so equipped, is properly
b. With the boom over the rear, the counterweight
stowed and secured.
used must be from 5443 kg (12,000 lb) to 8165 kg
7. Remove the hookblock and/or headache ball from the (18,000 lb).
hoist cable(s) and stow securely before traveling or
7. Swing lock and pin shall be engaged.
ensure headache ball is properly secured to the tie down
provided for that purpose. 8. Hookblock must be removed from main boom nose.
8. Ensure the outrigger stabilizers and outrigger beams are 9. Headache ball may be reeved over boom extension,
fully retracted and the floats are removed. hanging 0.9 m (3 feet) below sheave.
9. Ensure the center front stabilizer is fully retracted. Floats 10. Suspension air bags shall be inflated. 3
remain installed.
11. The tires shall be properly inflated.
10. Ensure the stabilizer floats are properly stowed in their
holding racks.
10.1 m (33 ft)/17.1 m (56 ft) Extension Plus One or Two
6.1 m (20 ft) Insert(s)
11. Ensure the cover doors on the outrigger control panels,
battery box, and sling box are closed. Travel is permissible under the following conditions.

12. Close and/or install all superstructure cab windows and 1. The 10.1 m (33 ft) or 17.1 m (56 ft) boom extension shall
door. be erected at minimum offset. If traveling with just the
10.1 m (33 ft) extension, the stinger section must be
13. If traveling on job site or off-highway, select auxiliary stowed on the boom base section, not on the extension
transmission LOW range to prevent clutch damage. base section.
a. Push the auxiliary transmission low range switch 2. Jobsite travel only on firm, level surface.
located on the carrier right side console to the right
to engage low range. 3. Main boom shall be fully retracted.

b. An amber indicator on the carrier left front console 4. Main boom angle: 3 degrees minimum, 30 degrees
will illuminate when the auxiliary transmission is in maximum.
low range. 5. Maximum travel speed: 4 km/h (2.5 mph).
c. The main transmission must be shifted in MANUAL 6. With the boom over the front, the counterweight used
mode if the auxiliary transmission is in LOW range. can be from 0 kg to 8165 kg (18,000 lb). Travel with the
boom over the rear is not permitted with insert(s)
Traveling With Boom Extension And/Or Inserts
erected.
Erected
7. Swing lock and pin shall be engaged.
10.1 m (33 ft)/17.1 m (56 ft) Extension
8. Auxiliary hoist or IPO counterweight must be installed.
Travel is permissible under the following conditions.
9. Hookblock must be removed from main boom nose.
1. The 10.1 m (33 ft) or 17.1 m (56 ft) boom extension shall
be erecte3d at minimum offset. If traveling with just the

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OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

10. Headache ball may be reeved over boom extension, target gear position of the transmission when in neutral
hanging 0.9 m (3 feet) below sheave. during a shift.
11. Suspension air bags shall be inflated.
Satisfactory Out of gear waiting Satisfactory
12. The tires shall be properly inflated. engagement for engine/ engagement
in 5th gear transmission rpm in 6th gear
UltraShift™ Transmission to reach
synchronous
The UltraShift™ is a fully automated mechanical Eaton®
Fuller® transmission that provides automatic operation (no
clutch pedal) using a manual transmission coupled with
electronic modules that automate the shifts. The electronics
direct the transmission to make each shift at the ideal engine
speed. SOLID FLASHING SOLID
FIGURE 3-12
Shifting Gears
Down arrows on the Gear Display indicate the transmission
Next to concern for safety, good shifting habits are probably
is waiting to verify decreased input shaft speed, before a
the most important capability a driver can have. Knowing
gear engagement from Neutral can be completed.
how and when to shift can return savings in trip time and
operating expense.

R - Reverse
N - Neutral
D - Drive The “DASH” indicates the transmission may be torque
M - MANUAL locked in gear (see Locked in Gear in this section).
L - LOW

6625
FIGURE 3-11
• R - Selects the reverse gear once vehicle speed is less
than 2 mph.
Start-up and Power Down
• N - Neutral is selected.
Start-up
• D - Selects the default starting gear and automatically
selects gears between the starting gear and top gear. 1. Turn the ignition to ON and allow the UltraShift™ to
po we r - up . E ng in e c r a nk in g i s de l ay ed un t il t h e
• Manual - Allows the driver to hold current gear and transmission power-up is complete and the gear display
manually select the appropriate gear for road condition shows a solid “N”
using the up/down buttons.
2. Start the engine.
• Low - Transmission downshifts at the earliest
opportunity for maximum engine braking down to the 3. Apply the service brake.
lowest allowable gear, until MANUAL or Drive is NOTE: If the service brake is not applied while selecting a
selected. starting gear, the initial start gear will not be found
• Up/Down Buttons - Used in the MANUAL mode to select and the driver will have to re-select neutral and
upshifts and downshifts. press the brake while re-selecting the desired
mode.
Gear Display
4. Select the desired mode and starting gear on the shift
The Gear Display (Figure 3-12) shows the current gear console.
position of the transmission. The Gear Display will flash the
5. Release the parking brake.

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TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

6. Release the service brake and apply accelerator. tr an smi ssio n will com ple te up sh ift s a nd do wns hif ts
automatically.
NOTE: The transmission is not intended to provide hill-
hold capability. The service brakes should be used Depending on conditions, the UltraShift™ can activate the
to stop and hold the machine on an incline. To engine brake in order to bring the engine down faster for an
prevent the machine from rolling when starting on upshift. This can happen if the engine brake dash switch is
an incline, place both feet on the brake pedal off.
before sliding the right foot to the throttle pedal.
Gradually back off the brake while applying as little Coast Mode
throttle as necessary to move along the incline. When coasting to a stop in lower gears with your foot off the
Power Down throttle, UltraShift™ may not finish downshifting until the
driver gets back on the throttle. The system will automatically
1. Select Neutral (N) on the shift control. track vehicle and engine speed during this time and engage
NOTE: If gear display does not show solid (N), neutral has the appropriate gear when the throttle is re-applied. This is a
not yet been obtained. normal condition for the UltraShift™ when in Drive “D” mode
only.
NOTE: Neutral should always be reached before Ultrashift
power down is performed, except in cases of Clutch Protection
emergency. Even though the crane does not have a clutch pedal, it still
2. Set the machine parking brakes. has a mechanical clutch. As you slowly increase and
decrease engine RPM from a stop, the clutch is engaging
3. Turn the ignition switch to off (vertical position) and allow and disengaging, just like slipping the clutch with an
the engine to shut down. AutoShift or Manual transmission.
Proper Starting Gear If you operate for long periods between engine idle and 1000
RPM during take off, you are slipping the clutch which, in
3
Chose a starting gear appropriate for the load and grade
conditions, while at a stop in Drive and MANUAL modes by turn, gets the clutch HOT.
using the up/down buttons. Refer to Drive Mode for detailed
information. CAUTION
If you see the (C) and then an (A) in the gear display
Skip Shifting during operation, stop the crane for at least 2 minutes and
Performed in MANUAL by pressing the shift button more let the clutch cool down.
than once. Continuing operation with the (C) and (A) flashing on the
gear display will cause the clutch to get even hotter and
Optimal Engine Braking the transmission may attempt to downshift into a lower
The LOW mode can be selected while moving. This initiates start gear and/or limit the engine to idle speed until the
downshifts as soon as possible to maximize the effect of clutch cools (approximately 3 minutes).
engine braking. Refer to LOW mode section for detailed Repeated incidents of clutch abuse may cause the clutch
information. to fail and the crane not to be able to move, resulting in
extended down time.
Skid Conditions
If a skid condition occurs, the UltraShift™ senses the vehicle Excessive clutch slippage creates heat, which is detrimental
speed dropping rapidly. In this case, the UltraShift™ delays to clutch life. If the system detects the clutch is being
downshifting. overheated, a warning tone will sound and the Gear display
will flash a (C) than an (A) (Figure 3-13) signifying clutch
Load Based Shifting abuse followed by the selected gear position. The alarm will
continue until the clutch system cools, the throttle is
In Dr ive, the Ul traS hif t™ will ad apt to t he c hang ing
released, or the clutch is fully engaged. If one of these is not
conditions of the vehicle. Right after power-up or after
done and the clutch heat continues to rise, the launch quality
changin g loads, UltraShift™ needs to learn the new
may be adversely affected and the clutch may be damaged.
conditions. While learning, the transmission may hold a gear
Selecting 1st gear (Figure 3-13) as the start up gear will
instead of upshifting. When this occurs simply push the Up
reduce the risk of clutch abuse.
button to start the upshift. It may take three or four shifts for
the UltraShift™ to learn the new conditions. After that the

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OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

Drive Mode
Depending on the transmission model and Shift Control
configuration, there may be alternate forward starting gears
available. While the vehicle is stopped in Drive, the up/down
buttons are used to change the starting gear. This selection
is used until it is changed again, or the UltraShift™ is
FIGURE 3-13 powered down.
In Drive mode, all upshifts and downshifts are performed
Example of clutch abuse is listed in (Table 3-1) along with automatically based on vehicle and transmission conditions.
helpful hints on how to avoid.
The driver can advance a shift (by about 75 rpm) by pressing
Table 3-1 the proper up/down button (up for upshifts, down for
downshifts) when the transmission is within 75 rpm of the
Example How To Avoid load based shift point.
Use service brakes to hold The Gear Display shows the status of the shift:
Starting on hills or holding
on hill. To start moving,
on hills using the throttle • The current gear is displayed solid.
apply the throttle and
rather than the service
release the brakes as you • At the start of the shift, the current gear is displayed solid
brake
feel the crane start to pull. until the transmission is pulled to the neutral position.

NOTE: The transmission is not intended to provide hill- • While the transmission is in neutral and synchronizing
hold capability. The service brakes should be used for the target gear, the target gear is flashed.
to stop and hold the vehicle on an incline. To • When the shift is complete, the new current gear is
prevent the vehicle from rolling when starting on an displayed solid.
incline, place both feet on the brake pedal before
sliding the right foot to the throttle pedal. Gradually Cruise Control
back off the brake while applying as little throttle as
necessary to move along the incline. If a shift is required while cruise control is active, cruise is
temporarily interrupted while the shift is performed and then
Reverse Mode automatically resumes after the shift.

The vehicle speed must be less than 2 mph before Reverse Manual Mode
is permitted. If the driver requests Reverse above 2 mph, the
shift is not performed until the speed has dropped below 2 Manual mode should be used whenever you want to select
mph. the shifts inst ead o f lett in g Ultra Shift ™ select t hem
automatically for you. For example, when you are moving
Depending on the transmission model, there may be a around the yard or on steep grade conditions.
number of reverse gears available. Each time Reverse is
selected from Neutral, the default reverse gear is engaged. Selecting From Neutral

While the vehicle is stopped in Reverse, the up/down buttons As described above for Drive Mode, the starting gear can be
are used to change the reverse gear. This selection is used changed in exactly the same way in Manual mode.
only until another mode is selected. If Manual mode is selected from a stop, the starting gear is
There is a speed limit on the reverse engagements, yet the maintained - no automatic shifts are performed, except for
driver can effectively rock the vehicle by moving the shift conditions noted below.
control from reverse to drive and drive to reverse. The driver can request shifts using the proper shift button (up
for upshifts, down for downshifts). The upshift or downshift is
10-Speed performed by the UltraShift™ provided the result in engine
speed is not outside of defined limits. For upshifts, the
resulting engine speed must be greater than 900 RPM; for
downshifts, the resulting engine speed must be less than
engine rated speed.
Selecting Manual from Drive or Low while Moving

LO Range HI Range If Manual mode is selected while moving, the current gear is
maintained - no shifts are performed, except for conditions
FIGURE 3-14
noted below.

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TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

As described above, the driver can request shifts using the appear on the display and the engine will not start. If a dash
proper shift button (up for upshifts, down for downshifts) appears during power up and the lever is in Neutral try the
within the same limits described. following:
Transmission Manual Override
If the vehicle is being back driven and the engine is
approaching a higher than normal level (approximately 300
RPM above rated speed), the UltraShift™ overrides the
MANUAL position and performs an upshift to prevent engine
damage.
If the gear being maintained is higher than starting gear, and 1. Turn the key OFF and let the transmission power down
the driver depresses the pedal, the UltraShift™ overrides the for a least 2 minutes.
Manual mode and shifts to the best available gear.
2. Depress the brake pedal.
Low Mode
3. Release the parking brake.
LOW mode should be used any time you want to maximize
engine braking and minimize the use of the brake pedal. For
example, when driving down long grades or when coming to CAUTION
a stop. Do not turn ignition key to off with transmission in gear.
Selecting Low From Neutral
4. Make sure the shifter is in Neutral.
If LOW mode is selected from Neutral while stopped, the
5. Turn the key to the ON position.
starting gear is always 1st gear. The starting gear cannot be
changed in LOW mode. 6. The transmission will attempt to shift into Neutral once 3
you turn the key ON, but you may have to slightly
If LOW mode is selected from Neutral while stopped, 1st
release the brake pedal to help let the torque off the
gear is maintained - no shifts are performed, except for
driveline.
conditions noted below.
7. Once it reaches Neutral a solid "N" will appear on the
Selecting Low From Drive or Manual While Moving
Gear Display and the machine will start. If a dash still
If LOW mode is selected while moving, no upshifts are appears after this procedure, get the vehicle to a service
performed, except for override conditions noted below. center.

Downshifts are performed at higher RPM's than normal to Diagnostics

enhance engine braking. The downshift point is chosen so
engine speed after the shift is about 50 rpm below engine NOTE: Refer to the Shop Reference and Maintenance
rated speed. Guide for fault code diagnostic procedures. If fault
codes cannot be retrieved, contact your local
Transmission Low Override distributor or Manitowoc CraneCARE.
If the vehicle is being back driven and the engine is In the event there is a problem with the UltraShift™, there
approaching a higher than normal level (approximately 300 are three primary tasks the driver should perform:
rpm above rated speed), the UltraShift™ overrides the LOW
1. Note the driving condition under which the problem
position and performs an upshift to prevent engine damage.
occurred.
If the gear being maintained is higher than the starting gear,
2. Note the condition of the UltraShift™ under which the
and the driver depresses the pedal, the UltraShift™ system
problem occurred (i.e. operation mode (Drive, MANUAL,
will override the LOW mode and shift to the best available
LOW), current gear, engine speed, etc).
gear if the engine lugs excessively.
3. Reset the system.
Locked In Gear
If the crane is shut down or stalls in gear, the UItraShift™ Transmission Reset Procedure
may become locked in gear. The transmission will attempt to In some cases, proper transmission operation can be
get to Neutral during the next power up if the shifter is in restored by "resetting" the transmission Electronic Control
Neutral. If Neutral is achieved, a solid "N" appears on the Unit (ECU). Use the following procedure to reset the ECU:
Gear Display. If Neutral can not be achieved, a "DASH" will

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OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

1. When it is safe to do so, stop the vehicle. When adverse conditions have passed, do the following:
1. Stop the crane and position the switch to the unlock
position.
CAUTION
Do not turn ignition key to off with transmission in gear. 2. Resume driving at a safe speed.

