Manitowoc GROVE 5540F Operator's Manual
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Manitowoc GROVE 5540F Operator's Manual

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© 2017 Manitowoc
Published 3-30-2017, Control # 516-04
OPERATOR MANUAL
Supplement
Crane Warm-up Procedures
!
An untrained operator subjects himself and others to death or
serious injury. Do not operate this crane unless:
•
You are trained in the safe operation of this crane.
responsible for qualifying personnel.
•
You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer's manuals and
load charts, your employer's work rules, and applicable government
regulations.
•
You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
•
The Operator Manual and Load Chart are in the holder provided on
crane.
DANGER
Manitowoc is not

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Summary of Contents for Manitowoc GROVE 5540F

  • Page 1 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
  • Page 2 SECTION CONTENTS Crane Warm-up Procedures......... . . 1 Engine.
  • Page 3 Lubrication section of your crane’s Operator Manual, operating temperature. by contacting your local Manitowoc distributor, or by contacting Manitowoc Crane Care directly). NOTE: Warm-up operation of 4-wheel drive transmission engaged in 2-wheel drive only could cause transmission damage.
  • Page 4 Rotate the superstructure at a speed of less than one- and engine immediately and contact a Manitowoc half RPM for at least two complete revolutions in one distributor.
  • Page 5 You are sure that all safety signs, guards, and other safety features are in place and in proper condition. • The Operator’s Manual and Load Chart are in the holder provided on crane. © 2011 Manitowoc Crane Group 10-21-2011 CTRL055-03...
  • Page 6             CALIFORNIA PROPOSITION 65 WARNING   Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth   defects, and other reproductive harm.     CALIFORNIA   PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain  ...

  • Page 7: Table Of Contents

    5540F/YB5515 OPERATOR’S MANUAL TABLE OF CONTENTS See End of this Manual for Alphabetical Index SECTION 1 ........Introduction The Manual .
  • Page 8 TABLE OF CONTENTS 5540F/YB5515 OPERATOR’S MANUAL Boom Extension ............2-22  ...
  • Page 9 5540F/YB5515 OPERATOR’S MANUAL TABLE OF CONTENTS Installing the Boom Extension......... . 5-5 Stowing the Boom Extension .
  • Page 10 TABLE OF CONTENTS 5540F/YB5515 OPERATOR’S MANUAL                           THIS PAGE BLANK                           TOC-4  ...

  • Page 11: The Manual

    5540F/YB5515 OPERATOR’S MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS The Manual ....... 1-1 Disclaimer .

  • Page 12: Disclaimer

    If you are the new owner of a Grove crane, please register it CUSTOMER SUPPORT   with Manitowoc Crane Care so we have the ability to contact Manitowoc and our Dealer Network want to ensure your you if the need arises.

  • Page 13: Nomenclature

    5540F/YB5515 OPERATOR’S MANUAL INTRODUCTION NOMENCLATURE a1841 Item Description Item Description Drop Block Outrigger (4) 3rd Boom Section (3 Section Boom) Rear Drive Axle (Steerable & Non-Steerable) 4th Boom Section (4 Section Boom) Enclosed Operator’s Cab (Shown) Optional Boom Extension Optional Cab Guard (Not Shown) Lift Cylinder Main Control Valve Location 1st Boom Section...
  • Page 14 INTRODUCTION 5540F/YB5515 OPERATOR’S MANUAL                           THIS PAGE BLANK                           Published 10-21-2011, Control # 055-03  ...

  • Page 15: Section 2

    5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION SECTION 2 SAFETY INFORMATION SECTION CONTENTS Safety Messages......2-1 Environmental Protection.

  • Page 16: General

    CAUTION personal injury accident, immediately contact your   Manitowoc dealer. If the dealer is unknown and/or cannot be Without the safety alert symbol, identifies hazards that reached, contact Product Safety at: could result in property damage if the message is ignored.

  • Page 17: Operator's Qualifications

    Manitowoc remains committed to providing reliable products that enable users and operators to safely lift and position loads. Manitowoc has been an industry leader in the incorporation of operational aids into the design of its cranes. Federal law requires that cranes be properly maintained and kept in good working condition.

  • Page 18: Load Moment Indication (Lmi) Systems (If Equipped)

    SAFETY INFORMATION 5540F/YB5515 OPERATOR’S MANUAL p r o v i d e s t h a t a r e s p e c i f i c f o r e a c h c r a n e a n d t h e Under no condition should it be relied upon to replace the  ...

  • Page 19: Work Area Definition System (Wads) (If Equipped)

    5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION Work Area Definition System (WADS) (If operating procedures and with the identification of symbol usage. Equipped) The work area definition system is intended as an aid to the If your crane is equipped with a WADS, you must read and operator.

