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Manitowoc GROVE RT890E Operator's Manual
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Manitowoc GROVE RT890E Operator's Manual

Manitowoc GROVE RT890E Operator's Manual

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OPERATOR'S MANUAL
This manual has been prepared for and is considered part of -
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SECTION 5
SECTION 6
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 stamped on the top of the outrigger box.
Always furnish crane serial number when ordering parts or
communicating service problems with your distributor or the factory.
© 2004 Manitowoc Crane Group
RT890E
Crane Model Number
6-828-100170
Part Number
This Manual is divided into the following sections:
INTRODUCTION
SAFETY INFORMATION
OPERATING CONTROLS AND PROCEDURES
SET-UP AND INSTALLATION
LUBRICATION
MAINTENANCE CHECKLIST
NOTICE
PUBLISHED DATE: April 2, 2004
UPDATED: May 27, 2004
UPDATED: September, 2004
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2
3
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Summary of Contents for Manitowoc GROVE RT890E

  • Page 1 The crane serial number is stamped on the top of the outrigger box. Always furnish crane serial number when ordering parts or communicating service problems with your distributor or the factory. PUBLISHED DATE: April 2, 2004 UPDATED: May 27, 2004 UPDATED: September, 2004 © 2004 Manitowoc Crane Group...
  • Page 2 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.
  • Page 3 RT890E OPERATORS MANUAL MASTER TABLE OF CONTENTS ASSEMBLY OF BOOM EXTENSIONS ........4-41 AUXILIARY SINGLE-SHEAVE BOOM TOP (ADDITIONAL EQUIPMENT) .
  • Page 4 OPERATORS MANUAL RT890E THIS PAGE BLANK...
  • Page 5 SECTION 1 INTRODUCTION TABLE OF CONTENTS GENERAL ............1-1 NOISE/VIBRATION TEST RESULTS .
  • Page 6 INTRODUCTION RT890E 1-ii...
  • Page 7 All crane functions are controlled from the fully- and equipment changes without notice. enclosed cab mounted on the superstructure. The crane is Grove Manitowoc and our Dealer Network want to ensure equipped with a five-section, full power, sequenced and synchronized boom. Additional reach is obtained by utilizing your satisfaction with our products and customer support.
  • Page 8 INTRODUCTION RT890E FIGURE 1-1 6263-5 Item Description Work Light Outrigger Float Outrigger Jack Cylinder Steps Valve Cover Counterweight...
  • Page 9 RT890E INTRODUCTION FIGURE 1-2 6263-2 Item Description Boom Nose Sheaves Boom Extension Mast Sheave Lift Cylinder Swingaway Nose Boom Pivot Main Hoist Auxiliary Hoist Counterweight Outrigger Jack Cylinder Rear Axle Hydraulic Tank Hydraulic Filter Front Axle Swingaway Extension Air Cleaner...
  • Page 10 INTRODUCTION RT890E FIGURE 1-3 Item Description Swingaway Extension Boom Hydraulic Tank Main Hoist Auxiliary Hoist Counterweight Muffler Windshield Washer Fluid Container Work Light Spotlight...
  • Page 11 RT890E INTRODUCTION FIGURE 1-4 Item Description Counterweight Auxiliary Hoist Main Hoist Boom Pivot Lift Cylinder Boom Boom Nose Sheaves Auxiliary Boom Nose Outrigger Jack Cylinder Front Axle Fuel Tank Oil Cooler Rear Axle Outrigger Float...
  • Page 12 INTRODUCTION RT890E THIS PAGE BLANK...
  • Page 13 SECTION 2 SAFETY INFORMATION TABLE OF CONTENTS DIESEL ENGINE EXHAUST ..........2-1 BATTERY POSTS, TERMINALS, AND RELATED ACCESSORIES .
  • Page 14 SAFETY INFORMATION RT890E 2-ii...
  • Page 15 RT890E SAFETY INFORMATION SECTION 2 SAFETY PRECAUTIONS DIESEL ENGINE EXHAUST Signal Words CALIFORNIA DANGER PROPOSITION 65 WARNING Identifies immediate hazards that will result in death or serious injury if the message is ignored. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
  • Page 16 Manitowoc Crane Care. The crane must not be returned to continued use or shutdown of the crane: service until it is thoroughly inspected for any evidence of damage.