2. Place the transmission shift lever in Neutral and turn the Service/Parking Brakes
ignition key to the OFF position. For the most effective braking and maximum life from the
3. Wait at least 2 minutes. brake system components, the following suggestions are
made.
4. Restart the engine.
1. Air brakes have light pedal operation and the driver is
5. If the problem continues, contact a service facility to cautioned to use extreme care in application until a good
have the vehicle and transmission system evaluated. feel is achieved.
6. In most cases, depending on the engine and axle ratios, 2. Use the engine as a brake when approaching a stop or
fuel can be saved by operating the crane at less than going down a long grade. On a downgrade, use the
governed rpm while in 8th gear. same transmission gear as would be needed to go up
the same grade.
Auxiliary Transmission Operation
3. When necessary to use brakes to reduce crane speed
on downgrades, use a on-and-off application to
CAUTION minimize heat and wear. Do not hold a continuous brake
Before job site or off-highway travel or pick and carry, application or slide the wheels.
select auxiliary transmission LOW range to prevent clutch 4. When driving on slippery pavement or under icy
damage. conditions, alternately and smoothly apply and release
the brakes to prevent skidding.
The auxiliary transmission low range switch is located on the
carrier right side console. 5. Keep the tires properly inflated. Improperly inflated tires
can reduce the efficiency of the brakes.
1. Push the auxiliary transmission low range switch to the
right to engage low range. 6. After driving through water, dry the brakes by applying
them lightly while maintaining a slow forward speed with
An amber indicator on the carrier left front console will an assured clear distance ahead until brake
illuminate when the auxiliary transmission is in low range. performance returns to normal.
Rear Tandem Inter-Axle/Cross-Axle Locks

CAUTION DANGER
Do not operate differential locks on dry roads. Stop immediately if low air pressure warning sounds and
determine cause of air loss, Stop by downshifting and use
To engage the inter-axle or cross axle differential locks for engine as a brake. Make final stop using a single brake
maximum pulling power when approaching slippery or poor pedal movement to avoid excessive loss of air and
road conditions, do the following: sudden engagement of parking brakes.

NOTE: If the pressure drops below 14 kPa (2 psi) per

minute with the engine stopped, have the air
CAUTION
system checked for leaks.
Do not engage or disengage differential locks while
wheels are spinning or at speeds over approximately 16 7. Regularly check the air pressure gauge. System air
km/h (10 mph). pressure should never drop below 310 kPa (45 psi). If
both systems drop below 310 kPa (45 psi), the
1. Stop the crane and position the switch to the lock automatic spring brakes will actuate. Normal operating
position. pressure is 724 to 827 kPa (105 to 120 psi).
2. Proceed over the poor road conditions cautiously.

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TMS800E OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES

Stowing and Parking

DANGER
Do not use parking brake for stopping crane except in DANGER
case of an emergency, as a severe sudden stop will Never park crane near holes, on rocky surfaces, or on soft
occur. spots. This may cause crane to overturn, resulting in
injury or death to personnel.

When parking the crane, do the following.

CAUTION
Release brakes before moving crane, or drive train 1. Remove the load from the hook.
damage will result. 2. Remove or stow boom extensions if so equipped.

NOTE: Park brake must be set before outrigger controls 3. Fully retract all boom sections.
can be operated. 4. Lower the boom to normal travel position.
8. The parking brakes are controlled by a push-pull knob 5. Engage the swing brake, swing lock pin, and 360 degree
on the front console. Pull the knob out to apply and push house lock.
the knob in to release the parking brake.
6. Retract all stabilizer cylinders and outrigger beams.
Engine Braking
7. Turn the crane function power switch to the off position
NOTE: Do not keep a foot lightly on the clutch pedal or the (press bottom of switch).
throttle pedal. This will cause the engine brake not
to come on. 8. Park the crane on a stable surface. 3
By energizing the engine brake, the power producing diesel 9. Apply the parking brakes and if necessary, chock
engine, in effect, becomes a power absorbing air wheels.
compressor. To retard a crane on a downgrade using the 10. Ensure all operating controls are in neutral position.
Engine Brake, the operator selects a gear which will provide
a balance between engine speed and road speed, then 11. Shut down engine following proper procedures specified
engages the engine brake. If the engine speed exceeds in this handbook and the applicable engine manual.
maximum rated rpm for a desired speed, a lower gear can be 12. Remove the keys.
selected or intermittent use of the service brakes can be
made. This selection of a lower gear will generally allow 13. Close and lock, if applicable, all windows, covers, and
complete control of the crane by the engine brake leaving the doors.
service brakes in reserve to be used for emergency stops.
With the engine brake turned on, the engine brake will not be Crane Shutdown Procedures
energized until the momentum is driving the engine. The following procedures will extend serviceable life of
1. Position the engine brake On/Off switch to on (push top various crane components, reduce vandalism, and accidents
of switch). during crane shutdown periods or anytime the crane is left
unattended.
2. Position the engine brake switch to either high (press top
of switch) or low (press bottom of switch) position, 1. Perform the procedures found under Shutdown
depending on the amount of braking desired. Procedure in this handbook.

3. Leave off the throttle to activate the engine braking

system and slow the crane.
NOTE: The engine braking system will automatically DANGER
deactivate when the throttle is depressed. Never park crane near holes, on rocky surfaces, or on soft
spots. This may cause crane to overturn, resulting in
injury or death to personnel.
CAUTION
Before engaging engine brake on slippery roads, be sure 2. Park the crane on a proper surface with the outrigger
crane is maintaining traction. stabilizers and beams fully retracted. Do not park in a
location where it may become frozen to the ground or
settle unevenly and overturn.

3-37
OPERATING CONTROLS AND PROCEDURES TMS800E OPERATOR’S MANUAL

3. Apply parking brakes and if necessary, chock the

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

3-38
 SECTION 4
SET-UP AND INSTALLATION
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installing Cable On The Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Installing Wedge and Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removable Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Mounting The Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Stowing The Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Checklists For Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Overview of the Required Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Check List: Installing the 56 ft (17.1 m) Manual Swingaway Lattice Extension . . . . 4-9
Check List: Removing the 56 ft (17.1) Swingaway Lattice Extension . . . . . . . . . . . 4-10
Check List: Rigging the 33 Ft (10.1m) Swingaway Lattice Extension. . . . . . . . . . . 4-10
Check List: Unrigging the 33 Ft (10.1 m) Swingaway Lattice Extension. . . . . . . . . 4-11
Checklist: Rigging the 56 ft (17.1 m) Two-Stage Swingaway Lattice Extension. . . 4-12
Checklist: Unrigging the 56 ft (17.1 m) Two-Stage Swingaway Lattice Extension . 4-13
Description Of Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Preparing the Crane for Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Checking the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Folding the Run-Up Rail Out/In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Connections With Folded Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Pin Connections on the Main Boom Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Pin Connections on the Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Swinging the Lattice Extension onto the Main Boom Head . . . . . . . . . . . . . . . . . . 4-24
Swiveling the Lattice Extension when Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Electrical Connections on the Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Folding Out/In the Mast Sheaves on the 33 ft (10.1 m) Section . . . . . . . . . . . . . . . 4-26
Positioning/Remove the Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Possible Reeving Methods on the Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . 4-28
Lifting Limit Switch on the Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4
Transportation on a Separate Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Raising And Setting Down The Main Boom With Rigged Lattice Extension . . . . . . . . . 4-29
Telescoping With Rigged Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Operation With The Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Procedure if the Permissible Wind Speed is Exceeded . . . . . . . . . . . . . . . . . . . . . 4-29
Malfunction When Working With Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Maintenance Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Maintenance Work, Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Boom Extension (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Identification and Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Assembly Of Boom Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Setting the Folding Swingaway Extension Offset . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Swingaway Mounting Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Checklists For Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Rigging the 76/96 Ft (23/29 m) Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Unrigging the 76/96 Ft (23/29 m) Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Description of Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Installing/Removing the Two-Stage Swingaway Lattice Extension for the Boom Extension4-36
Electrical Connection at the Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Positioning/Removing the Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Boom Positions and Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

4-i
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Maintenance Work, Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Auxiliary Single Sheave Boom Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Installing/Removing Auxiliary Single-Sheave Boom Top . . . . . . . . . . . . . . . . . . . . 4-40
Removing the Auxiliary Single-Sheave Boom Nose . . . . . . . . . . . . . . . . . . . . . . . 4-40
Rigging in Working Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Attaching and Removing Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Possible Reeving Methods on the Auxiliary Single-Sheave Boom Top. . . . . . . . . 4-41
Boom Extension Erecting and Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Erecting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Bi-fold (Stinger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Bi-fold (Stinger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Hook Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

4-ii
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

SECTION 4
SET-UP AND INSTALLATION
GENERAL NOTE: If the wedge does not seat securely in the slot,
carefully tap the top of the wedge with a mallet.
This section provides procedures for installing the hoist
cable on the hoist drum, cable reeving, and erecting and 5. Slowly rotate the drum, ensuring the first layer of cable is
stowing the boom extension. evenly wound onto the drum.
6. Install the remainder of the cable, as applicable.
INSTALLING CABLE ON THE HOIST
CABLE REEVING
CAUTION NOTE: There are two types of cable (wire rope) available
If cable is wound from the storage drum, the reel should on this crane; 6 x 36 WS and 35 x 7 (non-rotating).
be rotated in the same direction as the hoist. Within the limits of the load and range charts and permissible
line pull, multi-part lines allow the operator to raise a greater
NOTE: The cable should preferably be straightened before load than can be raised with a single part line. Various cable
installation on the hoist drum. reeving (part line) is possible with the boom nose and hook
Install cable on the hoist drum in accordance with the block. This reeving should be accomplished by a qualified
following procedure (Figure 4-1) rigger using standard rigging procedures.
.
CAUTION
Do not reeve Auxillary Hoist rope through the rope grab.
Do reeve the Main Hoist rope through the rope grab. If
both Main & Auxilliary Hoists are being reeved, neither
one may be reeved trough the rope grab. Keep it in the
down position. (Figure 4-2)

NOTE: Also use the rope grab when using the Main Hoist
with lattice extensions

Rope Grab
4

3155
FIGURE 4-1

1. Position the cable over the boom nose sheave and route
to the hoist drum.
2. Position the hoist drum with the cable anchor slot on top.

3. Insert the cable through the slot and position around the
anchor wedge.
6769
NOTE: The end of the cable should be even with the
bottom of the anchor wedge. FIGURE 4-2

4. Position the anchor wedge in the drum slot; pull firmly on n order to quick reeve the hook block without removing the
the free end of the cable to secure the wedge. wedge socket on the end of the cable (Figure 4-3).

4-1
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

CAUTION
If the socket is not positioned with the flat face away from
the boom sections, structural damage will occur.

When anchoring the socket to the boom, ensure the flat face
of the socket is in position, as shown, away from the boom
sections (Figure 4-4).

FIGURE 4-3

DEAD-END RIGGING/WEDGE SOCKETS

Wedge socket assemblies are popular rigging accessories
and have been successfully used for decades to terminate
wire ropes on mobile cranes. A wedge socket assembly is
easily installed and dismantled but it must be installed and
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. 6769
FIGURE 4-4
Since state and local laws may vary, alternate attachment
methods ma y be necessary d epending up on work Installing Wedge and Socket
conditions. If alternate methods are selected, the user is
responsible and should proceed in compliance with the 1. Inspect the wedge and socket. Remove any rough
regulations in force. If there are any questions, contact your edges and burrs.
local Grove Distributor or Manitowoc CraneCARE.
2. The end of the wire rope should be seized using soft, or
Do not mix components from different manufacturers. The annealed wire or strand. If the end of the rope is welded,
selection, installation and use of a wedge socket assembly the welded end should be cut off. This will allow the
must be in accordance with the requirements of the wedge distortion of the rope strands, caused by the bend
socket manufacturer and the wire rope manufacturer upon around the wedge, to adjust themselves at the end of the
whose wire rope the wedge socket assembly will be used. line.
Manitowoc/Grove Crane specifies the size, type, class and
line pulls for wire rope, predominately rotation resistant wire
rope, and rigging accessories such as overhaul balls and Live End
hook bloc k s for use with each new c rane that it
manufactures. Other wire ropes and rigging accessories are Dead End
ava ilab le fro m var ious ven do rs. Diff er ent wir e rop e
m an u f a ct u r e r s h a ve d i ff e r i ng r e q u ir e m e nt s f or t h e
construction, handling, cutting, seizing, installation,
termination, inspection and replacement of the wire ropes
they produce. Their advice should be sought for each
specific type of wire rope a crane user intends to install on a 5337
mobile crane.
Wrong
When assembly is complete, raise the boom to a working Right
position with a load suspended to firmly seat the wedge and FIGURE 4-5
rope into the socket before the crane is used operationally.
Make sure the live-loaded side (Figure 4-5) of the
rope is directly in line with the ears of the socket and
the direction of pull to which the rope will be
subjected. If the rope is loaded into the socket

4-2
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

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

Specialty Clip
Specialty Wedge

A B C D E F FIGURE 4-6

4-3
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

UPPER BOOM NOSE SHEAVES TO MAIN HOIST

LOWER BOOM NOSE SHEAVES

AUXILLIARY NOSE HOOKBLOCK DEAD END

HOOKBLOCK SHEAVE

9 PARTS LINE 6453

TO HOIST
TO HOIST

6568-6 6568-5
ONE PART LINE ONE PART LINE
USING BOOM EXTENSION USING BOOM EXTENSION
SHOWN AT 20° OFFSET SHOWN AT 40° OFFSET

FIGURE 4-7

4-4
 TMS800E OPERATOR’S MANUAL
33 FT (10 m) FIXED BOOM EXTENSION
SHOWN AT 0° OFFSET

SET-UP AND INSTALLATION

6453-1

56 FT (17 m) BI-FOLD BOOM EXTENSION

SHOWN AT 0° OFFSET
FIGURE 4-7 continued
4-5

4
4-6

SET-UP AND INSTALLATION

76 FT (23 m) BI-FOLD BOOM EXTENSION
SHOWN AT 0° OFFSET

TMS800E OPERATOR’S MANUAL

6453-2

96 FT (29 m) BI-FOLD BOOM EXTENSION

SHOWN AT 0° OFFSET
FIGURE 4-7 continued
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

REMOVABLE COUNTERWEIGHT counterweight using the attach pins in the cylinders.

Insert the retaining pins in the attach pins.
4. Push in, turn, and remove the long attach pins from the
counterweight and carrier frame lugs.
DANGER 5. Using the control levers, raise the counterweight up
Ensure that all mounting pins are properly installed and under the superstructure frame.
locked, during, and after operating the counterweight
removal system. NOTE: It may be necessary to jog the counterweight
removal control levers (Figure 4-8) to install the
• The 5443 kg (12,000 pound) removable counterweight upper attach pins.
consists of three slabs, each weighing 1814 kg (4000 6. Remove the upper attach pins from the stowage
pounds). bushings and install them into the upper counterweight
• The 8165 kg (18,000 pound) removable counterweight and superstructure frame lugs.
consists of three slabs each weighing 1814 kg (4000 7. Push in on the pins and turn to lock pin in the notch.
pounds) and one slab weighing 2721 (6000 pounds).
8. Insert the long pins into the bottom of the counterweight.
• An optional 10,885 kg (24,000 pound) removal Push in on the pins and turn to lock pin in the notch.
counterweight consists of two 1,360 kg (3000 pound)
“wing weights” that hang on the existing 8,165 kg 9. The crane is now ready for operation with the
(18,000 pound) counterweight stack. counterweight installed.

NOTE: This extra counterweight is not roadable due to the Stowing The Counterweight
overall width of the machine when installed, but
you can move around the jobsite with the full 1. Position the crane on a firm level surface. Fully extend
counterweight installed. and set the outriggers.

NOTE: The following procedures are applicable for 2. Rotate the superstructure to align the counterweight with
removal and installation of any or all pieces the stowage area. Engaging the pin type turntable lock
(Figure 4-8). will aid alignment.

The counterweight contains lugs for attachment to the NOTE: It may be necessary to jog the counterweight
removal cylinders and lugs to pin it under the hoist mounting. removal control levers to remove the weight of the
The additional slabs pin the structure to each other. The counterweight from the upper attach pins.
counterweights can be pinned to the carrier deck and are 3. Using the counterweight removal control valve levers,
transferred between the turntable and the carrier deck and
by two hydraulic removal cylinders. The cylinders are
raise the counterweight cylinders to relieve weight on
the upper attach pins. Push in, turn, and remove the
4
controlled from a valve assembly located under the hoist upper attach pins from the superstructure frame lugs
mounting. The valve contains an inlet section, an outlet and the counterweight
section with relief valve, and a working section for each
cylin der. T he valve is manu ally co ntrolled b y levers 4. Stow the upper attach pins in the bushings on the side of
extending through the turntable side plates on each side. the superstructure.
5. Push in, turn, and remove the long pins from the bottom
Mounting The Counterweight of the counterweight.
1. Position the crane on a firm level surface. Fully extend 6. Using the removal control levers, slowly lower the
and set the outriggers. counterweight onto the carrier stowage area.
2. Rotate and align the rear of the superstructure above the 7. Insert the long pins through the carrier lugs and
removable counterweight stowed on the carrier deck. counterweight. Push in and turn to lock pin in the notch.
Engaging the pin type turntable lock will aid alignment.
8. Remove the attach pins from the counterweight lugs and
3. Using the counterweight removal control valve levers cylinder ends. Raise the cylinders and stow the attach
located on either side of the turntable, lower the pins in cylinder and insert retainer clip pins.
counterweight cylinders. Pin the cylinders to the
9. The carrier is now ready for highway travel with the
counterweight stowed.