  • Page 20: Load Charts

    Wind forces can exert extreme dynamic loads. Manitowoc recommends that a lift not be made if the wind can cause   a loss of control in handling the load. Manitowoc recommends that, if the wind speed (velocity) is between 20  ...

  • Page 21: Lifting Operations

    5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION Table 2-1 Wind Force Wind Velocity Visible Indicator Beauford mph (km/h) Effects of wind as observed on land Designation Scale Zero (0) Calm less than 1 (<2) No wind; smoke rises vertically Light Air 1-3 (2-5) Wind direction seen by smoke but not by wind vanes Light Breeze 4-7 (6-11)

  • Page 22: Counterweight

    The “balance point” for stability testing To avoid death or serious injury, keep all parts of the crane, according to SAE and Manitowoc criteria is a condition of rigging and load at least 20 feet (6 meters) away from any  ...
  • Page 23 5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION If contact is ever accidentally made with a power line and any Electrocution can occur even without direct contact with the part of this crane, its rigging or load, never touch the crane or crane. even approach or come near the crane.

  • Page 24: Set-Up And Operation

    SAFETY INFORMATION 5540F/YB5515 OPERATOR’S MANUAL Set-Up and Operation not assure that electrical contact will not occur. Even if codes   or regulations require the use of such devices, failure to During crane use, assume that every line is energized (“hot” follow the rules listed here may result in serious injury or or “live”) and take the necessary precautions.

  • Page 25: Electrical Contact

    L o c o m o t i v e C r a n e s , a n d i n O S H A r e g u l a t i o n s 29CFRI910.180 for General Industry and 29CFRI926.1431 Special Operating Conditions and for Construction. Equipment Use of a Manitowoc crane to handle personnel is acceptable Never operate the crane during an electrical thunderstorm. provided: When operating near transmitter/communication towers •...

  • Page 26: Environmental Protection

    NEVER use this crane for bungee jumping or any form Manitowoc reminds crane owners to ensure that all safety of amusement or sport. decals are in place and legible. Manitowoc continues to urge   crane owners to upgrade their cranes with load moment •...

  • Page 27: Service And Repairs

    Use a piece of cardboard, or piece of paper, to search for leaks. Wear gloves to protect your hands from • Consult with Manitowoc Crane Care to determine if load spraying fluid. testing is required after a structural repair is performed.

  • Page 28: Tires

    Wire Rope should never be used as its working load.   Use only the wire rope specified by Manitowoc as indicated • Each type of fitting attached to a wire rope has a specific on the crane’s Load Chart. Substitution of an alternate wire efficiency rating which can reduce the working load of  ...

  • Page 29: Sheaves

    5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION periodically. Refer to the Service Manual for more • When a wire rope has been removed from service information. because it is no longer suitable for use, it must not be reused on another application. •...

  • Page 30: Batteries

    SAFETY INFORMATION 5540F/YB5515 OPERATOR’S MANUAL To attain maximum wire rope life and minimize hook block allow the radiator time to cool before removing the radiator   rotation, it is recommended that even numbers of parts-of- cap. line be used in multiple-part reeving whenever possible. Shut down the engine and disconnect the battery before  ...
  • Page 31 5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION Death or serious injury could result from being crushed by Check load limit of bridges. Before traveling across bridges, revolving tires. ensure they will carry a load greater than the crane’s weight. If it is necessary to take the crane on a road or highway, “Stunt”...

  • Page 32: Work Practices

    Operator’s Manual when extending or retracting the system that have not been evaluated and approved by outriggers. Death or serious injury could result from improper Manitowoc Crane Care.   crane set up on outriggers. Do not step on surfaces on the crane that are not approved Be familiar with surface conditions and the presence of or suitable for walking and working.

  • Page 33: Lifting

    5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION Sparks from the crane’s electrical system and/or engine exhaust can cause an explosion. Do not operate this crane in an area with flammable dust or vapors, unless good ventilation has removed the hazard. Carbon monoxide fumes from the engine exhaust can cause suffocation in an enclosed area.

  • Page 34: Hand Signals

    SAFETY INFORMATION 5540F/YB5515 OPERATOR’S MANUAL Check the hoist brake by raising the load a few inches, If the boom should contact an object, stop immediately and   stopping the hoist and holding the load. Be sure the hoist inspect the boom. Remove the crane from service if the brake is working correctly before continuing the lift.
  • Page 35 5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION GROVE 2-21 Published 10-21-2011, Control # 055-03...