  • Page 17 RT890E SAFETY INFORMATION boom lengths at which the lift will be made by actual CRANE STABILITY/STRUCTURAL measurements or marking on the boom. STRENGTH When a level indicator is inoperative or malfunctioning, To avoid death or serious injury, ensure that the crane is on a other means shall be used to level the crane.
  • Page 18 SAFETY INFORMATION RT890E Use adequate cribbing under outrigger floats to distribute All four outrigger beams must be equally extended to the mid weight over a greater area. Check frequently for settling. position vertical stripe or fully extended position before beginning operation. All four outrigger beam lock pins must be engaged before operating from the mid-extend position.
  • Page 19 RT890E SAFETY INFORMATION Work Site Measure the load radius before making a lift and stay within approved lifting areas based on the range diagrams and Prior to any operation, you must inspect the ENTIRE work working area diagrams on the crane’s load chart. site, (including ground conditions) where the crane will travel Verify the crane’s capacity by checking the Load Chart and operate.
  • Page 20 SAFETY INFORMATION RT890E Avoid sudden starts and stops when moving the load. The load is not frozen or otherwise attached to the ground before inertia and an increased load radius could tip the crane over lifting. or cause it to fail structurally. Use only one hoist at a time when lifting loads.
  • Page 21 RT890E SAFETY INFORMATION Use outriggers on cranes so equipped. dropping the lifting device to the ground and possibly injuring personnel working below. Be certain cranes are of adequate lifting capacity. Caution must be used when lowering or extending the boom. Let out load line(s) simultaneously to prevent two-blocking Calculate the amount of weight to be lifted by each crane and attach slings at the correct points for proper weight...
  • Page 22 SAFETY INFORMATION RT890E Electrocution Hazard Even if the crane operator is not affected by an electrical contact, others in the area may become seriously injured or killed. It is not always necessary to contact a power line or power source to become electrocuted. Electricity, depending on magnitude, can arc or jump to any part of the load, load line, or crane boom if it comes too close to an electrical power source.
  • Page 23 Following any contact with an energized electrical source, Proximity sensing and warning devices are available in the local, authorized, Manitowoc/Grove distributor must be different types. Some use boom nose (localized) sensors immediately advised of the incident and consulted on and others use full boom length sensors.
  • Page 24 SAFETY INFORMATION RT890E Special Operating Conditions and You must always be aware of everything around the crane while lifting or traveling. If you are unable to clearly see in the Equipment direction of motion, you must post a look out or signal person Never operate the crane during an electrical thunderstorm.
  • Page 25 Construction. legible. Manitowoc/Grove continues to urge Manitowoc/ Use of a Manitowoc/Grove crane to handle personnel is Grove crane owners to upgrade their cranes with load acceptable provided: moment indicator (LMI) and control lever lockout systems for all lifting operations.
  • Page 26 Maintenance and Inspection Manual. Any questions with regard to crane height, width, and length. regarding procedures and specifications should be directed to the your local, authorized Manitowoc/Grove CraneCARE Never back up without the aid of a signal person to verify the Distributor.
  • Page 27 Use ONLY the wire rope specified by Manitowoc/Grove conditions.
  • Page 28 SAFETY INFORMATION RT890E Work Practices If applicable to your crane, the use of nylon (nylatron) sheaves, as compared with metallic sheaves, may change Crane Access the replacement criteria of rotation- resistant wire rope. You must take every precaution to ensure you do not slip NOTE: If applicable to your crane, the use of cast nylon and/or fall off the crane.
  • Page 29 RT890E SAFETY INFORMATION Before moving the crane, you must be THOROUGHLY familiar with the planned route of travel and area of operation, including surface conditions and the presence of overhead obstructions and power lines. Always keep the crane clean, free of dirt, debris, and grease. Fuel the crane ONLY with the engine turned off.
  • Page 30 SAFETY INFORMATION RT890E Hand Signals Keep everyone away from suspended loads. Allow no one to walk under a load. Ensure that all slings, ties, and hooks are A qualified signal person shall be used at all times when: correctly placed and secured before raising or lowering the load.