4-7
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

13

12

10 14

16 11

6, 8 1

11

2, 3, 4
6 5

10

7 6533
9
15 FIGURE 4-8

Item Description Item Description

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

4-8
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

CHECKLISTS FOR RIGGING WORK 3. Lift (two-stage) swingaway lattice extension in front of
the main boom with the auxiliary crane and lock the 33 ft
Overview of the Required Rigging Work (10.1 m) section to the right of the main boom head
(Figure 4-9).
There are different initial states for rigging the lattice
extension, depending on whether:
- the lattice extension is folded at the side of the main
boom
- the lattice extension has been removed.
Table 4-2 shows you which checklist describes the required
rigging work for your initial state.

Table 4-2
FIGURE 4-9
Corresponding 4. Establish electrical connection between the lattice
Initial State
Rigging Work extension and the main boom.
The lattice 5. Attach the guide rope to the head of the 33 ft (10.1 m)
Check Lists: Rigging section (Figure 4-10)
Before the extension is
the 33 ft (10.1 m)
crane located at a side
swingaway lattice
operation on the main
extension.
boom

The lattice
Check List: Installing
extension was
two-stage swingaway
removed
lattice extension
completely

Check List: Unrigging

the 33 ft (10.1 m)
The lattice FIGURE 4-10
swingaway lattice
After the extension must extension. NOTE: If the lattice extension needs to be rigged in front of
crane be folded to the
Unrigging the 56 ft the main boom, proceed as from point 8.
operation side of the main
boom (17.1 m) two-stage
swingaway lattice
6. If the lattice extension is to be folded up at the side of the 4
main boom, fold out run-up rail.
extension.
7. The other types of rigging work for folding up the lattice
The lattice Check List: extension at the side are described in the Check List:
extension is to Removing the two- Unrigging the 33 ft (10.1 m) swingaway lattice extension
be removed for stage swingaway
as from point 8.
on-road driving lattice extension.
8. If the lattice extension needs to be rigged in front of the
main boom, attach guide ropes to the head of the 33 ft
Check List: Installing the 56 ft (17.1 m) (10.1 m) section.
Manual Swingaway Lattice Extension
The other types of rigging work for the 33 ft (10.1 m)
Prerequisites: swingaway lattice extension are described in the Check
List: Rigging the 33 ft (10.1 m) swingaway lattice
- The crane is on outriggers or the main boom is
extension as from point 12.
placed on the boom support.
The other types of rigging work for the 56 ft (17.1 m) two-
- An auxiliary crane is available.
stage swingaway lattice extension are described in the
1. Check the transport condition of the (two-stage) Check List: Rigging the 56 ft (17.1 m) swingaway lattice
swingaway lattice extension. extension as from point 11.
2. Sling two-stage swingaway lattice extension on auxiliary
crane.

4-9
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

Check List: Removing the 56 ft (17.1)

Swingaway Lattice Extension
Prerequisites:
- The crane is on outriggers or the main boom is
placed on the boom support.
- An auxiliary crane is available.
1. Carry out all of the rigging work for a rigged 33 ft (10.1
m) swingaway lattice extension listed in the Check List: FIGURE 4-12
Unrigging 33 ft (10.1 m) swingaway lattice extension up
to and including point 9 in this section. NOTE: If only the 33 ft (10.1 m) section is folded at the side
of the main boom - proceed from point 7.
2. Carry out all of the rigging work for a rigged 56 ft (17.1
m) two-stage swingaway lattice extension listed in the 4. Move the connection in the middle area on 33 ft (10.1 m)
Check List: Unrigging 56 ft (17.1 m) two-stage section (Figure 4-13)
swingaway lattice extension up to and including point
15.
3. Disconnect electrical connection between the lattice
extension and the main boom.
4. Slinging (two-stage) swingaway lattice extension on
auxiliary crane.
6568-1
5. Remove locking pins on both sides between 33 ft (10.1
m) section and main boom head and place (two-stage) FIGURE 4-13
swingaway lattice extension onto separate vehicle using 5. Release connection at the pivot point between 33 ft
auxiliary crane. (10.1m) section and 23 ft (7.1 m) section.
6. If only the 33 ft (10.1m) section is folded at the side of
the main boom, remove connection between 33 ft
(10.1m) section and main boom (rear).
7. Establish electrical connection between the lattice
extension and the main boom.
8. Swing 33 ft (10.1m) section onto the main boom head.
9. Fasten 33 ft (10.1m) section onto the main boom head
with pins on right-hand side (Figure 4-14)
FIGURE 4-11

6. Check the transport condition of the (two-stage)

swingaway lattice extension.

Check List: Rigging the 33 Ft (10.1m)

Swingaway Lattice Extension
1. Prepare the crane for rigging the swingaway lattice
extension.
2. Check if the lattice extension was unrigged properly and
FIGURE 4-14
is in transport condition.
3. Folding out the run-up rail. 10. Secure the lattice extension on the main boom with
guide rope.
11. Release the connection in the front area. If necessary,
press down the slewing axle mechanically.

4-10
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

Check List: Unrigging the 33 Ft (10.1 m)

Swingaway Lattice Extension
1. Prepare the crane for unrigging.
2. Retract the main boom completely and lower it into the
horizontal position(Figure 4-18)
6568-1
FIGURE 4-15

12. Swing the 33 ft (10.1m) section in front of the main boom

head.
13. Pin the 33 ft (10.1m) section in front of the main boom 6568-1
head on the left-hand side. FIGURE 4-18
14. Fold out deflection sheave on the 33 ft (10.1m) section if 3. Unreeve the hoist cable from the hook block and remove
offset angle is 20° or 40°. it from the lattice extension.
15. Place the hoist cable over the deflection sheave and 4. Fold in the deflection sheave on the 33 ft (10.1m) section
head sheave of the 33 ft (10.1m) section if angle is 20° (Figure 4-19).
or 40° offset (Figure 4-16).

NOTE: 40° Offset shown.

6455-4
6568-5 FIGURE 4-19 4
FIGURE 4-16 5. Reel hoist cable up to the main boom head.
16. Reeve the hoist cable on the hook block. 6. Attach the guide rope to the head of the 33 ft (10.1m)
17. Attach the lifting limit switch weight and guide hoist rope section.
through the weight (Figure 4-17) 7. Remove the left-hand locking pin between the 33 ft
(10.1m) section and the main boom head.
8. Swing the 33 ft (10.1m) section onto the main boom.

FIGURE 4-17

w3312a
FIGURE 4-20

4-11
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

9. Establish the connection in the front area. 19. Fold in the run-up rail (Figure 4-24).

6568-1
FIGURE 4-21

10. Remove the right hand locking pin between the 33 ft FIGURE 4-24
(10.1m) section and the main boom head.
20. If necessary, remove hose drum connection for
11. Swing the 33 ft (10.1m) section on the run-up rail onto hydraulic supply.
the main boom (Figure 4-22).
Checklist: Rigging the 56 ft (17.1 m) Two-
Stage Swingaway Lattice Extension
1. Prepare the crane for rigging the swingaway lattice
extension.
2. Check if the lattice extension was unrigged properly and
is in transport condition.
3. Fold out the run-up rail.
FIGURE 4-22 4. Move the connection in the middle area 23 ft (7 m)
section/33 ft (10.1m) section.
12. Secure the connection in the front area.
5. Remove the connection between 23 ft (7 m) section and
13. If the 23 ft (7 m) section is not attached to the main the main boom in the rear area.
boom, proceed to step connection in the middle area 23
6. Establish electrical connection between the lattice
ft (7m) section/33 ft (10.1m) section.
extension and the main boom.
14. Establish the connection at the pivot point between 33 ft
(10.1m) section and 23 ft (7 m) section (Figure 4-23).

FIGURE 4-25
6510-8
7. Swing the lattice extension onto the main boom head
FIGURE 4-23 (Figure 4-26).
15. If the 23 ft (7 m) section is attached to the main boom,
proceed to step 16.

16. Establish the connection between 33 ft (10.1m) section

and the main boom in the rear area.
17. Remove electrical connection between the lattice
extension and the main boom.
18. Check whether the lattice extension is in transport
condition.
FIGURE 4-26

4-12
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

8. Fasten 33 ft (10.1m) section onto the main boom head

with pins on the right-hand side.
9. Secure the lattice extension on the main boom with
guide rope (Figure 4-27).

FIGURE 4-30

17. Establish electrical connection between the 33 ft

(10.1m) and the 23 ft (7 m) sections.

FIGURE 4-27 18. Fold out deflection sheave on the 33 ft (10.1m) section if
offset angle is 20° or 40°.
10. Remove the connection in the front area. If necessary,
19. Place the hoist cable over the deflection sheave and
press down the slewing axle mechanically.
head sheave of the 23 ft (7 m) section (Figure 4-31).
11. Swing the lattice extension in front of the main boom
head.
12. Pin the 33 ft (10.1m) section onto the main boom head
on the left-hand side (Figure 4-28)

6568-5
FIGURE 4-31
FIGURE 4-28
13. Attach the guide rope to the head of the 23 ft (7 m)
20. Reeve the hoist cable on the hook block. 4
section. 21. Guide the hoist rope through the weight.

14. Move the connection in the middle area of the 33 ft Checklist: Unrigging the 56 ft (17.1 m) Two-
(10.1m) section. Stage Swingaway Lattice Extension
15. Swing the 23 ft (7 m) section in front of the 33 ft (10.1m)
1. Prepare the crane for unrigging.
section.
2. Retract the main boom completely and lower it into the
horizontal position.
3. Unreeve the hoist cable from the hook block and remove
it from the lattice extension.
4. Remove hoist rope from the head sheave and guide it to
the ground on the left-hand side of the lattice extension.
NOTE: If the 23 ft (7 m) section needs to be removed and
only the 33 ft (10.1m) section at the side of the
FIGURE 4-29 main boom needs to be folded, proceed to point 12.

16. Fasten the 23 ft (7 m) section on the left-hand side of the 5. Attach the guide rope to the head of the 23 ft (7 m)
33 ft (10.1m) section with a pin. section (Figure 4-32).

4-13
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

FIGURE 4-32 w3346a

FIGURE 4-34
6. Remove the locking pins on the left-hand side between
the 23 ft (7 m) section and 33 ft (10.1 m) section. 17. Establish the connection in the front area.
7. Swing the 23 ft (7 m) section in front of the 33 ft (10.1 m) 18. Remove right hand locking pin between the 33 ft (10.1m)
section. section and the main boom head.
19. Swing the lattice extension on the run-up rail onto the
main boom.
20. Secure the connection in the front area.
NOTE: If the 23 ft (7 m) section has been removed,
proceed to step 23.

21. If the 23 ft (7 m) section has been removed, establish a

connection between the 33 ft (10.1m) and the main
boom.
FIGURE 4-33
22. Remove electrical connection between the lattice
8. Move the connection in the middle area 23 ft (7 m) extension and the main boom.
section/33 (10.1m) section.
23. Check whether the lattice extension is in transport
9. If the 23 ft (7 m) section needs to be removed, attach 23 condition.
ft (7 m) section on the auxiliary crane, remove all locking
pins between the 23 ft (7 m) section and the 33 ft 24. Fold in the run-up rail (Figure 4-35).
(10.1m) section and place 23 ft (7 m) section on a
separate vehicle.
10. Fold in deflection sheave on the 33 ft (10.1m) section.
11. Reel hoist cable up to the main boom head.
12. Attach the guide rope to the head of the 33 ft (10.1m)
section.
13. Remove the left-hand locking pin between the 33 ft
(10.1m) section and the main boom head. FIGURE 4-35
14. Raise the main boom slightly above level.
25. If necessary, remove the hose drum connection for
15. Swing the lattice extension onto the main boom. hydraulic supply.
16. Lower the lattice extension so that it is positioned on the
run-up rail (Figure 4-34)
DESCRIPTION OF RIGGING WORK
Preparing the Crane for Rigging
NOTE: The data is this section also applies to the rigging
of the boom extension.

4-14
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

Requirements for rigging

Before you rig a lattice extension or the boom extension, the
following requirements must be met:
DANGER
- The swingaway lattice extension is mounted on the Always secure the lattice extension with a guide rope on
side of the main boom and is in transport condition. the main boom before removing any connections. This will
- The counterweight version required according to the prevent the lattice extension from slipping off the run-up
lifting capacity table for the planned operation with rail, swinging around and knocking you off the carrier or
the lattice extension is rigged. injuring other persons in the slewing range.

- The crane is supported by the outrigger span Secure the lattice extension as follows:
required according to the lifting capacity table for the
planned operation with the lattice extension and is • Attach a cord at the front of the lattice extension.
aligned horizontally. • Guide the cord underneath the lattice extension, via
the holding rod on the main boom and back again.
- The main boom is completely retracted and has
been lowered into horizontal position. • Have a helper hold the cord tight while you are
removing the last connection.
- If the crane is equipped with two hoists with
additional equipment, the hook block is unreeved on NOTE: If you are alone, secure the other end of the cord
the hoist, which is not used for working with the on the crane (e.g. on the steps of the access ladder
lattice extension. to the carrier). Leave enough play in the cord that it
is tight only when you swing the lattice extension
Requirements for unrigging towards the main boom head later on.
Before you lower a lattice extension or the boom extension
into a horizontal position, the following requirements must be Checking the Transport Condition
met: For transportation you must establish certain connections
- No other load is raised apart from the hook block. between both parts of the lattice extension. The connections
which need to be established depend on whether the lattice
- The counterweight version required according to the extension:
lifting capacity table for the planned operation with
the lattice extension is rigged. - is folded up at the side of the main boom for
transportation or
- The crane is supported with the outrigger span
prescribed for operation with the rigged lattice - is completely removed for transportation.
extension according to the lifting capacity table.
4
- The main boom is fully retracted.
Securing lattice extension with cord DANGER
If the crane is not well aligned, the lattice extension may Be careful not to damage the lattice extension and the
swing out of its own accord when you remove the last main boom. Always put the lattice extension into transport
connection that held the lattice extension at the side of the condition when folded at the side or working with the main
main boom. boom. Only then is the lattice extension secured against
slipping. This way you prevent the partly fastened lattice
You must therefore secure the lattice extension before you exten sion hitt ing th e main boom or t he ind ivid ual
begin with the rigging work. components of the lattice extension hitting each other and
becoming damaged.

You must check transport condition:

- After unrigging 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 rigging the lattice
extension.

4-15
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

1
2

6510-2
7
6510-8

3
6510-7

6 5
4

5
4
6

6510-5

6
6510-3

6510-4
6510-1 FIGURE 4-36

4-16
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

Transport condition with lattice extension folded at

the side
The transport condition with the lattice extension folded at
the side is created when all of the following connections are
established.
1
• Check the connections and establish them if
necessary (Figure 4-36)
If 23 ft section and 33 ft section are folded at the side:
- The 33 ft section is locked at the slewing axle (1) in
front on the main boom and the slewing axle is
secured with a retaining pin (2) 2

- The pins (4) are inserted on the pivot point between

the 23 ft section and the 33 ft (10.1m) section.
4
- The connection (7) in the middle area is in the
position 23 ft (7 m) section/33t (10.1m) section. 3
- The connection (5) between 23 ft (7 m) section and
main boom in the rear area is established. FIGURE 4-37

If the 33 ft (10.1m) section only is folded at the side: • (1) engages in the bore hole (4).