  • Page 36: Boom Extension

    The drive line can be instructions are intended to allow the crane to be placed in damaged when attempting to free a frozen crane. the most stable and secure position. However, Manitowoc   recognizes that certain jobsite conditions may not permit the...

  • Page 37: Temperature Effects On Hydraulic Cylinders

    5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION If applicable to your crane, always handle propane tanks movement of the boom may be undetected by the operator according to the supplier’s instructions. unless a load is suspended for a long period of time. To minimize the effects of thermal contraction or “Stick-slip”...

  • Page 38: Overload Inspection

      stopped immediately and Crane Care must be contacted publication for overloads up to 50%. for corrective action. • Stop operating the crane and contact Manitowoc   Crane Care immediately for overloads of 50% and higher.   NOTE: If your crane is equipped with CraneSTAR, an  ...
  • Page 39 5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION Overload less than 25% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect for damage. Retainers Overload from 25% to 49% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect all for damage. Retainers Collar-welds Inspect all for damage.

  • Page 40: Superstructure Inspection

    SAFETY INFORMATION 5540F/YB5515 OPERATOR’S MANUAL Superstructure Inspection               10,11     8, 9                                   2-26 Published 10-21-2011, Control # 055-03  ...
  • Page 41 5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION Overload less than 25% Lift Cylinder Inspect for leaking. See topic in Introduction section Wire Rope Inspect all for damage. of Service Manual. Turntable See topic in Swing section of Check bolts for proper torque. Bearing Service Manual.

  • Page 42: Carrier Inspection

    SAFETY INFORMATION 5540F/YB5515 OPERATOR’S MANUAL Carrier Inspection                               5, 6                       2-28 Published 10-21-2011, Control # 055-03  ...
  • Page 43 5540F/YB5515 OPERATOR’S MANUAL SAFETY INFORMATION Overload less than 25% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Overload from 25% to 49% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Outrigger Inspect for deformation and cracked welds.
  • Page 44 SAFETY INFORMATION 5540F/YB5515 OPERATOR’S MANUAL                                                     2-30 Published 10-21-2011, Control # 055-03  ...

  • Page 45: Section 3

    5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES SECTION CONTENTS Controls, Switches, and Gauges....3-2 Outrigger Monitoring System (OMS) (Optional—Standard in North America) ..3-22 Cab Controls .

  • Page 46: Controls, Switches, And Gauges

    OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL CONTROLS, SWITCHES, AND GAUGES   Cab Controls   p1615   Boom and Outrigger   Controls         Transmission Shift Lever   Travel Select Control         Brake Pedal    ...

  • Page 47: Panel Switches

    5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Boom Controls a1858 See Figure 3-2 for the following procedure. Outrigger Control p1616 Telescope Control Boom Control Swing Control Hoist Control Outrigger Controls-Standard Outriggers FIGURE 3-3 p1616 Outrigger Controls FIGURE 3-2 Swing Control See Figure 3-2 for the following procedure.
  • Page 48 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL   p1617 Dual Fuel Auxiliary Heater/Defroster Work/Head Light Switch Winch Switch Switch Switch                         p1617 Optional Ignition Switch Steering Windshield Parking Brake Axle Lockout Selector Wiper Switch...
  • Page 49 5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Steering Selection Switch - Standard Optional Axle Lockout Switch See Figure 3-5 for the following procedure. See Figure 3-5 for the following procedure. This switch is used to select one of three steering modes in This switch engages and disengages the optional rear axle which the crane can be steered.

  • Page 50: Gauges And Indicators

    OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL The up position places the transmission in 4 wheel Emergency Flasher   p0896 drive. Turn Signal Switch Lever The down position places the transmission in 2 wheel   drive.   p1618      ...
  • Page 51 5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES p0898 p1036 Typical Hourmeter Engine Low Pressure Warning FIGURE 3-12 Light FIGURE 3-14 Low Battery Warning Light Engine High Temperature Warning Light See Figure 3-13 for the following procedure. When this light is illuminated it is an indication that the See Figure 3-15 for the following procedure.
  • Page 52 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL Transmission Low Oil Pressure Warning Light   See Figure 3-16 for the following procedure. When this light is illuminated it is an indication that the   t r a n s m i s s i o n o i l p r e s s u r e i s l o w e r t h a n w h a t i s recommended for proper operation of the transmission.
  • Page 53 5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Dual Fuel Engine Warning Light Error Codes Error Description See Figure 3-19 for the following procedure. Inlet air temp sensor - low Inlet air temp sensor - high p1659 Electronic ignition control error Drive by wire error System voltage low Manifold absolute pressure sensor error...
  • Page 54 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL Crane Level Indicator limit is exceeded. The operator is warned by a flashing light   on the display panel. See Figure 3-21 for the following procedure. In conjunction with the display panel (receiver), there is a This is a bubble-type indicator that allows the operator to  ...