  • Page 31 RT890E SAFETY INFORMATION 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. •...
  • Page 32 SAFETY INFORMATION RT890E TEMPERATURE EFFECTS ON HYDRAULIC If a load and the boom is allowed to remain stationary for a period of time and the ambient temperature is cooler than the CYLINDERS trapped oil temperature, the trapped oil in the cylinders will Hydraulic oil expands when heated and contracts when cool.
  • Page 33 SECTION 3 OPERATING CONTROLS AND PROCEDURES TABLE OF CONTENTS CONTROLS AND INDICATORS ......... . . 3-1 Defroster Switch .
  • Page 34 OPERATING CONTROLS AND PROCEDURES RT890E Seat Switch (Not Shown)..........3-9 Cab Dome Light.
  • Page 35 RT890E OPERATING CONTROLS AND PROCEDURES Four-Wheel Drive Operation ........3-16 Proper Operation of Differential Lock .
  • Page 36 OPERATING CONTROLS AND PROCEDURES RT890E 3-iv...
  • Page 37 RT890E OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES Ignition Switch NOTE: The following paragraphs describe all the available (standard and optional; some machines may not be The (IGNITION) switch (3) is located at the bottom of the equipped with the optional controls shown) controls front console, to the right of the steering column.
  • Page 38 OPERATING CONTROLS AND PROCEDURES RT890E FIGURE 3-1 6235...
  • Page 39 RT890E OPERATING CONTROLS AND PROCEDURES FIGURE 3-2 6269, 6269-1...
  • Page 40 OPERATING CONTROLS AND PROCEDURES RT890E Item Description Item Description Defroster Switch Cab Circulating Fan Hand Throttle Control Knob Electrical System Diagnostics Indicator Ignition Switch Swing Brake Pedal Voltmeter Telescope Control Foot Pedal Transmission Oil Temperature Gauge Windshield Wiper Heat Control Knob Defroster Fan Fan Control Switch Service Brake Pedal...
  • Page 41 RT890E OPERATING CONTROLS AND PROCEDURES The differential lock (AXLE DIFF) control switch (11) is Item Description located on the left side of the front console. It is a two Boom Not Sync Indicator position, momentary rocker switch placarded LOCK and UNLOCK.
  • Page 42 OPERATING CONTROLS AND PROCEDURES RT890E Headlights Switch Idle Switch The IDLE switch (23) is a two position (+/-) momentary The HEADLIGHTS switch (17) is located on the left side of rocker switch that provides idle-control inputs that increases the front console. This two-position rocker switch (ON/OFF) and decreases the engine idle (when the test mode switch is controls operation of the instrument lights, switch LED’s, and in the OFF position) or diagnostic mode fault codes (when...
  • Page 43 RT890E OPERATING CONTROLS AND PROCEDURES Load Moment Indicating (LMI) and Work armrest. The auxiliary hoist switch must be in either HIGH or LOW position before the auxiliary hoist can be operated. Area Definition System Control Panel Positioning this switch to OFF prevents the operator from The LMI and Work Area Definition System control panel (28) accidentally activating the auxiliary hoist.
  • Page 44 OPERATING CONTROLS AND PROCEDURES RT890E power brake valve to apply pressure to the brake assembly. move the lever up or down, pull back on the lever first. To This pressure aids the spring pressure to overcome the shift the transmission to first, second, or third gear, rotate the hydraulic pressure being applied to the brake release circuit knob to 1, 2, or 3.
  • Page 45 RT890E OPERATING CONTROLS AND PROCEDURES controlled valve on the main hoist to direct the flow of for the operator to plug in a 12 Vdc accessory. It is protected hydraulic oil to the hoist motors. When the switch is in either by a 10 amp circuit breaker with an 8 amp maximum the HIGH or LOW position, the amber LED square in the allowable load...