- The 33 ft (10.1m) section is locked at the slewing Folding in the run-up rail
axle (1) in front on the main boom and the slewing
axle is secured with a retaining pin (2).
- The connection between the 33 ft (10.1m) section
and the main boom in the rear area is established
(6).
1
If the 23 ft (7 m) section only is folded at the side:
- The connection in the middle area is in the position
23 ft (7 m) section/main boom (3).
- The connection between the 23 ft (7 m) section and
the main boom in the rear area is established.
4
2
Transport condition with removed lattice extension
The transport condition for the removed lattice extension is
established when all of the following connections have been 4
made.
3
• Check the connections and establish them if
necessary.
FIGURE 4-38
- The connections on the pivot point between the 23 ft
(7 m) section and the 33 ft (10.1m) section have • Pull the locking bar (1) downwards against the
been established (4). spring force, and out of the bore hole (4).

- The connection in the middle area is in the position • Fold out the run-up rail (3) to a small extent and let
23 ft (7 m) section/33 ft (10.1m) section (7). go of the locking bar (1).
• Fold in the run-up rail completely.
Folding the Run-Up Rail Out/In
• Secure the run-up rail with the spring latch (2).
The run-up rail is folded out for rigging and folded back in for
on-road driving after derigging. Connections With Folded Lattice Extension
Fold out the run-up rail (Figure 4-37) The lattice extension is turned sideways to the main boom in
the folded position.
• Unscrew the spring latch (2).

4-17
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

In this position there are four areas on the main boom basic Securing the connection (Figure 4-40)
section, where various connections have to be disconnected
• Swing the lattice extension on the run-up rail onto
and reconnected again during rigging and unrigging.
the main boom until the bores on the 33 ft (10.1m)
- in the front area, in front of the locking point at section and the main boom are aligned.
100%, • Release the retaining pin and remove the locking
- in the middle area, in front of the locking point at pin (2) from the holder (3).
50%,
- in the rear area, over the side panelling.
In each area there are bearing points that can be used for
establishing connections. Depending on the rigging mode 1
and job, different parts of the lattice extension must be 2
connected to each other or connected to the main boom
basic section. 3

DANGER
Risk of accidents due to falling parts. Always secure the
pins both in the bearing points and in the holders using
retaining pins. This prevents unsecured pins from
becoming loose, falling out and causing injuries.

Connections in the front area w3332a FIGURE 4-40

In the front area there is a connection between the 33 ft • Insert the locking pin in the bore holes (1) and
(10.1m) section and the main boom. secure it with a retaining pin.
This connection must be disconnected when the lattice
extension is being rigged or removed.
The connection is made of retaining pins (3), slewing axle DANGER
(1), at the basic section and the holders (2) at the 33 ft
Risk of accidents from a falling lattice extension.
(10.1m) section.
The locking pin prevents mechanical pressing down of the
1
slewing axle and secures the 33 ft (10.1m) section to the
main boom. Therefore, always secure the laterally folded
2 lattice extension in the front area with the locking pin. This
will prevent the lattice extension (e.g. for main boom
operation) from sliding from the slewing axle and falling.
3

Removing the connection (Figure 4-41) and

(Figure 4-42)

FIGURE 4-39

For removing the connection, the 33 ft (10.1m) section is DANGER

locked in the slewing axle.
Risk of accidents from a falling lattice extension.
For establishing the connection, the 33 ft (10.1m) section is Before removing the connection, make sure that the 33 ft
locked in the slewing axle and is secured with locking pins. (10.1m) section is pinned on the main boom head. This
will prevent the lattice extension from falling and causing
injury to you or other persons.

4-18
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

DANGER
2
Risk of accidents from lattice extension swinging of its
own accord.
Always secure the lattice extension with a guide rope on
the main boom before derricking out the lattice extension
from the slewing axle. This will prevent the lattice
extension from slipping off the run-up rail, swinging
around and knocking you off the carrier or injuring other
persons in the slewing range.
5 6
• Secure the lattice extension with a guide rope.

2 w3342a
3 FIGURE 4-42

4 With this, the connection is in the correct position for next

5 unrigging.
Establishing a connection
• Place the lattice extension on the run-up rail.

2 3
4
5
w3341a FIGURE 4-41

• Remove the locking pin (4) from the bore hole (3) and
secure it in the holder (5) with a retaining pin. 4
• Derrick the lattice extension fully on one of the control
units.
• Ensure the holder (2) on the 33 ft (10.1m) section is fully
derricked downwards from the slewing axle (1).
If the slewing axle is still partly in the holder, then you must
push it downwards mechanically: w3339a
FIGURE 4-43
• Lift the lever (6) against the spring force and hold it in the
bracket (5). During this, the slewing axle (1) is pressed • Check if the locking pin (4) is pulled out of the bore hole
downwards. (3).
• Swing the lattice extension outward until the bracket (2) • Check if the lever (7) is under the bracket (6).
is no longer above the slewing axle (1).
• Swing the lattice extension on the run-up rail sideways
• Lift the lever sideways from the bracket and slowly yield onto the main boom. First the slewing axle (1) is pressed
to the spring force. Once again the slewing axle is down by the holder (2) and then it is locked in the holder.
pressed upwards.
• Check if the slewing axle projects upwards from the
bracket.
• Remove the locking pin (4) from the holder (5), insert it in
the bore holes and secure it with the retaining pin.

4-19
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

Connections in the middle area • Fasten the locking bar (1) with a pin (3) onto the 23 ft (7
m) section and with a pin (2) onto the 23 ft (7 m) section
When connecting in the middle area, three different joints
(Figure 4-45).
can be established:
- 23 ft (7 m) section/33 ft (10.1 m) section joint
- 23 ft (7 m) section/main boom joint
- Joint at the 33 ft (10.1 m) section
23/33 ft (7 m/10 m) section joint
This joint has to be established:
- when rigging the 56 ft (17.1 m) two-stage
swingaway lattice extension - before the lattice
extension is swung onto the main boom head.
3
- when rigging the 56 ft (17.1 m) two-stage
swingaway lattice extension - after the 23 ft (7 m)
section was folded onto the 33 ft (10.1 m) section.
2
- when rigging the 33 ft (10.1 m) swingaway lattice
1
extension - after the 33 ft (10.1 m) swingaway lattice
extension was swung sideways onto the main 6510-8
boom,
FIGURE 4-45
- before removing the two-stage swingaway lattice
extension. • Secure both the pins, each with one retaining pin.
• Fasten the locking bar (1) with a pin (2) onto the 33 ft Joint at the 33 ft (10.1 m) section
(10.1 m) section and with a pin (3) onto the 23 ft (7 m)
This joint has to be established:
section (Figure 4-44)
- when rigging the 56 ft (17.1 m) two-stage
swingaway lattice extension - before the 23 ft (7 m)
section is folded before 33 ft (10.1 m) section.

2
1
6510-8

FIGURE 4-44 2
3 1
• Secure both the pins, each with one retaining pin. 6510-7

33 (17.1 m) ft section/main boom joint FIGURE 4-46

This joint has to be established: - Before operating with the 33 ft (17.1 m) swingaway
lattice extension, if the 23 f t (7 m) section is
removed.

4-20
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

- Fasten the locking bar (1) with a pin (2) and (3) onto
the 33 ft (17.1 m) section (Figure 4-46).
- Secure both the pins, each with one retaining pin.
Connections in the rear connection
Connection between 23 ft (7 m) section and main
boom
The connection must be made: 1

- when unrigging of the 56 ft (17.1 m) two-stage

swingaway lattice extension,
- for operation with the 33 ft (10.1 m) swingaway 2
lattice extension.
The connection must be removed:
3
- when rigging the 56 ft (17.1 m) two-stage
swingaway lattice extension,
- for unrigging the 56 ft (17.1 m) two-stage
swingaway lattice extension.
6510-2
Removing the connection (Figure 4-47)
FIGURE 4-47

DANGER
Risk of accidents from falling 23 ft (7 m) section.
DANGER
Risk of accidents due to falling parts.
Make sure the connection is established at the pivot point
between the 23 (7 m) ft section and the 33 ft (10.1 m) Always secure the pins both in the bearing points and in
section before you remove the connection between the 23 the holders using retaining pin. This prevents unsecured
ft (7 m) section and the main boom. This will prevent the pins from becoming loose, falling out and causing injuries.
23 ft (7 m) section from falling down when releasing the
connection.

• Release the retaining pin (2) and remove the pin (1) from
4
the bearing point. DANGER
Risk of accidents from lattice extension swinging of its
• Insert the pin in the retaining sheet (3) and secure it with
own accord.
a retaining pin.
Always secure the lattice extension with a guide rope
Establishing a connection before removing any connections. This will prevent the
• Swivel the lattice extension into the main boom until the lattice extension from swinging around of its own accord
bearing point is aligned. and causing injury to you or other persons.

• Release the retaining pin (2) and take one pin (1) out of
the retaining sheet (3).
• Insert the pin into the bearing points and secure it with a
retaining pin. DANGER
Risk of accidents from a falling lattice extension.
Pin Connections on the Main Boom Head Make sure that the connection in the front area is
The lattice extension and main boom head are connected on established before you release the connection on the right
the bearing points using pins. The pins can be found in side of the main boom head. This will prevent the lattice
holders on the lattice extension and are secured there with extension from falling and causing injury to you or other
retaining pins. persons.

4-21
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

Connections on the left side • Insert the two pins into the bearing points (1) and (4) and
secure them with retaining pins.
The connection needs to be established after the lattice
extension has been swiveled in front of the main boom head Connection on the left side
during rigging.
The connection has to be removed so that the lattice 3
extension can be swiveled onto the main boom side during 1
unrigging.
5
Connections on the right side
The connection needs to be established so that the lattice
extension can be swiveled in front of the main boom head for
4 2
rigging.
The connection needs to be removed so that the lattice
extension can be swiveled onto the main boom when it is on
the run-up rail during unrigging.
Establishing connections
For these connections you will find four pins in holders on the
fixed part of the 33 ft (10.1m) section.
6455-6
Connections on the right side (Figure 4-48)

FIGURE 4-49
3
• Swing the lattice extension in front of the main boom
he ad, un til the be ar ing po int s ( 1) an d ( 2) ar e in
alignment.
• Remove the retaining pins from the pins in the holders
2 (5).
4
• First, insert the pin (3) in the upper bearing point (1).
5
1 • Then insert pin (4) into the bottom bearing point (2). If
the bearing points do not align, you can take the weight
off the bearing points.
• Use retaining pins to secure the pins in the bearing
points.
Connections remove
Secure the lattice extension with a guide rope before
removing any connections.
Connections on the left side (Figure 4-50)
6455-5 • Remove the retaining pins from pins in the bearing
FIGURE 4-48 points (1) and (2).
• First hammer the pin(4) out of the lower bearing point. If
• Swing the lattice extension onto main boom head, until
the pin cannot be hammered out, you can unload it.
the bearing points (1) and (4) are in alignment.
• You may then hammer the pin (3) out of the upper
• Remove the retaining pins and take the two pins (2) and
bearing point.
(5) out of the holders (3).
• Insert both pins into the holders (5) and secure them
with retaining pins.

4-22
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

• Hammer the two pins out of the bearing points.

3
• Insert both the pins (2) and (5) into the holders (3) and
secure them with retaining pins.
1
5 Relieving the load on bearing points (Figure 4-52)
The dead weight of the lattice extension can cause the
4 2 bearing points on the left side to be misaligned or the pins to
get weighted which makes it impossible to knock them out.
When establishing or disconnecting the connections,
proceed as follows:
• Lower the lattice extension until it is on the ground with
the supports (1) (if necessary, override the lifting limit
switch).
• Continue to lower carefully until the connecting points
6455-6 FIGURE 4-50 (2) align or until the load has been removed from the
pins.
Connections on the right side (Figure 4-51)

2
DANGER
Risk of accidents from a falling lattice extension.
Make sure that the connection in the front area is
established before you release the connection on the right
side. This will prevent the lattice extension from falling 6455-3
1
and causing injury to you or other persons. FIGURE 4-52

Pin Connections on the Lattice Extension

3
The 33 ft (10.1 m) section and the 23 ft (7 m) section are
connected on the bearing points using pins. The pins are
inserted into the 23 ft (7 m) section, at the rear of the
retaining sheet on the upper boom. 4
2 4

5 1
DANGER
Risks of accidents due to falling parts.
Always secure the pins both in the bearing points and in
the holders using retaining pins. This prevents unsecured
pins from becoming loose, falling out and causing injuries.

DANGER
6455-5 Risk of accident due to 23 ft (7 m) section swinging of its
FIGURE 4-51 own accord.
• Swing the lattice boom onto the main boom, and Always secure the 23 ft (7 m) section with a guide rope
establish the connection in the front area. before removing any connections. This will prevent the 23
ft (7 m) section from swinging around of its own accord
• Remove the retaining pins from the pins (2) and (5) in and causing injury to you or other persons.
the bearing points (1) and (4).

4-23
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

• The pin on each side stows in the bushing on the base

section.
Removing the connection (Figure 4-53)
DANGER
Risk of accidents from falling 23 ft (7 m) section. • Remove the retaining pins and take pins (one on each
side) out of the bearing points (1) and (2) on the left side.
Make sure that the connections between the 23 ft (7 m)
section and the main boom (in the rear area) and between • Insert pins (one on each side) and stow in bushing on
the 23 ft (7 m) section and the main boom have been the base section.
made before you release the connection on the right side
Connection on the pivot point
of the pivot point. In this way, you prevent the 23 ft (7 m)
section from falling when this connection is released and Before removing this connection, the connections between
causing injury to you or others. the 23 ft (7 m) section and the main boom in the rear area
must be established and the connection in the middle area
Connection on the left side must be in position.
The connection needs to be established after the 23 ft (7 m) Removing the connection
section has been swiveled in front of the 33 ft (10.1 m)
• Remove the retaining pins and pull the pins (one on
section during rigging.
each side) out of the bearing points.
The connection needs to be removed so that the 23 ft (7 m)
• Secure the pins (one on each side) with retaining pins.
section can be folded at the side of the 33 ft (10.1m) section
during unrigging. Establishing a connection
Connection on the pivot point, on the right side Remove the retaining pins from each side and take the
conical pin and another bolt out of the retaining sheet.
This connection must be established if the 33 ft (10.1 m)
swingaway lattice extension is unrigged and the 23 ft (7 m) • Insert the pins (one on each side) into the bearing
section is attached to the main boom. points, the conical pin (4) is designed for the lower
bearing point.
This connection must be removed if the 33 ft (10.1 m)
swingaway lattice extension is rigged and the 23 ft (7 m) • Secure the pins using retaining pins.
section is attached to the main boom.
NOTE: Always insert the conical pin in the lower bearing
Connection on the left side point, so that you can knock it down while removing
the connection.
• Swivel the 23 ft (7 m) section in front of the 33 ft (10.1 m)
section until the bearing points on the left side are in
Swinging the Lattice Extension onto the
alignment. If necessary, you can unload the bearing
points in the same way, as in the case of pin connections Main Boom Head
on the main boom. This section describes slewing the lattice extension
Establishing a connection - onto the main boom head when rigging and
- onto the main boom basic section when unrigging.
1
2 1

FIGURE 4-54
2 The lattice extension must be swung out of the transport
6568-2 position onto the main boom head so that the 33 ft (10.1 m)
section can be fastened to the right side of the main boom
FIGURE 4-53 head with pins.