  • Page 55: Operator's Cab

    5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES SEAT FORE & AFT ADJUSTMENT - To adjust the seat, p0301 move the control lever (Figure 3-25) to the right. Move the seat to proper position and then move the control lever back to the left to lock the seat position.
  • Page 56 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL   p1135 p0285               Opening Door - Inside FIGURE 3-27 Heater Location FIGURE 3-29   Opening the Sliding Side Windows (Enclosed Cab) p1025 Both the left and right side windows open and close the  ...

  • Page 57: Machine Operation

    5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES To run the engine on Liquid Petroleum Gas, place the switch in the “LPG” position. Starting The Engine Normal Engine Starting NOTE: Never leave the engine running while the crane is u n a t t e n d e d . S h u t o ff t h e e n g i n e t o i n h i b i t unauthorized persons from operating the controls.
  • Page 58 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL Engine Starting Procedures p0992   NOTE: DO NOT crank the starter motor continuously for more than 30 seconds. Damage to the starter   motor could occur. DO NOT operate the engine at full RPM or apply a  ...
  • Page 59 5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES p0895 WARNING Typical Cold Start Switch FIGURE 3-33 Do not smoke while changing ether cylinders or where If the engine does not start after the first injection of ether cylinders are stored. Keep ether cylinders away from open flames.
  • Page 60 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL Applying Fluid From A Spray Canister NOTE: NEVER jump start the engine directly to the starter   or starter solenoid. Serious injury could result from the crane moving forward or back and running over the person performing the jump starting procedure.

  • Page 61: Traveling With The Crane

    5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES NOTE: To help inhibit accidents, use a Slow Moving a0048 Vehicle sign and a flashing strobe light (where Positive Jumper Battery on legal) for traveling on highways or public roads. Cable Machine Negative Jumper Cable Connects to a Booster Battery...
  • Page 62 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL Up shifting to the next gear (travel speed) may be done w0026   at any engine speed, while the crane is in motion, but first ease up on the accelerator pedal and press and hold the dump switch.
  • Page 63 5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES These modes are selected using the Steering Selector p1617 Switches shown in Figure 3-39 and Figure 3-40. Two-Wheel Steer Mode See Figure 3-41 for the following procedure. The front wheels steer the crane. The rear wheels remain in the fixed forward position.

  • Page 64: Operating The Outrigger Controls

    OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL towing with another vehicle. The power train does   a0566 not allow starting this way, and transmission damage may occur.   NOTE: The following practices could result in transmission failure:   • Shifting between forward and reverse while the engine is at high speed or heavy throttle, such  ...
  • Page 65 5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES the outriggers. Release the accelerator pedal and the a1858 outrigger control lever when the outriggers are fully extended. Outrigger To Raise - (Figure 3-45) Pull back on the control lever Control and hold it in the RAISE position. Press the accelerator pedal to increase the engine speed, which will accelerate the speed of the outriggers.

  • Page 66: Independent Outriggers

    OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL Independent Outriggers position of the outrigger beam and should not be used to   deploy the beam. To Raise and Lower the Outriggers   On cranes equipped with independent outrigger controls, each outrigger is independently controlled (Figure 3-46).  ...

  • Page 67: Operating The Boom Controls

    5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES NOTE: Left Outrigger control shown. The remaining outrigger controls work the same as the left front outrigger control. Outrigger lower - push forward Outrigger raise - pull backward FIGURE 3-48 Operating the Boom Controls Swing Control Telescope Control Four levers in the operator’s cab control the boom functions.
  • Page 68 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL Anti-Double Blocking System Boom Swing Operation   This system inhibits the hook block from being pulled into the boom head during extension of the booms, raising of the   booms and during hoist operation. If the hook block touches the anti-double block bracket (Figure 3-50) under the boom  ...
  • Page 69 5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Swing Right - Push Forward Swing Left - Pull Backward a1844 Boom Swing FIGURE 3-51 Boom Telescope Operation boom head, a switch is activated and the hydraulic flow to extend the telescope cylinder is stopped. A NOTE: Always operate the hoist control to unwind the wire horn will sound, warning the operator that the block...
  • Page 70 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL To Extend the Booms   Press the accelerator pedal to increase the engine speed to maximum rpm. Slowly push forward on the telescope control   lever (Figure 3-52) until the desired extend speed is obtained.
  • Page 71 5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Boom Lift Operation NOTE: Look for overhead obstructions before raising the boom. Possible damage or electrocution could occur if the boom comes in contact with over head power lines. Always operate the hoist control to unwind the wire rope when raising the boom.
  • Page 72 OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL   Lower Booms - push forward   Raise booms - pull backward       a1846                   Raising and Lowering the Booms FIGURE 3-53   Hoist Operation  ...
  • Page 73 5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Know the capacity of the crane. The operator must be lower the drop block to stop the horn and allow for familiar with the crane’s capacity chart before lifting a other boom functions. load.

  • Page 74: Optional Controls Operation

    OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL Optional Controls Operation To Stop the Winch   Release the toggle switch. Auxiliary Winch   To Retract the Wire Rope See Figure 3-55 for the following procedure.   Hold the toggle switch in the down position  ...

  • Page 75: Attaching The Load

    5540F/YB5515 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Attaching the Load b. Load, boom and other parts of the crane do not contact any obstruction. The hoist rope must not be wrapped around the load as the The load must not be lowered below a point where less wire rope will be damaged.

  • Page 76: Unattended Crane

    OPERATING CONTROLS AND PROCEDURES 5540F/YB5515 OPERATOR’S MANUAL Unattended Crane     WARNING   Tipping Hazard! Changing weather conditions including but not limited to:   wind, ice accumulation, precipitation, flooding, lightning, etc. should be considered when determining the location   and configuration of a crane when it is to be left unattended.

  • Page 77: Section 4

    5540F/YB5515 OPERATOR’S MANUAL CAPACITY CHART SECTION 4 CAPACITY CHART SECTION CONTENTS Using the Capacity Chart ....4-1 Things to Observe When Using the Capacity Chart .

  • Page 78: Determining Lift Capacity At The Boom Extension

    CAPACITY CHART 5540F/YB5515 OPERATOR’S MANUAL shall be considered as part of the load. The weights for The capacity of the boom extension is determined in two (2)   these items is stated on the capacity chart. steps. First, as with the main boom, check the main capacity chart after determining the operating radius.
  • Page 79 5540F/YB5515 OPERATOR’S MANUAL CAPACITY CHART a0870 FOR REFERENCE ONLY USE THE LOAD CHART IN THE OPERATOR’S Load Rating and Range Diagram Chart- 4 Section Boom FIGURE 4-3 GROVE Published 10-21-2011, Control # 055-03...
  • Page 80                           THIS PAGE BLANK                            ...

  • Page 81: Section 5

    5540F/YB5515 OPERATOR’S MANUAL ATTACHMENTS SECTION 5 ATTACHMENTS SECTION CONTENTS Hoist Block ....... 5-1 Stowing the Boom Extension.

  • Page 82: Installing The Hoist Block

    ATTACHMENTS 5540F/YB5515 OPERATOR’S MANUAL FOURTH BOOM SECTION   Remove Pins p1624 The fourth boom section is an optional feature on this crane. Use the following procedure to extend and retract the fourth   boom section.   Extending the Fourth Boom Section Extend the outriggers.
  • Page 83 5540F/YB5515 OPERATOR’S MANUAL ATTACHMENTS a1851 FIGURE 5-4 a1854 FIGURE 5-5 GROVE Published 10-21-2011, Control # 055-03...

  • Page 84: Retracting The Fourth Boom Section

    ATTACHMENTS 5540F/YB5515 OPERATOR’S MANUAL Retracting the Fourth Boom Section Hook the handle of pin “A” into hole “B”.   Fully extend the telescope cylinder by actuating the Extend the outriggers. telescope lever in the cab (Figure 5-7).   Lower the boom to its horizontal position. Install pin “A”...

  • Page 85: Boom Extension

    5540F/YB5515 OPERATOR’S MANUAL ATTACHMENTS FIGURE 5-8 BOOM EXTENSION Remove the wire rope from the boom head sheaves. Using the hoist control release more wire rope from the Installing the Boom Extension hoist drum and install the wire rope over deflector sheave at the base of the boom extension.
  • Page 86 ATTACHMENTS 5540F/YB5515 OPERATOR’S MANUAL Remove pin at location No. 9 and swing the boom 10. Install and secure the pins removed from locations No. 4   toward the stow position. and 9 back into those positions on the boom extension to inhibit loosing the pins.

  • Page 87: Down Haul Weight

    5540F/YB5515 OPERATOR’S MANUAL ATTACHMENTS DOWN HAUL WEIGHT Remove the transmitter from the boom head by removing the transmitter mounting hardware (bolts, Installing the Down Haul Weight lockwashers and flat washers). Follow instructions at the beginning of this section to Whenever a single part line is used on a crane to lift a load, remove the hoist block.