4-24
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

Prerequisites - The 33 ft (10.1 m) section is fastened to the right

side of the main boom head.
- The lattice extension is in transport position when
the lattice extension is folded at the side. - The lattice extension is secured on the head of the
33 ft (10.1 m) section with a guide rope.
- The required connections among the individual
lattice extension sections or the lattice extension - Disconnect the connection between the 33 ft (10.1
sections and the main boom have been removed. m) section and the main boom.
Swinging the Lattice Extension - Swing the lattice extension until it is no longer above
the run-up rail.
When swung, the lattice extension rolls on the run-up rail,
turns around the connection in the front area and makes - Carefully lower the lattice extension from the control
contact at the front at the bearing points. unit on the foot of the 33 ft (10.1 m) section until it
starts to swing out.
• When rigging, pull the lattice extension at the back away
from the basic section until it is at the front and the If a helper is holding the guide rope, he can now swing the
bearing point are aligned. lattice extension in front of the main boom head.
• When unrigging, push the lattice extension onto the run- If you are alone and securing the fixed guide rope to the
up rail until the connection in the front area is ensured. crane, the lattice extension turns only so far until the guide
Secure the connection with the retaining pins. rope is tight. You can now turn the lattice extension with the
guide rope in front of the main boom head.
Swiveling the Lattice Extension when Proceed in the opposite order for unrigging.
Rigging
Swing the 23 ft (7 m) section in front of the 33 ft (10.1
NOTE: This section describes the swinging of the lattice m) section
extension during rigging. If you want to swing the
lattice extension for unrigging, proceed in the Prerequisites
opposite order. - The 33 ft (10.1m) section is locked in front of the
When rigging the 33 ft (10.1 m) swingaway lattice extension main boom head.
an d th e 56 ft ( 1 7. 1 m ) t wo- sta ge s wing awa y lat ti ce - The lattice extension is secured on the head of the
extension, you have to swing the 33 ft (10.1 m) section in 23 ft (7 m) section with a guide rope.
front of the main boom head.
- Move the connection on the 33 ft (10.1m) section
When rigging the 56 ft (17.1 m) two-stage swingaway lattice middle area.
extension, you must also swing the 23 ft (7 m) section in front
of the 33 ft (10.1 m) section. - Turn the 23 ft (7 m) section using the guide rope in
front of the 33 ft (10.1 m) section.
4
Proceed in the opposite order for unrigging.

DANGER Electrical Connections on the Lattice

Danger of accident due to lattice extension turning of its Extension
own accord.
The lifting limit switch and the lowering limit switch are
Always secure the lattice extension with a guide rope connected via the electrical connection on the lattice
before you swing it from the run-up rail. Ensure that there extension.
are no people or objects in the slewing range of the lattice
extension and always swing out the lattice extension with For the 33 ft swingaway lattice extension the electrical
a guide rope from the ground. connection is made or disconnected on the left side of the
main boom head.
Swinging the 33 ft (10.1 m) section in front of the main Establishing the electrical connection
boom
• Remove the short-circuit plug from the socket on the
Prerequisites main boom and plug it in the dummy cap.
- The lattice extension has been swiveled onto the • Unclip the cable from the boom extension clip.
main boom head.
• Remove the plug from the dummy cap and insert it in the
socket on the main boom head.

4-25
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

Disconnecting electrical connection Disconnecting electrical connection (Figure 4-56)

• Remove the plug from the socket on the main boom
head and insert it in the dummy cap on the 33 ft (10.1m)
section.
• Remove the short-circuit plug from the dummy cap and 2
plug it in the socket on the main boom junction box.
• Install connector onto the retaining clip. 4

• Stow the cable inside of the extension fly section.

• Check if the dummy plug is inserted in the socket at the
front of the 33 ft (10.1 m) section.
6509-4
56 ft (17.1 m) Two-Stage Swingaway Lattice 6509-3 1
Extension
For the 56 ft (17.1 m) swingaway lattice extension an
additional connection is made or disconnected between the 3 6509-1
33 ft (10.1m) section and the 23 ft (7 m) section as well as
FIGURE 4-56
the electrical connection of the 33 ft (10.1m) swingaway
lattice extension. • Remove the connector cable (1) from its stowed position
• First make the electrical connection for the 33 ft (10.1m) in the fly section and install to the junction box (2).
swingaway lattice extension. • Install connector cable on junction box (2) prior to fly
section erection for accessibility.
• Secure cable assembly (3) to inside of extension with tie
1 wrap.
2
3 • Connect connector cable (1) to junction box (4) and stow
cable inside the extension fly section.

Folding Out/In the Mast Sheaves on the 33 ft

6509-3 (10.1 m) Section
To prevent the hoist rope dragging on the main boom or
lattice extension during operation with the lattice extension
or boom extension, the hoist rope is guided via the mast
sheave.

6509-2 On the 33 ft (10.1m) section, there is a mast sheave at the

FIGURE 4-55 rear (1). Fold out the mast sheave if the boom extension
offset angle is 20° or 40°.
Establishing the Electrical Connection NOTE: For zero (0) degree offset, leave the mast
• Remove the plug (3) from the dummy socket (1) on the assembly in the stowed position.
33 ft (10.1 m) section. • for operation with the swingaway lattice extension.
• The cable is stowed in the fly section. • for operation with the 56 ft. (17.1 m) two-stage
• The plug (3) has lanyard to the junction box (2). swingaway lattice extension.
For transportation the mast sheave must be folded in.

4-26
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

• Secure the pin with a retaining pin.

1 Folding In Deflection Sheave
• Remove the pin (2) from the bore (1).
• Fold the deflection sheave down and insert the pin in the
bore (3).
• Secure the pin with a retaining pin.

Positioning/Remove the Hoist Cable

6568-2
DANGER
FIGURE 4-57 Risk of accidents due to falling parts.
Always secure the hoist cable holding rollers and rods
Folding Rear Deflection Sheave with retaining pin. This prevents elements from coming
loose, falling down and injuring people.

Positioning Hoist Cable (Figure 4-59)

DANGER
• Remove the hoist cable holding rollers and rod (1).
Risk of crushing.
Always hold the deflection sheave by the handle, when • Guide the hoist rope via the deflection sheaves (3) and
removing the pin. You might get your fingers crushed if via the head sheave (2) on the 33 ft (10.1 m) section or
you hold the sheave by the side plates. on the 23 ft (7 m) section. Put all hoist cable holding
rollers and rods back in place and secure these with
retaining pins.
Folding Out Deflection Sheave (Figure 4-58)
• Attach the hook tackle or the hook block. The hoist rope
• Remove the pin (2) from the bore (1).
may now, depending on the length or lattice extension,
• Fold the deflection sheave up and secure it with the pin be reeved once or twice.
in the bore (3).
Removing Hoist Cable (Figure 4-59)
• Unreeve the hook block.
• Remove the hoist cable holding rollers and rods (1).
4
• 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 these with retaining pins.

6568-4
FIGURE 4-58

4-27
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

1 2 3

1
3

2
6453-1

FIGURE 4-59

Hook tackle, max. lifting capacity:

1 fall
10 U.S. Tons

Maximum load bearing capacity:

Single reeving 8.4 U.S. Tons

FIGURE 4-60

Possible Reeving Methods on the Lattice Transportation on a Separate Vehicle

Extension
On the 56 ft (17.1 m) two-stage swingaway lattice extension
and on the 76/96 ft (23/29 m) boom extension the hoist cable
can only be used with single part line (Figure 4-60). DANGER
Risk of accidents from a falling lattice extension.
Lifting Limit Switch on the Lattice Extension Only attach the lattice extension in such a way that it is
positioned in the center of gravity and always use lifting
The functions raise hoist, extend main boom and lower main
gear with sufficient lifting capacity. This prevents the
boom are monitored during operation with the lattice
lattice extension from falling and injuring people while
extension by the lifting switch on the lattice extension and
loading.
are switched off when the lifting limit switch is actuated.
• Check if all the required connections for transport
condition are established.

4-28
 TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

TELESCOPING WITH RIGGED LATTICE

EXTENSION

CAUTION
The main boom may become overloaded!
If you telescope the main boom with a rigged lattice
1 2 6455-3 extension or boom extension. You must not rotate the
superstructure at the same time. This prevents the main
boom being subjected to additional side forces and
increased vibration and becoming overloaded.
FIGURE 4-61
• For transportation, place the lattice extension on the skid NOTE: Do not actuate the slewing gear when telescoping.
(1) at the front and onto the lower cross strut (2) at the
rear of the 33 ft (10.1 m) section (Figure 4-61). OPERATION WITH THE LATTICE
• Always secure the lattice extension on the separate EXTENSION
vehicle with belts as well as to prevent slipping and
NOTE: The information in this section also applies to
overturning.
operation with the boom extension. Observe the
following safety instruction before working with the
boom extension.
CAUTION
Risk of damaging the lattice extension.
Always secure the lattice extension by tying it down with CAUTION
suitable belts when it is transported on the separate Ri sk of ove r tu r nin g wh en w or ki ng wi th t h e bo om
vehicle. This prevents the two-stage swingaway lattice extension!
ex ten sion tip ping an d b eco ming da mag ed dur ing
transportation. When lifting over the swingaway and/or jib combinations,
deduct the total weight of all load handling devices reeved
over the main boom nose directly from the swingaway or
RAISING AND SETTING DOWN THE MAIN jib capacity.
BOOM WITH RIGGED LATTICE EXTENSION
NOTE: The hoisting, lowering, slewing, derricking and
NOTE: The information in this section also applies for
raising and setting down the main boom with a
rigged boom extension.
telescoping movements are done in the same way
as when operating with the main boom.
4
Telescoping is permitted only at main boom angles
NOTE: To raise and lower the main boom with a rigged of approximately 75° - 80°, depending on the length
lattice extension, the main boom must be fully of the lattice extension.
retracted.
Procedure if the Permissible Wind Speed is
For raising and lowering, the following prerequisites must be
fulfilled: Exceeded
- Apart from the hook block there is no load on the Strong winds can overstrain the crane. Therefore, closely
lattice extension. observe the instructions in table.
If the maximum permissible wind speed according to the
lifting capacity table is exceeded during the main boom
operation, proceed as follows:

4-29
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

MALFUNCTION WHEN WORKING WITH

With wind speed With wind speed LATTICE EXTENSION
up to 66 ft/s over 66 ft/s
NOTE: The information in (Table 4-3) applies to
• Set down the load. • Set down the load. malfunctions during operation with the 33/56 ft
• Fully retract the main (10.1/17.1 m) lattice extension.
• Slew the superstructure
so that the main boom boom.
creates as little wind • Set down the lattice
resistance as possible. extension.

Table 4-3

Malfunction Cause Remedy

No function of the lifting limit switch Lifting limit switch not connected Connect the lifting limit switch.
Electrical connection between the
boom head and lattice extension and
Establish electrical connection.
between 33 ft (10.1 m) section and 23
ft (7 m) section is not established.
Lifting limit switch on the main boom Override the lifting limit switch on the
head not overridden. main boom head.
When operating with a 56 ft (17.1 m)
lattice extension or boom extension,
Insert short-circuit plug.
the short-circuit plug is not inserted on
the head of the 33 ft (12.5 m) section.
The main boom cannot be telescoped The main boom is derricked to such an
Derrick the main boom to the required
with the rigged lattice extension or ang le a t whic h te lesco ping is n ot
angle.
boom extension. permissible

MAINTENANCE WORK BOOM EXTENSION (ADDITIONAL

EQUIPMENT)
Maintenance Work, Monthly
Pins Identification and Slinging Points
Lubricate all attach, securing and retaining pins, in other Identification
words: The boom extension consists of the 56 ft (17.1 m) two-stage
- the pins for the pin connection on the lattice swingaway lattice extension and two boom extension
extension, sections. The boom extension is designed for the crane it
was delivered with. The parts which belong to the crane have
- the retaining pins on the return pulleys, the same serial number as the crane.
- the retaining pins used for fastening the lattice The following sections are identified by the serial number:
extension sections for transport,
- All parts of the 56 ft (17.1 m) two-stage swingaway
- the spring latch on the run-up rail. lattice extension.
NOTE: The maintenance interval applies to average - Both sections of the boom extension 20 ft (6.1 m)
operation. Also, lubricate the pins after high- sections.
pressure cleaning and generally at an interval that
will prevent them getting dry. CAUTION
Operate the crane only with those sections of the boom
extension which have the same serial number as the
crane. This prevents malfunctions and damage.

4-30
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

NOTE: For technical reasons a crane may only be set with Serial numbers on the 20 ft (6.1 m) sections
one boom extension.
The serial number is on a sheet at the front of the 20 ft (6.1
If you wish to use the boom extension on several Manitowoc/ m) sections.
Grove cranes, the parts of the boom extension must be
adjusted for these cranes and labeled with all of the Slinging Points
respective serial numbers.

CAUTION
CAUTION This section shows the slinging points of the 20 ft (6.1 m)
Have the adjustment of the boom extension only carried sections. Attach the sections only to these slinging points
out on site by Grove CraneCARE! because they will then automatically have the correct
center of gravity. Use only lifting gear with sufficient load
bearing capacity.

6453-2
FIGURE 4-62

of the locking pin (on the main boom head) and the
1
1
front edge of the head sheave.
The designation 33 ft (10.1 m) section, 23 ft (7 m)
4
section, and 20 ft (6.1 m) section have been
adjusted to these lengths.The total length of the
individual sections is greater or smaller.

Setting the Folding Swingaway Extension

Offset

DANGER
Ensure any blocking material used is adequate to support
the weight of the extension assembly without tipping or
6456 FIGURE 4-63 falling.

The 20 ft (6.1 m) sections have two slinging points (1) (one 1. Extend and set the outriggers and swing the boom to
slightly offset on each side) (Figure 4-62) over the front. Position the boom to above horizontal.
2. Block up under the tip of the extension assembly
ASSEMBLY OF BOOM EXTENSIONS section.
NOTE: The lengths of 76 ft (23.0 m) and 96 ft (29 m)
respectively equal the distance between the center

4-31
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

3. To set the offset from a lesser degree to higher degree, NOTE: For 20 or 40 degree offset (Figure 4-64), make
perform the following procedures. sure the mast is in the raised position.
b. Remove the offset link clip pins and attach pins
securing the offset links in the lesser degree offset
CAUTION
position. If going to maximum offset, stow them in
Do not overload the extension anchor fittings or the the stowage lugs. If going to the intermediate (20
extension base section when lowering the boom. degree) offset, install them in the offset links for that
degree of offset.
a. Slowly lower the boom until the pressure is relieved
on the offset link pins.

6568-2
SHOWN AT 0° OFFSET

TO OBTAIN MAXIMUM
DEGREE OFFSET,
REMOVE PIN AND STOW IN
LUG.
OFFSET
LINK PIN
OFFSET
PIN LINK

SHOWN AT 20° OFFSET 6568-4 SHOWN AT 40° OFFSET

6568-3 FIGURE 4-63

c. Slowly elevate and telescope the boom at the same boom. Make the connection at the front stowage bracket
time so that the extension does not move off of the and support with lifting device.
blocking until the offset links take the full weight of
2. Pivot the boom extension on the front support bracket.
the extension.
Adjust the front support bracket adjustment bolts to
d. Reeve the hoist cable as described under normal maintain a loose condition when the boom extension
erecting procedures. anchor fittings engage the boom anchor lugs.

Swingaway Mounting Adjustment. 3. Secure the guide rail on the middle boom extension
stowage bracket in the out position.
1. Set the 33 ft (10.1m) section with the 23 ft (7m) section
stowed on the side, on cribbing. Use an adequate lifting 4. Swing the boom extension until it contacts the guide rail
device to place the boom extension at the side of the at the middle boom extension stowage bracket.

4-32
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

NOTE: When pushing the jib extension onto the guide rail,
make sure contact does not occur at the rear boom
extension mounting bracket and prevent proper
alignment.

5. Adjust the middle stowage bracket so the roller supports

on the 33 ft (10.1m) section role on the guide rail and
aligns the roller support on the 23 ft (7m) section. This
should align the hole in the mounting lug on the 23 ft
(7m) section with the hole in the mounting piece on the
stowage bracket. When adjusted properly, the pin can FIGURE 4-65
be inserted to make the stowage connection.
8. Attach the guide rope to the head of the 23 ft (7 m)
6. Adjust the adjustment bolts on the rear support bracket section (Figure 4-66)
to support the boom extension and provide installation of
attach pins.

7. Remove the lifting device used for support when the

boom extension is secured.