  • Page 88: Removing The Down Haul Weight

    ATTACHMENTS 5540F/YB5515 OPERATOR’S MANUAL Removing the Down Haul Weight Insert the cable through the slot and position around the   anchor wedge (1) Figure 5-12. Whenever the down haul block is removed, the load indicator NOTE: The end of the cable should be even with the transmitter must be removed from the down haul block and  ...

  • Page 89: Wire Rope Wedge Socket

    Of the methods shown below, Manitowoc prefers that Wedge Socket method A or F be used, i.e., clipping a short piece of wire...
  • Page 90 ATTACHMENTS 5540F/YB5515 OPERATOR’S MANUAL Table 5-1   Wire Rope Clip Torque Values   Clip Sizes Torque Inches lb-ft   3.18 3/16 4.76   6.35 5/16 7.94   13.28 7/16 11.11 12.70   9/16 14.29 15.88   19.05 22.23   25.40 1-1/8 28.58  ...

  • Page 91: Part Wire Rope Reeving

    5540F/YB5515 OPERATOR’S MANUAL ATTACHMENTS 4 PART WIRE ROPE REEVING a0136 Place the wire rope over the top sheave in the boom head and then down and over the lower left sheave. Thread rope through one of the sheaves in the hoist block and then over the second lower sheave in the boom head.
  • Page 92 ATTACHMENTS 5540F/YB5515 OPERATOR’S MANUAL                           THIS PAGE BLANK                           5-12 Published 10-21-2011, Control # 055-03  ...

  • Page 93: Section 6

    5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE SECTION 6 MAINTENANCE SECTION CONTENTS Introduction....... 6-1 Scheduled Maintenance .

  • Page 94: Lubricants

    Wire rope cable clamps and connections   • Check for loose or missing parts. It is not the policy of The Manitowoc Company, Inc. to publish lists of approved lubricants or guarantee lubricant Anti-Double Blocking System   performance. The responsibility for the quality of the •...

  • Page 95: Preventive Maintenance

    5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE PREVENTIVE MAINTENANCE In addition to the following scheduled maintenance, perform the scheduled maintenance suggested in Maintenance Schedule and Checklist the engine manual furnished with the crane. When performing maintenance, do the required NOTE: Hour intervals in each maintenance chart show the maintenance interval as well as all previous interval correct time for service.
  • Page 96 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL   1000 Daily 2000 Hours Hours Hours Service Check before Hours Hours Hours   Three operation Weekly Monthly Yearly Weeks Months Months   Inspect the anti-double blocking system Inspect the wire rope   Inspect reeving, clamps and connections  ...
  • Page 97 5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE 1000 Daily 2000 Hours Hours Hours Service Check before Hours Hours Hours Three operation Weekly Monthly Yearly Weeks Months Months Check axle wheel hub lubricant level (4) Check axle housing lubricant level (2) Check Hoist gearbox and brake lubricant level Lubricate the outrigger slides Add grease to swing gearbox...

  • Page 98: Lubrication Points

    MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL Lubrication Points   Apply grease to the following fitting after the first 20 hours of operation, thereafter every 50 hours of operation, whichever   occurs first. Use a Lithium Base, E.P. No. 2 bearing grease or equivalent.
  • Page 99 5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE p1639 p1638 Lift Cylinder Pivots Lube Points (Base End) FIGURE 6-4 Two Fittings Located On Inside Surface or Bearing Ring p1664 Mast Bearing Lubrication Point FIGURE 6-1 p1663 Lift Cylinder Pivots Lube Point (Rod End) FIGURE 6-5 Boom Pivot Lubrication Points FIGURE 6-2 p0417...
  • Page 100 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL p0421   p0418               Steering Cylinder Pivot Ends Lube Points (Front Axle) Steering Knuckle Lube Points (Rear Axle) FIGURE 6-7 FIGURE 6-10   p0419 p0420            ...

  • Page 101: Scheduled Maintenance

    5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE p0392 p0423 Jib Boom Deflector Sheave Lube Point FIGURE 6-15 SCHEDULED MAINTENANCE Daily (Walk-around) Inspection Rear Axle Pivot Lube Point FIGURE 6-12 NOTE: You must read and understand the warnings and p0391 basic safety rules, found in Section 2 of this manual, before performing any operation or maintenance procedures.
  • Page 102 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL   w0015 WARNING WARNING   Loads may fall if the wedge and socket is not installed   properly or has damage. A falling load can injure or kill. DO NOT operate the crane if any of the above are found.  ...
  • Page 103 5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE Check the Transmission Oil Level Level the crane, engage the parking brake and shut off the engine. Check the oil level when the oil is cold. Level the crane, Check that the overflow bottle (Figure 6-17) is at least engage the parking brake and shut off the engine.
  • Page 104 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL Check the Air Cleaner Restriction Indicator   The air cleaner is equipped with a filter restriction indicator (Figure 6-19). The air cleaner element needs cleaning or   replacing if the indicator’s colored piston has popped out and is visible when the engine is running at high idle.
  • Page 105 5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE Always clean the gasket sealing surfaces of the housing. Install the Element An improper gasket seal is one of the most common Install the safety element over the stud in the housing causes of engine contamination. Make sure that all and slide it all the way in.

  • Page 106: Hours Of Operation (Weekly)

    MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL 50 Hours of Operation (Weekly) • It indicates if you are using the most suitable type of   rope. NOTE: You must read and understand the warnings and • It makes possible the discovery and correction of faults basic safety rules, found in Section 2 of this  ...
  • Page 107 5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE Reduction from normal diameter of 9/16” (14 mm) of more than 1/32” (0.8mm). Evidence of heat damage from any cause. Kinking, crushing, or distortion of rope structure 6 broken wires in any one lay or 3 broken wires in one strand in any lay.
  • Page 108 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL a1876                           FIGURE 6-23                           6-16 Published 10-21-2011, Control # 055-03  ...

  • Page 109: Hours Of Operation (Two Weeks)

    5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE 100 Hours of Operation (Two Weeks) A belt that is too loose will see excessive vibration and increased wear. A belt that is too tight produces wear on the NOTE: You must read and understand the warnings and belt and the bearings of the pulleys it travels around.

  • Page 110: Hours Of Operation (Monthly)

    MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL 250 Hours of Operation (Monthly)   Inspect the Hydraulic Hoses   Inspect hydraulic hose assemblies for leaks, damaged fittings and worn exterior. Do not use your hands to check for   hydraulic leaks. Hydraulic oil under pressure can cause serious injury or possible death.
  • Page 111 5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE Tighten all battery hardware to keep the battery securely in place. w0022 Disconnect the battery cables. Sprinkle the batteries with baking soda to neutralize the acid. Rinse with water. Be careful not to get water inside the battery.
  • Page 112 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL Replace the Crankcase Oil and Filter p1644   Change the engine oil more frequently if operating under difficult conditions, for example in high or low temperatures,   dusty surroundings or frequent starting and stopping. NOTE: If it is necessary to climb under the crane to change  ...

  • Page 113: Hours Of Operation (3 Months)

    5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE NOTE: Use only special Grade 8 for replacement of the Inspect the thickness of the brake pads (Figure 6-30). mast bolts. Order the bolts from your dealer, see Replace the brake pads if they are 0.028 inches (0.71 mm) your parts manual.
  • Page 114 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL causes of engine contamination. Make sure that all For maximum protection of the engine cooling system, add a   hardened ridges are completely removed, both on the corrosive inhibitor to the radiator. When the engine is cold, bottom and top of the housing.
  • Page 115 5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE p0430 p0438 Check Plug Location Fill/CHeck Plug- Rear Axle Housing Swing Gearbox Grease Fitting FIGURE 6-35 FIGURE 6-33 Check the lubricant level, which should be even with the Engage the parking brake and shut off the engine. bottom of the fill/check hole.

  • Page 116: 1000 Hours Of Operation (6 Months)

    MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL If necessary, add Mobil Fluid 424 to fill the hub to the Check the lubricant level which should be level with the   recommended level. bottom of the check plug hole. Repeat Steps 1 through 4 for the other wheel hubs.  ...
  • Page 117 5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE p1655 p1653 Transmission Oil Filter Transmission Strainer FIGURE 6-41 FIGURE 6-39 Fill the transmission with Mobil ATF 210, or equivalent, p1654 transmission fluid to the upper mark on the dipstick (approximately 3.43 gallons [13 liters]). 10. Start the engine and let it run at idle speed for a period not exceeding five minutes.
  • Page 118 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL Replace Axle Wheel Hub Lubricant p0429   p1385           Fill Plug Drain Plug   Axle Housing Drain and Fill Plugs (Front Axle) FIGURE 6-42   Drain Plug Location FIGURE 6-45 p0430   Using the outriggers, raise the tires slightly off of the ground.
  • Page 119 5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE Replace the Hoist Gearbox and Brake Lubricant In very cold temperatures, SAE 5W or SAE 5W-20 oils can be used if the viscosity of the oil will not be Hoist Gearbox less than 60 SUS (Saybolt Universal Seconds) at maximum operating temperature.
  • Page 120 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL When the tank is empty, disconnect the two hydraulic ignition key is removed and chock blocks are in   lines from the rear of the hydraulic oil tank (Figure 6-49). place before climbing under the crane. Remove the suction strainer from the suction port and Locate the hydraulic oil filter under the machine clean it in a suitable solvent.