CHECKLISTS FOR RIGGING WORK

Rigging the 76/96 Ft (23/29 m) Boom
Extension
FIGURE 4-66
Prerequisites
9. Move the connection in the middle area on 33 ft (10.1 m)
- The crane is on outriggers or the main boom is section.
placed on the boom support.
10. Swinging the 23 ft (7 m) section in front of the 33 ft (10.1
- An auxiliary crane is available. m) section (Figure 4-67)
1. Prepare the crane for unrigging.
2. If the lattice extension is folded up at the side of the main
boom, remove the lattice extension.
3. If necessary, connect the hose drum for hydraulic
supply.
4
4. Check the transport of the two-stage swingaway lattice
extension.
5. Install 20 ft (6.1 m) sections in front of the main boom:
FIGURE 4-67
One 20 ft (6.1 m) section for the 76 ft (23.0 m) boom
extension. 11. Fasten the 23 ft (7 m) section on left-hand side in front of
33 ft (10.1 m) section with a pin.
Two 20 ft (6.1 m) sections for the 96 ft (29 m) boom
extension.
6. Sling the two-stage swingaway lattice extension on
auxiliary crane.
7. Install folded two-stage swingaway lattice extension in
front of the 20 ft (6.1 m) section (Figure 4-65).

FIGURE 4-68

12. Establish electrical connections.

4-33
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

3. Unreeve the hoist cable from the overhaul ball and

remove it from the lattice extension (Figure 4-72)

FIGURE 4-69
6513
13. Reeve the hoist cable on the overhaul ball(Figure 4-70) FIGURE 4-72

4. Detach electrical connections 1.

6513
FIGURE 4-70
FIGURE 4-73
14. Attach the lifting limit switch weight and guide hoist rope
through the weight (Figure 4-71). 5. Reel hoist cable up to the main boom head
(Figure 4-74).

FIGURE 4-71
FIGURE 4-74
NOTE: Operation with the boom extension is carried out in
the same way as for the lattice extension. 6. Attach the guide rope to the head of the 23 ft (7 m)
Raising the boom; section (Figure 4-75).

Telescoping;

Unrigging the 76/96 Ft (23/29 m) Boom

Extension
Prerequisites
- The crane is on outriggers or the main boom is
placed on the boom support.
- An auxiliary crane is available.
FIGURE 4-75
1. Prepare the crane for unrigging.
2. Fully retract and set down the main boom. 1.

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TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

7. Remove the locking pins on the left-hand sided between

23 ft (7 m) section and 33 ft (10.1 m) section
(Figure 4-76).

FIGURE 4-79

12. Remove 20 ft (6.1 m) sections from the main boom:

FIGURE 4-76 One 20 ft (6.1 m) section for a 76 ft (23 m) boom
extension.
8. Swinging the 23 ft (7 m) section in front of the 33 ft (10.1
m) section (Figure 4-77). Two 20 ft (6.1 m) sections for a 96 ft (29 m) boom
extension.

FIGURE 4-77
FIGURE 4-80
9. Position the central area of the connection 23 ft (7 m)
section/33 ft (10.1 m) section position.
Description of Rigging Work
10. Sling two-stage swingaway lattice extension on auxiliary
Installing/Removing 20 ft (6.1 m) Sections
crane (Figure 4-78).
(Figure 4-81)
- In order to rig the 76 ft (23 m) boom extension, you
must install the 20 ft (6.1 m) section with support
4
roller in front of the main boom head (Figure 4-62)
- In order to rig the 96 ft (29 m) boom extension, you
must additionally install the 20 ft (6.1 m) section
without support roller in front for the 20 ft (6.1 m)
section with support roller (Figure 4-62)
NOTE: An auxiliary crane must be used to install and
FIGURE 4-78 remove the 20 ft (6.1 m) sections.
11. Remove folded two-stage swingaway lattice extension The securing pins (1) for the connection are secured with
from the 20 ft (6.1 m) section (Figure 4-79). retaining pins in the holders at the foot of the 20 ft (6.1 m)
sections.

4-35
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

FIGURE 4-82

You can also install the folded two-stage swingaway lattice

extension in front of a 20 ft (6.1 m) section (e.g. when you are
cha ngi ng dir ect ly f ro m t he 56 ft (1 7.1 m ) t wo- stag e
1
2 swingaway lattice extension to a boom extension).
6456
NOTE: An auxiliary crane is required to install and remove
the two-stage swingaway lattice extension.

FIGURE 4-81

Installing 20 ft (6.1 m) sections

• Sling the 20 ft (6.1 m) section with support roller on an
auxiliary crane and lift it in front of the main boom head
so that the lug pin holes align on both sides.
1
NOTE: If necessary, adjust the upper and lower cross strut
adjustment screws on the boom extension insert to
align the holes.
• Insert the securing pins into the bearing points (2) on
both sides.
• Install the second 20 ft (6.1 m) section in front of the first
20 ft section for the 96 ft (29 m) boom extension in the
same way. 6456-1
Removing 20 ft (6.1 m) sections
FIGURE 4-83
• Sling the 20 ft (6.1 m) section on an auxiliary crane and
lift it until the bearing points (2) and (3) are relieved. The securing pins (1) (Figure 4-83) for the connection are in
the holders at the foot of the 33 ft (10.1 m) sections and are
• Release the pins and knock them out of the bearing
secured with retaining needles.
points (2) and (3) on both sides.
Installation
• Insert the pins into the holders at the foot of the 20 ft (6.1
m) sections and secure them with retaining needles. • Sling the two-stage swingaway lattice extension onto an
auxiliary crane.
Installing/Removing the Two-Stage
• Lift the two-stage swingaway lattice extension in front of
Swingaway Lattice Extension for the Boom the 20 ft (6.1 m) section so that the bearing points align
Extension on both sides.
This section describers the installation and removal of the • Insert the securing pins into the bearing points on both
folded two-stage swingaway lattice extension. sides.
• Secure all pins with retaining needles.
Removal
• Sling the two-stage swingaway lattice extension onto an
auxiliary crane.

4-36
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

• Lift the two-stage swingaway lattice extension until the There is a junction box (1) at the front of each 20 ft (6.1 m)
bearing points are relieved. section (Figure 4-84).
• Release the pins and knock them out of the bearing For transport, the sockets are covered with protective caps.
points on both sides.
At the 76 ft (23 m) Boom Extension
• Insert the pins into the holders on the 33 ft (10.1 m)
Establishing a Connection
section and secure them with retaining needles.
• Connect the cable of the 33 ft (10.1 m) section to the
Electrical Connection at the Boom socket of the 20 ft (6.1 m) section at the front junction
Extension box.

This section only described the electrical connections at the • Connect the cable of the 20 ft (6.1 m) section to the
20 ft (6.1 m) sections. For establishing the electrical socket at the main boom junction box.
connection at the two-stage swingaway lattice extension.
Disconnecting
Transport condition of the connection • Detach the electrical connection between 33 ft (10.1 m)
For transport, bring the electrical connections always into the and 20 ft (6.1 m) section.
following condition. • Detach the electrical connection between 20 ft (6.1 m)
section and main boom head.
• Prepare the electrical connections at the 33 ft (10.1 m)
section for transport.
At the 96 ft (29 m) Boom Extension
Establishing a Connection
• Connect the cable of the 33 ft (10.1 m) section to the
socket of the second 20 ft (6.1 m) section at the front
junction box.
• Connect the cable of the second 20 ft (6.1 m) section to
1 the socket of the first 20 ft (6.1 m) section at the front
junction box.
• Connect the cable of the first 20 ft (6.1 m) section to the
socket at the main boom junction box.
Disconnecting
4
6509-4
2 • Detach the electrical connection between the 33 ft (10.1
FIGURE 4-84 m) and front 20 ft (6.1 m) section.
• Detach the electrical connection between the two 20 ft
There is a cable with a plug (2) at the rear of the 20 ft (6.1 m)
(6.1 m) sections.
sections(Figure 4-84).
• Detach the electrical connection between the rear 20 ft
For transport, clip the cable on the insert and install cap.
(6.1 m) section and the main boom head.
• Prepare the electrical connections at the 20 ft (6.1 m)
section for transport.
• Prepare the electrical connections at the 33 ft (10.1 m)
section for transport.

1
6512
FIGURE 4-85

4-37
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

Positioning/Removing the Hoist Cable • Remove the hoist rope holding rollers and rods (1).
• For both boom extensions, guide the hoist rope via the
deflection sheaves (4) and (3), and via the head sheave
(2) on the 23 ft (7 m) section (Figure 4-86)
DANGER
Risk of accidents due to falling parts. • Put all hoist cable holding rollers and rods back in place
and secure them with retaining pins.
Always secure the hoist cable holding rollers and rods
with r et ai nin g pin s. T his pr ev en ts ele me nt s f ro m • Attach the hook tackle. The hoist rope can only be
becoming loose, falling down and injuring people. reeved once.

1
1

1
1 4
1 3
1

2 1 4

3
6453-1 FIGURE 4-86

Boom Positions and Axle Loads • Move the boom into the prescribed position.

The vehicle may only be moved if certain conditions are met.

MAINTENANCE WORK
The boom may have to be moved to a specified position,
depending on the installed counterweight.
Maintenance Work, Monthly
• Lubricate all attach, securing, and retaining pins.
CAUTION NOTE: The maintenance interval applies to average
Damage may occur to the axle lines! operation. Also lubricate the pins after high-
Always move the boom to the prescribed position before pressure cleaning and generally at an interval that
you move the rigged crane. The permitted load on the will prevent them getting dry.
axle lines will be exceeded if the boom is in a position
which deviates from the prescribed position.

4-38
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

AUXILIARY SINGLE SHEAVE BOOM NOSE The auxiliary single-sheave boom nose is designed for the
crane it was delivered with.
Identification
CAUTION
Operate the crane only with the auxiliary single-sheave
boom nose that has the identical serial number.
1

6462-2

FIGURE 4-87

4-39
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

If you wish to use the auxiliary single-sheave boom nose on • Secure the pin (1) with a retaining pin (3).
sever al Grove cranes, it needs to be adapted to the
• Depending on the application, bring the auxiliary single-
corresponding crane and marked with all the serial numbers.
sheave boom nose into working position or remove from
machine.

CAUTION Removing the Auxiliary Single-Sheave

The auxiliary single-sheave boom nose should only be Boom Nose
adjusted by Manitowoc CraneCARE at the particular
location.

The serial number (1) is on a plate, in the front on the

auxiliary single-sheave boom nose.

Installing/Removing Auxiliary Single-Sheave

Boom Top
1 1

DANGER
Risk of accidents if boom nose should fall off! During
installation and removal, always use the proper materials
with sufficient load bearing capacities.

Installing Auxiliary Single-Sheave Boom Nose

(Figure 4-88)
6462-6
FIGURE 4-89

In the working position, the auxiliary single-sheave boom

nose is positioned in front of the main boom head and is
1
fastened with two pins (1)(Figure 4-89)

Rigging in Working Position

6462-1

2 1

FIGURE 4-88
6462-2
• Loosen the retaining pin (3) and remove the pin (1) from
the bearing point (2).
FIGURE 4-90
• Align the auxiliary single-sheave boom nose so that the
bearing point (2) lines up to the front bore holes in the On the left side of the main boom head, there is a holding
holding device. device. In working position, the auxiliary single-sheave boom
nose is attached to the main boom head at both bore holes
• Secure the auxiliary single-sheave boom nose to the (1).
holding device using a pin (1).

4-40
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

• Unplug electrical connector (1) (Figure 4-92) from the

junction box.
• Uncoil the cable.
• Plug electrical connector into the junction box.
1
Attaching and Removing Hoist Cable

1
2

6462-1
FIGURE 4-91
1
• Release the retaining pin (3) and remove the thin pin (1)
from the bearing point (2).
• Swing the auxiliary single-sheave boom nose in front of
the main boom head. 6462-2
• Remove the retaining pin (3) and take out both thin pins
(1) from the holders. FIGURE 4-93
• Insert both pins into the pivot points at the front of the
main boom head and secure them with retaining pins • Remove the cable holding rods (1) (Figure 4-93) from
(3). the head of the main boom and from the auxiliary single-
sheave boom nose.
• Insert the thin pin into the bearing point (2) and secure it
with a retaining pin (3). • When reeving, guide the hoist cable over the left head
sheave of the main boom.
The auxiliary single-sheave boom nose is now in working
position. • Insert the rope holding rod into the appropriate bore
holes and secure them with the corresponding retaining 4
pins.
• Fasten the cable end clamp on the hook tackle or the
hook block.
Reverse the sequence of operations to remove the hoist
cable before slewing the auxiliary boom top into transport
position.

Possible Reeving Methods on the Auxiliary

Single-Sheave Boom Top
NOTE: The hoist cable may only be used with single part
line.
• maximum load bearing capacity:
1 for single-reeving 16,800 lbs (7.6 tons)

6518

FIGURE 4-92

4-41
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

BOOM EXTENSION ERECTING AND

STOWING PROCEDURE
General Warnings

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

6645-1 FIGURE 4-94

NOTE: Tag line is used to control movement of the boom

DANGER extension during erecting procedure.
B oo m a ng les a re u sed t o con tr ol sp ee d a t whi ch
extensions swing during erecting and stowage. Improper 3. Attach tag line to tip of extension (Figure 4-95).
boom angles will cause uncontrollable swing speeds of
extension. Tag Line

NOTE: Tag line used in these procedures is to control the

movement of the boom extension.

Erecting Procedure
Boom Extension

DANGER
To prevent serious injury or death, do not stand on
decking until extensions are secure.
6645 FIGURE 4-95
1. Visually check to ensure all pins are installed.
4. Pull the ramp latch pin (Figure 4-96).
2. Crane should be set up on outriggers using normal
setup procedures (Figure 4-94). 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.

Latch Pin

6642-3 FIGURE 4-96

5. Swing the stowage ramp out (Figure 4-97).

4-42
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

8. Stow the pin in pin holder provided on the swingaway

extension (Figure 4-100).

Pin
Holder

Stowage Ramp FIGURE 4-97

6642-4
Stowage Pin
6. Remove the stowage pin retainer clip at the bi-fold and 6642-7 FIGURE 4-100
base section connection (Figure 4-98)
9. If not using the bi-fold (stinger), remove pin from the
locking bar. Move locking bar to the base section
attachment bar and install pin. Secure with retaining pin
(Figure 4-101).

Locking
Bar

Pin
Locking
6642-5
Retainer Clip
FIGURE 4-98 Bar
4
7. Remove the stowage pin (Figure 4-99)

6642-8 6642-9 Base Section

Locking Bar

FIGURE 4-101

10. If not using the bi-fold (stinger), remove the extension bi-
fold pin. Allow the pin attaching the bi-fold (stinger) to the
base section to remain in place to retain the bi-fold
(stinger)(Figure 4-102).

6642-6 Stowage Pin FIGURE 4-99

4-43
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

Pin

Tag Line
6642-14
FIGURE 4-105
6642-10 FIGURE 4-102
14. Remove horizontal locking pin under latch pin and stow
11. Swing extension into position and align the lugs on the in holder (Figure 4-106). Secure pin with retainer clip.
extension with holes on the boom nose (Figure 4-103)

Horizontal
Locking Pin In
Holder

Boom Lug
Retainer
Clip

Extension Lugs

6642-15 FIGURE 4-106

6642-11 FIGURE 4-103 15. Disengage front latch assembly by pushing handle up
12. Install pins in holes (right side of boom nose) and secure and into the handle rest (Figure 4-107).
with retainer clips (Figure 4-105).

Front Latch
Handle

Handle
Pins
Rest

6642-12 Retainer Clip

6642-16 FIGURE 4-107
6642-13
16. Remove tag line from superstructure.
FIGURE 4-104
NOTE: Tag line is used to control movement of the boom
13. Secure tag line to superstructure (Figure 4-105) extension during erecting procedure.

4-44
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

a. Remove LMI cable end connector and route through

boom extension (Figure 4-110).

DANGER
To prevent serious injury or death, do not stand on the
crane deck to pull extension off ramp.

17. Using the tag line (rope), pull the extension off the ramp
(Figure 4-108).
18. While maintaining control of the extension with the tag
line, swing extension into position on boom nose
(Figure 4-108)

LMI Cable End

Connector

6642-19 FIGURE 4-110

b. Remove dummy plug (Figure 4-111).

6642-17 FIGURE 4-108

19. Remove pins from holders and install on left side of

boom nose and secure with retainer clips
(Figure 4-109).

Dummy Plug
6642-20 FIGURE 4-111 4
c. Install cable end connector from boom extension
Upper Pin where dummy plug was removed(Figure 4-112).
Installed

Lower Pin Cable End

Shown In Connector
Holder Installed

Install
Lower Pin
Here

6642-18 FIGURE 4-109

20. Connect LMI cables:

6642-21 FIGURE 4-112

4-45
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

21. Lower boom and remove tag line (Figure 4-113) 4. Using the tag line to maintain control of the bi-fold
(stinger), swing stinger into erected position
(Figure 4-116).

Tag Line

Tag Line
6642-22 Removed FIGURE 4-113

Bi-fold (Stinger) FIGURE 4-116

6642-25
1. Secure tag line to stinger nose (Figure 4-114)
5. Lower the stinger.
6. Remove pin from swingaway. Install pin in stinger and
retain with clip pin (Figure 4-117)

Tag Line To
Stinger

6642-23 FIGURE 4-114

Pin
2. Raise boom slightly above horizontal.
3. Remove retainer clip and remove stinger stowage pin
(Figure 4-115).

6642-26 FIGURE 4-117

Stinger 7. Connect LMI connector to LMI connection box

Stowage (Figure 4-118)
Pin

Clip Pin

6642-24 FIGURE 4-115

4-46
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

6642-28 LMI Connection FIGURE 4-120

LMI Connector 3. Remove retainer clip and remove the left side stinger
6642-27 FIGURE 4-118 retaining pin (Figure 4-121)

8. Remove tag line before operating crane.

NOTE: Reeve the hoist cable as described under rigging
and unrigging procedure in this section.

Stowing Procedure
Bi-fold (Stinger)

DANGER Pin
To prevent serious injury or death, do not stand on
decking until extensions are secure.

1. Attach tag line to stinger nose (Figure 4-119).

6642-26 FIGURE 4-121 4

4. Using tag line to control movement of stinger, swing
stinger into stowed position (Figure 4-122).

Tag Line To
Stinger

6642-23 FIGURE 4-119

2. Disconnect LMI connection (Figure 4-120).

6642-29 FIGURE 4-122

5. Connect stowage link to stinger and install retainer clip

(Figure 4-123).

4-47
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

Stinger
Stowage
Pin

Clip Pin

6642-24 FIGURE 4-123 Dummy Plug

6642-20 FIGURE 4-126
6. Remove tag line from stinger.
c. Route cable through boom extension
Boom Extension
(Figure 4-127).
7. Lower boom and secure tag line to tip of boom extension
(Figure 4-124).

LMI Cable End

Connector

6642-19 FIGURE 4-127

Tag Line FIGURE 4-124
6642-30 9. Remove retainer clips and remove pins attaching the
8. Disconnect LMI Cable. boom extension to the left side of boom nose. Stow the
pins in the boom extension pin holders and install the
a. Remove connector (Figure 4-125). retainer clips (Figure 4-128).

Cable End
Connector
Stow Pin In
Extension Remove Pin
Top and From Boom
Bottom) Nose (Top
and Bottom)

6642-21 FIGURE 4-125

b. Install dummy plug (Figure 4-126)

6642-31 FIGURE 4-128

4-48
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

10. Raise boom to horizontal.

11. Pull the front latch handle down (Figure 4-129).

Latch Handle Down

6642-35 FIGURE 4-131 continued

6642-32 FIGURE 4-129

DANGER
12. Raise boom to slightly above horizontal.
If latch does not engage, STOP. DO NOT climb onto
13. Use the tag line to maintain control of the boom decking. Contact Manitowoc CraneCARE for correct
extension, and swing the extension into the stowed adjustments.
position (Figure 4-130).
15. Visually verify stowage latch has engaged base section
(Figure 4-132).

4
6642-41 FIGURE 4-130

14. Raise boom until front latch engages (Figure 4-131). Latch Pin Properly
Verify handle is in down position and against stop bar. Engaged

6642-36 FIGURE 4-132

16. Secure tag line to hole in rear of superstructure while

boom is still elevated (Figure 4-133)

6642-34 FIGURE 4-131

4-49
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

Upper Pin
Removed

Pin In
Holder

6642-14 Tag Line

FIGURE 4-133

17. Lower boom to horizontal.

6642-38 FIGURE 4-135
18. Install front horizontal locking pin and retainer clip
(Figure 4-134). 20. Raise boom until extension swings against main boom.
21. Lower boom.
22. Install rear stowage pin and retainer clip (Figure 4-136).

Locking Pin

Rear
Stowage
Pin

6642-37 FIGURE 4-134

19. Remove pins from right side of the boom nose. Stow the Retainer
pins in pin holders on boom extension and install Clip
retainer clips (Figure 4-135)
6642-39 FIGURE 4-136

23. Swing ramp to stowed position(Figure 4-137)

4-50
TMS800E OPERATOR’S MANUAL SET-UP AND INSTALLATION

Hook Block
Description
A 68 metric ton (75 ton) hook block and a 9 metric ton (10
ton) top headache ball are available for the crane. The hook
block utilizes a one-piece pivot block and the hook is
equipped with a safety latch. The hook block is the quick
reeve design.

Maintenance
Periodic Maintenance
It is recommended that the hook block and/or headache ball
be inspe cted eve ry 50 h our s. A c omple te assem bly
inspection should be conducted every quarter or 500 hours
6642-40 Ramp Stowed FIGURE 4-137 in the area of the hook, hex nut, and threaded areas for
24. Remove tag line. corrosion and proper fit. After assembly of the hook, a liberal
coating of multipurpose grease should be applied to the nut
NOTE: Reeve the hoist cable as described under rigging and threaded area by brush or hand to prevent corrosion.
and unrigging procedure in this section.
For hook blocks and other load handling devices not
manufactured by Manitowoc Cranes, Inc.; follow the
manufacturer’s inspection and testing recommendations to
assure an adequate preventative maintenance program is
established.

4-51
SET-UP AND INSTALLATION TMS800E OPERATOR’S MANUAL

THIS PAGE BLANK

4-52
 SECTION 5
LUBRICATION
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Arctic Conditions Below -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Superstructure Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . . 5-8
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-i
LUBRICATION TMS800E OPERATOR’S MANUAL

5-ii
TMS800E OPERATOR’S MANUAL LUBRICATION

SECTION 5
LUBRICATION
GENERAL operating time. The most efficient method of keeping track of
lube requirements is to maintain a job log indicating crane
Following the designated lubrication procedures is important usage. The log must use the engine hourmeter to ensure
in ensuring maximum crane lifetime and utilization. The coverage of lube points that will receive attention based on
procedures and lubrication charts in this section include their readings. Other lubrication requirements must be made
information on the types of lubricants used, the location of on a time basis, i.e. weekly, monthly, etc.
the lubrication points, the frequency of lubrication, and other
information. All oil levels are to be checked with the crane parked on a
level surface in transport position, and while the oil is cold,
The service intervals specified are for normal operation unless otherwise specified.
where moderate temperature, humidity, and atmospheric
conditions prevail. In areas of extreme conditions, the On plug type check points, the oil levels are to be at the
service periods and lubrication specifications should be bottom edge of the check port.
altered to meet existing conditions. For information on On all hoists with a check plug in the drum, the fill plug shall
extreme condition lubrication, contact your local Grove be directly on top of the hoist and the check plug level.
distributor or Manitowoc CraneCARE.
All grease fittings are SAE STANDARD unless otherwise
CAUTION indicated. Grease non-sealed fittings until grease is seen
extruding from the fitting. 0.28 kg (1 oz) of EP-MPG equals
Chassis grease lubricants must not be applied with air
one pump on a standard 0.45 kg (1 lb) grease gun.
pressure devices as this lubricant is used on sealed
fittings. Over lubrication on non-sealed fittings will not harm the
fittings or components, but under lubrication will definitely
lead to a shorter lifetime.
On sealed U-joints, care must be exercised to prevent
rupturing seals. Fill only until expansion of the seals first
CAUTION becomes visible.
The multipurpose grease installed during manufacture is
of a lithium base. Use of a noncompatible grease could Unless otherwise indicated, items not equipped with grease
result in damage to equipment. fittings, such as linkages, pins, levers, etc., should be
lubricated with oil once a week. Motor oil, applied sparingly,
will provide the necessary lubrication and help prevent the
Arctic Conditions Below -18°C (0°F) formation of rust. An Anti-Seize compound may be used if
rust has not formed, otherwise the component must be
In general, petroleum based fluids developed especially for
cleaned first.
low temperature service may be used with satisfactory
results. However, certain fluids, such as halogenated Grease fittings that are worn and will not hold the grease
hydrocarbons, nitro hydrocarbons, and phosphate ester gun, or those that have a stuck check ball, must be replaced.
hydraulic fluids, might not be compatible with hydraulic
Where wear pads are used, cycle the components and
system seals and wear bands.If you are in doubt about the
relubricate to ensure complete lubrication of the entire wear
suitability of a specific fluid, check with your authorized
area.
Grove distributor or Manitowoc CraneCARE.
NOTE: All fluids and lubricants may be purchased by Surface Protection for Cylinder Rods 5
contacting the Manitowoc CraneCARE Parts
Steel cylinder rods include a thin layer of chrome plating on
Department.
their surfaces to protect them from corroding. However,
Regardless of temperature and oil viscosity, always use chrome plating inherently has cracks in its structure which
suitable start-up procedures to ensure adequate lubrication can allow moisture to corrode the underlying steel. At typical
during system warm-up. ambient temperatures, hydraulic oil is too thick to penetrate
these cracks. Normal machine operating temperatures will
LUBRICATION POINTS allow hydraulic oil to warm sufficiently to penetrate these
cracks and if machines are operated daily, protect the rods.
A regular frequency of lubrication must be established for all Machines that are stored, transported, or used in a corrosive
lubrication points. Normally, this is based on component environment (high moisture, rain, snow, or coastline

5-1
LUBRICATION TMS800E OPERATOR’S MANUAL

conditions) need to have the exposed rods protected more Protectant available in 12 oz. cans that can be ordered
frequently by applying a protectant. Unless the machine is through the Parts Department.
operated daily, exposed rod surfaces will corrode. Some
NOTE: Cylinder operation and inclement weather will
cylinders will have rods exposed even when completely
remove the Boeshield® protectant; therefore,
retracted. Assume all cylinders have exposed rods, as
insp ect machi nes o nce a wee k an d r eap ply
corrosion on the end of the rod can ruin the cylinder.
Boeshield® to unprotected rods.
It is recommended that all exposed cylinder rods be
protected using Boeshield® T-9 Premium Metal Protectant. Table 5-1
Manitowoc CraneCARE has Boeshield® T-9 Premium Metal Lube Symbol Chart

Symbol Description
AFC Antifreeze/Coolant - 50/50 Blended, Fully Formulated - SAE Grade J1941
EO Engine Oil - SAE 15W-40, API Service Classification CI-4.
EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2.
SGL-5 Synthetic Gear Lubricant - SAE Grade 50, API Gravity 23.
HYDO Hydraulic Oil - Must meet John Deere Standard JDM-J20C, Allison C4, and ISO 4406 level.
SSGL-5 Semi-Synthetic Gear Lubricant - SAE Grade 80W-90, API Service Designation GL-5.
ASC Anti-Seize Compound - Military Specifications MIL-A-907E.
EP-OGL Open Gear Lubricant - Fucs Ceplattyn 300 Spray, NLGI Class 1-2
RO-PAG Polyalkylene Glycol Refrigeration Oil
R-134a HFC R-134a Refrigerant
AGMA No. 4 EP Extreme Pressure Gear Lube

Table 5-2
Lube Description

Lubrication Description Lube Specification

50/50 Fully Formulated Anti-Freeze Coolant A6-829-101130
Engine Oil SAE 15W40 A6-829-003483
Extreme Pressure Multi-Purpose Grease A6-829-003477
Synthetic Gear Lube A6-829-013433
Hydraulic Oil A6-829-006444
Semi-Synthetic Gear Lube A6-829-012964
Anti-Seize Compound A6-829-003689
Open Gear Lube A6-829-102971
Polyalkylene Glycol Refrigerant Oil A6-829-013436
Refrigerant A6-829-013460
Extreme Pressure Gear Lube A6-829-100213
Wire Rope See Service Manual

The following describe the lubrication points and gives the corresponds to the index number shown on the Lubrication
lube type, lube interval, lube amount, and application of Chart (refer to Figure 5-1 through 5-3, Table 5-1 and Table 5-
each. Each lubrication point is numbered, and this number 2).

5-2
TMS800E OPERATOR’S MANUAL LUBRICATION

Drain, fill, and replace filter every 80,450 km (50,000 mi)

or 2 years; whichever interval occurs first
CAUTION
The following lube intervals are to be used as a guideline CAUTION
only. Actual lube intervals should be formulated by the
Axle fluid levels shall be adjusted to bottom of fill plug
operator to correspond accordingly to conditions such as
threads. Check with crane on level ground, at its normal
continuous duty cycles and/or hazardous environments.
ride height; cold or room temperature oil only.

CARRIER LUBRICATION Lube Amount - Capacity - 19 liters (20 quarts)

1. Engine Crankcase Application - Fill to check plug on the left-hand side of
Lube Type - EO - 15W40 the transmission.

Lube Interval - Check fluid level every 10 hours or daily; 4. Pump Drive Shaft
whichever interval occurs first. Drain, fill and replace a. U-Joints
filter every 400 hours.
Lube Type - EP-MPG
Lube Amount - Capacity - 37 liters (9.7 gallons)
Lube Interval - 250 hours
Application - Fill to full mark on dipstick.
Lube Amount - Until grease extrudes
2. Engine Cooling System
Application - 2 grease fittings
Lube Type - AFC
b. Spline
Lube Interval - Check coolant level every 10 hours or
daily; whichever interval occurs first. Drain and refill Lube Type - EP-MPG
cooling system every 2000 hours or 12 months. Lube Interval - 500 hours
Lube Amount - Capacity - 49 liters (52 quarts) Lube Amount - Until grease extrudes
Application - 1 grease fitting
CAUTION 5. Auxiliary Transmission
Improper filling of the engine coolant system can result in
engine damage. Lube Type - SGL-5
Lube Interval - Check, drain and fill every 500 hours, 6
Application - months or 9,000 miles; whichever interval occurs first
a. Open petcock in upper radiator tube to vent air
during initial fill. CAUTION
Fill slowly. Flows exceeding 12 l/min (3 gpm) can Axle fluid levels shall be adjusted to bottom of fill plug
give a false level. When coolant squirts out, close threads. Check with crane on level ground, at its normal
petcock, then fill radiator to bottom of filler neck with ride height; cold or room temperature oil only.
mixture of 50% AFC and 50% water.
Lube Amount - 10.4 liters (2.75 gallons)
Run engine through two (2) thermal cycles.
Application - Fill through oil fill level plug
Wait 1 minute and recheck coolant level and refill as

3.
required.
Transmission
6. Driveline Slip
Lube Type - EPMPG
5
Lube Type - SGL-5 Lube Interval - 500 Hours or 10,000 miles whichever
interval occurs first
Lube Interval - Check fluid level every 500 hours, 6
months, or 9,000 miles, whichever interval occurs first. Lube Amount - Until grease extrudes
Application - 3 grease fittings