  • Page 121: 2000 Hours Of Operation (Yearly)

    5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE Check Swing Gear/Pinion Backlash Replace the Spark Plugs (Gasoline Engine) Remove the cover to expose the swing pinion and ring Disconnect one spark plug wire at a time and then replace gear. the old spark plug with a new plug. Correct spark plug as AC 41-932 spark plug.

  • Page 122: Miscellaneous Maintenance

    MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL Inspect the Crane Structure and Booms for Damage Checking the Charging System   Thoroughly inspect the crane structure and booms for the Check the voltmeter reading on the instrument panel. following: Normal voltmeter readings are as follows:  ...

  • Page 123: Fuel System

    5540F/YB5515 OPERATOR’S MANUAL MAINTENANCE • Internal - Drink large quantities of water. Follow with Fuel Storage milk of magnesia, beaten egg or vegetable oil. Get Storage of fuel for an extended period causes accumulation immediate medical attention. of sediment, dirt, water and other foreign materials in the NOTE: In case of internal contact, DO NOT give fluids that fuel.
  • Page 124 MAINTENANCE 5540F/YB5515 OPERATOR’S MANUAL p1645                           Fuse Cover Location FIGURE 6-52                           6-32 Published 10-21-2011, Control # 055-03  ...

  • Page 125: Section 7

    5540F/YB5515 OPERATOR’S MANUAL ADJUSTMENTS SECTION 7 ADJUSTMENTS SECTION CONTENTS All adjustments must be performed by a qualified Refer to the Service Manual for the proper procedures....... 7-1 mechanic.
  • Page 126 ADJUSTMENTS 5540F/YB5515 OPERATOR’S MANUAL                           THIS PAGE BLANK                           Published 10-21-2011, Control # 055-03  ...

  • Page 127: Lubricants And Capacities

    5540F/YB5515 OPERATOR’S MANUAL SPECIFICATIONS SECTION 8 SPECIFICATIONS SECTION CONTENTS Lubricants And Capacities ....8-1 Tires........8-4 Engine Oil Specifications .

  • Page 128: Engine Oil Specifications

    SPECIFICATIONS 5540F/YB5515 OPERATOR’S MANUAL Component Capacity Lubricant/fluid Hoist gearbox 1-1/2-2 qts. (1.4-1.9 liters) SAE 90 EP gear lubricant or equivalent Hoist brake 1/2-1 pt. (.2-.5 liters) SAE 20-20 motor oil Swing gear pinion As required Open gear lube Engine Oil Specifications Viscosity Grades Arctic Operation Diesel Engine...

  • Page 129: Fuel Types

    5540F/YB5515 OPERATOR’S MANUAL SPECIFICATIONS Gasoline Engine FUEL TYPES To achieve proper engine performance and durability, it is Diesel Fuel important that only the correct type of engine oil be used in the engine. Quality oil provides maximum efficiency for The Cummins Diesel Engine operates most efficiently with crankcase ventilation systems, which reduces pollution.

  • Page 130: Relief Valve Settings

    SPECIFICATIONS 5540F/YB5515 OPERATOR’S MANUAL RELIEF VALVE SETTINGS   Relief Valve Pressure Setting   Hoist, Telescope & Boom Circuits 3500 ± 50 psi (241 ± 3.5 bar)   Swing Circuit 3000 ± 50psi (138 ± 3.5 bar) Outrigger Circuit 3000 ± 50psi (241 ± 3.5 bar)  ...

  • Page 131: Wire Rope

    5540F/YB5515 OPERATOR’S MANUAL SPECIFICATIONS 4 Section Boom....................52’ 3” (15.93 m) Boom Extension (optional) ................15 ft. (4.57 m) Wire Rope Size ........................1/2” (12.7 mm) 6 x 19 EIPS-IWRC Length 3 Section Boom....................240 ft. (73.0 m) 4 Section Boom....................290 ft. (88.4 m) Hydraulic System Filters ........................10 micron return line filter ..........................30 mesh suction filter in tank...

  • Page 132: Dimensions

    SPECIFICATIONS 5540F/YB5515 OPERATOR’S MANUAL DIMENSIONS   1710362                                                 FIGURE 8-1   Published 10-21-2011, Control # 055-03  ...
  • Page 133 5540F/YB5515 OPERATORS MANUAL ALPHABETICAL INDEX 4 Part Wire Rope Reeving ..........5-11 Accidents .
  • Page 134                           THIS PAGE BLANK                            ...

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