5-3
LUBRICATION TMS800E OPERATOR’S MANUAL

7. Power Steering Gearbox 13. Front Axle Brake Slack Adjusters

Lube Type - EP-MPG Lube Type - EP-MPG
Lube Interval - 1000 hours Lube Interval - 1000 hours
Lube Amount - Until grease extrudes Lube Amount - Until grease extrudes
Application - 1 grease fitting Application - 4 grease fittings
8. Steering Relay Arms 14. Front Axle Brake Camshafts
Lube Type - EP-MPG Lube Type - EP-MPG
Lube Interval - 250 hours Lube Interval - 1000 hours
Lube Amount - Until grease extrudes Lube Amount - Until grease extrudes
Application - 2 grease fittings Application - 4 grease fittings
9. Front Aluminum Wheel Pilots 15. Rear Aluminum Wheel Pilots
Lube Type - ASC Lube Type - ASC
Lube Interval - When wheels are removed for service. Lube Interval - When wheels are removed for service.
Lube Amount - Generously coat the wheel pilot or hub Lube Amount - Generously coat the wheel pilot or hub
pads with Anti-Seize (ASC) compound. Do not apply pads with Anti-Seize (ASC) compound. Do not apply
Anti-Seize compound to the face of the wheel of the hub. Anti-Seize compound to the face of the wheel of the hub.
Application - Brush on Application - Brush on; 8 places
10. Front Axle Hubs 16. Front Rear Axle Differential
Lube Type - SSGL-5 Lube Type - SSGL-5
Lube Interval - Check fluid level every 250 hours and Lube Interval - Check lubricant level every 250 hours
refill as necessary. and refill as necessary. Drain, fill, change filter, and
clean magnetic drain plug every 80,467 km (50,000 mi)
Lube Amount - 0.95 liters (1.0 quart)
or 2 years; whichever interval occurs first.
Application - Fill to the oil level mark on the housing with
the fill plug and the oil level mark horizontal.
CAUTION
11. Front Axle Tie Rod Ends
Axle fluid levels shall be adjusted to bottom of fill plug
Lube Type - EP-MPG threads. Check with crane on level ground, at its normal
ride height; cold or room temperature oil only.
Lube Interval - 1000 hours
Lube Amount - Until grease extrudes
Application - 4 grease fittings
CAUTION
12. Front Axle King Pins If the makeup amount is substantially more than 0.23 liter
(0.5 pint) check for leaks.
Lube Type - EP-MPG
Lube Interval - 1000 hours Lube Amount - Capacity - 27 liters (57 pints) Normal
makeup - less than 0.23 liter (0.5 pint)
Lube Amount - Until grease extrudes
Application - Fill to bottom of fill plug threads.
Application - 8 grease fittings

5-4
 TMS800E OPERATOR’S MANUAL
2
26 28
4
8

21 17 3 4 21
16 5 23 24 21

7
8
6 22
20 1 12
6556-1

6 22 11 12 11
20 22 6 13, 14 13, 14
15 15
18, 19 27 9, 10
18, 19 9, 10

LUBRICATION
FIGURE 5-1
5-5

5
LUBRICATION TMS800E OPERATOR’S MANUAL

Item Description
1 Engine Crankcase
2 Engine Cooling System
3 Transmission
4 Pump Drive Shaft U-Joints and Spline
5 Auxiliary Transmission ___ Correct: Lube level at
6 Transmission bottom of filler hole.
- - - Incorrect: Lube level
7 Power Steering Gearbox below filler hole.
6626
8 Steering Relay Arms
FIGURE 5-2
9 Front Aluminum Wheel Pilots
10 Front Axle Hubs NOTE: Figure 5-2 pertains to the differentials and the
Planetary Hubs and Wheel Bearings.
11 Front Axle Tie Rod Ends
17. Rear Rear Axle Differential
12 Front Axle King Pins
Lube Type - SSGL-5
13 Front Axle Brake Slack Adjusters
Lube Interval - Check lubricant level every 250 hours
14 Front Axle Brake Camshafts
and refill as necessary. Drain, refill, and clean magnetic
15 Rear Aluminum Wheel Pilot drain plug every 80,450 km (50,000 mi) or 2 years;
whichever interval occurs first.
16 Front Rear Axle Differential
17 Rear Rear Axle Differential
18 Rear Axle Brake Slack Adjusters CAUTION
Axle fluid levels shall be adjusted to bottom of fill plug
19 Rear Axle Brake Camshafts
threads. Check with crane on level ground, at its normal
20 Outrigger Beams ride height; cold or room temperature oil only.
21 Jack Cylinder Support Tubes
22 Jack Cylinder Barrels
23 Hydraulic Reservoir CAUTION
If the makeup amount is substantially more than 0.23 liter
24 Hydraulic Filter
(0.5 pint) check for leaks.
25 Fuel Filter
26 Air Cleaner Lube Amount - Capacity - 17.5 liters (37 pints) Normal
makeup - less than 0.23 liter (0.5 pint)
27 Coolant Strainer (Superstructure Cab Heater)
Application - Fill to bottom of fill plug threads.
28 Air Conditioner
18. Rear Axle Brake Slack Adjusters
Lube Type - EP-MPG
CAUTION
Lube Interval - 1000 hours
Use of no n-semi- synthetic lu bricant may dama ge
components and/or invalidate published lubrication Lube Amount - Until grease extrudes
intervals.
Application - 4 grease fittings
NOTE: Lube level (Figure 5-2) close enough to the hole to 19. Rear Axle Brake Camshafts
be seen or touched is not sufficient. It must be level
with the hole. Lube Type - EP-MPG

When checking lube level, also check and clean Lube Interval - 1000 hours
housing breathers. Lube Amount - Until grease extrudes
Application - 4 grease fittings

5-6
TMS800E OPERATOR’S MANUAL LUBRICATION

20. Outrigger Beams 25. Fuel Filter

Lube Type - EP-OGL Drain water trap every 10 hours or daily and change filter
every 500 hours or 6 months.
Lube Interval - 500 hours or 6 months; whichever
interval occurs first 26. Air Cleaner Filter
Lube Amount - Spray lubricate on bottom of outrigger Replace air cleaner filter element when indicator shows
beams. red (25” H2O).
Application - Spray on; 8 places 27. Coolant Strainer (Superstructure Cab Heater)
21. Jack Cylinder Support Tubes Close the shutoff valves. Unscrew the hex plug and
clean the strainer screen after first 100 hours and every
Lube Type - EP-OGL
2000 hours or 12 months thereafter.
Lube Interval - 500 hours or 6 months; whichever
28. Air Conditioner
interval occurs first
Lube Type - RO-PAG and R-134a
Lube Amount - Spray lubrication on ID of jack cylinder
support tubes before installing jack cylinders. Lube Interval - Check and fill; refer to applicable air
conditioner manual
Application -Spray on; 5 places
22. Jack Cylinder Barrels SUPERSTRUCTURE LUBRICATION
Lube Type - EP-OGL 29. Turntable Gear Box
Lube Interval - 500 hours or 6 months; whichever Lube Type - SSGL-5
interval occurs first
Lube Interval - Check and fill every 50 hours. Drain and
Lube Amount - Fully extend outriggers and spray fill after first 250 hours and every 500 hours or 12
lubricant onto cylinder barrels. months thereafter; whichever interval occurs first.
Application - Spray on; 5 places Lube Amount -5.4 liters (1.4 gallons)
23. Hydraulic Reservoir Application - Fill until oil level is at top of sight gauge
Lube Type - HYDO 30. Turntable Gear and Drive Pinion
Lube Interval - Check fluid level every 10 hours or daily, Lube Type - OGL
using sight gauge on side of tank, with boom down and
all outrigger cylinders retracted; drain and refill as Lube Interval - 500 hours or 6 months; whichever
necessary. Replace oil every 2000 hours or 2 years; interval occurs first
whichever interval occurs first. Lube Amount - Coat all teeth
NOTE: After 2000 hours or 2 years of service, an oil Application - Spray on; 2 places
sample should be taken and laboratory analyzed. If
it continues to meet a minimum cleanliness level of 31. Turntable Bearing
ISO 19/17/14, the service interval can be increased Lube Type - EP-MPG
to 3000 hours or 3 years.
Lube Interval - 500 hours or 6 months; whichever
Lube Amount - 692.7 liters (183 gal.) (tank only), To the interval occurs first
FULL mark on sight gauge.
Application - Fill through breather/fill cap on top of tank.
Lube Amount - Until grease extrudes the whole
circumference of the bearing.
5
When tank is drained, clean the magnetic pipe plug.
Application - 2 grease fittings. Rotate the turntable 90°
Repla ce b re ath er ever y 5 00 hour s o r 6 mo nth s; and apply grease to fittings. Continue rotating 90° and
whichever interval occurs first. grease the fittings until the whole bearing is greased.
24. Hydraulic Filter
Check filter every 500 hours or 6 months, whichever
interval occurs first.
Change the filter when the indicator is red.

5-7
LUBRICATION TMS800E OPERATOR’S MANUAL

32. Main Hoist 36. Retract Cable Sheaves

Lube Type - AGMA EP-4 Lube Type - EP-MPG
Lube Interval - Check and fill every 1000 hours or 12 Lube Interval - 250 hours or 3 months; whichever
months; whichever interval occurs first. Drain and fill interval occurs first
annually.
Lube Amount - Until grease extrudes
Lube Amount - Capacity - 14.7 liters (15.5 quarts)
Application - 2 grease fittings; extend boom for entry
Application - Fill until level with the check plug opening. through access holes in front of inner mid section at
boom length of 39 m (128 feet)
33. Auxiliary Hoist
37. Telescope Cylinder Wear Pads
Lube Type - AGMA EP-4
Lube Type - EP-MPG
Lube Interval - Check and fill every 1000 hours or 12
months; whichever interval occurs first. Drain and fill Lube Interval - Every boom teardown.
annually.
Lube Amount - Thoroughly coat all areas the wear pads
Lube Amount - Capacity - 14.7 liters (15.5 quarts) move on.
Application - Fill until level with the check plug opening. Application - By brush; 5 places.
NOTE: Should boom chatter or rubbing noises in the boom
BOOM, BOOM EXTENSION, AND BOOM occur, it will be necessary to lubricate the telescope
ACCESSORIES LUBRICATION cylinder wear pads. By adding an extension
adapter to a grease gun the wear pads and wear
NOTE: To service the boom at boom lengths longer than
areas can be reached through the lubrication
120 ft (to access grease fittings, gr ease the
access holes in the side of the boom and through
sections, or to cha nge the holding va lve) , a
the access hole in the boom nose between the
minimum of 12,000 pounds of counterweight must
sheaves.
be installed on the turntable and the outriggers
must be fully extended. Boom must be positioned 38. Internal Side and Bottom Wear Pads (Inner Sections)
over the right-hand side of the machine. No rigging,
Lube Type - EP-MPG
no hook block, or overhaul ball may be installed on
the nose of the boom. Lube Interval - 250 hours or 3 months; whichever
interval occurs first. Lubricate more frequently if
Extend boom to desired length at a boom angle of
environmental conditions and/or operating conditions
20 degrees. Lower boom until LMI limits the boom
necessitate.
lower function. Override LMI per LMI Operator’s
Manual and lower boom to desired angle. Lube Amount - Thoroughly coat all areas the wear pads
move on.
34. Boom Pivot Shaft
Application - By brush: 14 places; with boom in extended
Lube Type - EP-MPG
position through access holes in inner and outer mid
Lube Interval - 250 hours or 3 months; whichever section.
interval occurs first
39. Boom Section Upper Wear Pads
Lube Amount - Until grease extrudes
Lube Type - EP-MPG
Application - 2 grease fittings, one on each side
Lube Interval - 50 hours or 1 week; whichever interval
35. Extend Cable Sheaves occurs first. Lubricate more frequently if environmental
conditions and/or operating conditions necessitate.
Lube Type - EP-MPG
Lube Amount - Until grease extrudes
Lube Interval - 250 hours or 3 months; whichever
interval occurs first Application - 8 places; with boom in extended position
through access holes.
Lube Amount - Until grease extrudes
Application - 1 grease fitting; extend boom for entry
through access holes in fly and outer mid sections.

5-8
TMS800E OPERATOR’S MANUAL LUBRICATION

40. Boom Section Upper and Lower Wear Pads 46. Hook Block Swivel Bearing
Lube Type - EP-MPG Lube Type - EP-MPG
Lube Interval - 50 hours or 1 week; whichever occurs Lube Interval - 250 hours or 3 months; whichever
first. L ubricate more fr equent ly if environme ntal interval occurs first
conditions and/or operating conditions necessitate.
Lube Amount - Until grease extrudes
Lube Amount - Thoroughly coat all areas the wear pad
Application - 1 grease fitting
moves on.
47. Hook Block Sheaves
Application - By brush; 12 places; with boom in extended
position. Lube Type - EP-MPG
41. Upper Boom Nose Sheaves Lube Interval - 250 hours or 3 months; whichever
interval occurs first
Lube Type - EP-MPG
Lube Amount - Until grease extrudes
Lube Interval - 250 hours or 3 months; whichever occurs
first Application - 1 grease fitting per sheave
Lube Amount - Until grease extrudes (4 fittings total - 75 ton)
Application - 2 grease fittings per sheave 48. Overall Ball Swivel Top
42. Lower Boom Nose Sheaves Lube Type - EP-MPG
Lube Type - EP-MPG Lube Interval - 250 hours or 3 months; whichever
interval occurs first
Lube Interval - 250 hours or 3 months; whichever occurs
first Lube Amount - Until grease extrudes
Lube Amount - Until grease extrudes Application - 1 grease fitting
Application - 4 grease fittings per sheave 49. Air Conditioner
43. Boom Extension Sheaves Lube Type - RO-RAG and R-134a
Lube Type - EP-MPG Lube Interval - Check and fill; refer to applicable air
conditioner manual.
Lube Interval - 250 hours or 3 months; whichever occurs
first
WIRE ROPE LUBRICATION
Lube Amount - Until grease extrudes
Wire rope is lubricated during manufacturing so that the
Application - 2 grease fittings strands, and individual wires in strands, may move as the
44. Boom Extension Mast Sheave rope moves and bends. A wire rope cannot be lubricated
sufficiently during manufacture to last its entire life.
Lube Type - EP-MPG Therefore, new lubricant must be added periodically
Lube Interval - 500 hours or 12 months; whichever throughout the life of a rope to replace factory lubricant which
occurs first is used or lost.

Lube Amount - Until grease extrudes NOTE: Wire rope may be purchased by contacting the
Manitowoc CraneCARE Parts Department.
Application - 1 grease fitting
For more detailed information concerning the lubrication and 5
45. Auxiliary Boom Nose Sheave inspection of wire rope, refer to WIRE ROPE in Section 1-
Lube Type - EP-MPG INTRODUCTION in the Service Manual.

Lube Interval - 250 hours or 3 months; whichever

interval occurs first
Lube Amount - Until grease extrudes
Application - 1 grease fitting

5-9
5-10

LUBRICATION
40
41 31 38 34 32
35 39 39 33
36, 39

42
37
46 49
Left Side View
6556-2

47

33 32 34 29 41

45

TMS800E OPERATOR’S MANUAL

44 42
48
43 43
6556-3

30
Right Side View
FIGURE 5-3
TMS800E OPERATOR’S MANUAL LUBRICATION

Item Description
29 Turntable Gearbox
30 Turntable Gear and Drive Pinion
31 Turntable Bearing
32 Main Hoist
33 Auxiliary Hoist
34 Boom Pivot Shaft
35 Extend Cable Sheaves
36 Retract Cable Sheaves
37 Telescope Cylinder Wear Pads
Internal Side and Bottom Wear Pads (Internal
38
Sections)
39 Boom Section Upper Wear Pads
40 Boom Section Upper and Lower Wear Pads
41 Upper Boom Nose Sheaves
42 Lower Boom Nose Sheaves
43 Boom Extension Sheaves
44 Boom Extension Mast Sheave
45 Auxiliary Boom Nose Sheave
46 Hook Block Swivel Bearing
47 Hook Block Sheaves
48 Overall Ball Swivel Top
49 Air Conditioner

5-11
LUBRICATION TMS800E OPERATOR’S MANUAL

THIS PAGE IS BLANK

5-12
 SECTION 6
MAINTENANCE CHECKLIST
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6
6-i
MAINTENANCE CHECKLIST TMS800E OPERATOR’S MANUAL

6-ii
TMS800E OPERATOR’S MANUAL MAINTENANCE CHECKLIST

SECTION 6
MAINTENANCE CHECKLIST
GENERAL INSTRUCTIONS
T hi s se ct io n c on t ai ns a lis t o f d ai ly i ns pe c ti on an d S e e S e r v i c e M a n u a l f o r sp e c i f ic m a i n t e na n c e a n d
maintenance checks. Performing the checks will help adjustment procedures.
maintain the safety, dependability, and productivity designed
See Section 5 (in this handbook) for lubrication intervals,
into your crane.
types of fluids, and lube point locations.

6
6-1
MAINTENANCE CHECKLIST TMS800E OPERATOR’S MANUAL

6-2