  • Page 46 OPERATING CONTROLS AND PROCEDURES RT890E Boom Not Sync Indicator NOTE: If this indicator light illuminates, see Engine Operator’s Manual. The BOOM NOT SYNC indicator (72) is located on the left Engine Warning Indicator side of the console on the indicator light display. It illuminates red when the boom sections are no longer telescoping in the The ENGINE WARNING indicator (66) is located on the correct synchronization.
  • Page 47 RT890E OPERATING CONTROLS AND PROCEDURES 2 Speed Swing Switch modes; A and B. These two modes are used when lifting and are controlled by the LMI System. The A mode retains the The 2-speed swing switch is located on the left side of the inner mid section fully retracted until all other sections are front console.
  • Page 48 OPERATING CONTROLS AND PROCEDURES RT890E OPERATING PROCEDURES Inspect sheaves, guards, guides, drums, flanges, and any other surfaces that may come in contact with the rope for any Pre-Starting Checks condition that could cause possible damage to the rope. Hook Block A complete walk-around visual inspection of the crane should always be made with special attention to structural Visually inspect for nicks, gouges, cracks, and evidence of...
  • Page 49 RT890E OPERATING CONTROLS AND PROCEDURES Starting Procedure The engine is equipped with an electric air heater grid at the air inlet elbow to aid in cold starting and reduce white smoke Make an under-the-hood inspection for fuel, oil, and coolant at start-up.
  • Page 50 OPERATING CONTROLS AND PROCEDURES RT890E Crane Travel Operation The WAIT-TO-START lamp is illuminated during the preheat time that takes place when the IGNITION switch Traveling - General is in the ON position during cold weather starting. To minimize cranking time during cold weather starting, the engine should not be cranked until the WAIT-TO-START lamp turns off.
  • Page 51 RT890E OPERATING CONTROLS AND PROCEDURES Remove the hook block and/or headache ball from the hoist cable(s) and stow securely before traveling or CAUTION make sure the hook block or headache ball is properly secured to the tie down provided for that purpose. Should the crane become mired down, use a tow truck or tractor to free the vehicle.
  • Page 52 OPERATING CONTROLS AND PROCEDURES RT890E CAUTION Apply service brakes and bring crane to a complete stop before shifting transmission into reverse. Four-Wheel Drive Operation If more traction is required due to slipping or spinning wheels, engage the front axle drive as follows: CAUTION Before shifting from two-wheel drive to four wheel drive (or from four back to two), crane travel must be stopped.
  • Page 53 RT890E OPERATING CONTROLS AND PROCEDURES each axle. The lock position will also protect against spinout. This will fully engage the differential locks. When When normal driving conditions exist (during periods of good activated the square amber LED on the switch should be traction), the differential locks should not be actuated.
  • Page 54 OPERATING CONTROLS AND PROCEDURES RT890E General Crane Operation The load chart contains outrigger capacity charts for fully extended, mid extended, outriggers for the main boom and Pump Drive boom extension, and fully retracted outrigger beams for main boom only. In addition, the load chart contains two on-rubber The main hydraulic pumps are mounted on the torque capacity charts: 360°...
  • Page 55 RT890E OPERATING CONTROLS AND PROCEDURES fully extended position are used to mark the boundaries of After all four outrigger beams have been fully extended, the lifting areas. position the appropriate STABILIZER rocker switch on the OUTRIGGER SELECTOR panel and hold the A boom extension capacity chart and notes are included to outrigger EXTENSION/RETRACTION rocker switch to list the capacities for the extension length, load radius, and...
  • Page 56 OPERATING CONTROLS AND PROCEDURES RT890E Engaging the Mid-Extend Lock Pin After all outriggers have been fully retracted, stow the outrigger floats. Turn the locking pin 90° from its stowed position and Stowing the Mid-Extend Lock Pin allow the pin to rest on top of the outrigger beam. NOTE: It may be necessary to jog the outrigger extension/ Retract the outrigger extension/retraction cylinder.
  • Page 57 RT890E OPERATING CONTROLS AND PROCEDURES Elevating and Lowering the Boom Telescoping the Boom Elevating the Boom Extending the Boom WARNING WARNING Keep the area above and below the boom clear of all When extending the boom, simultaneously let out the obstructions and personnel when elevating the boom.
  • Page 58 OPERATING CONTROLS AND PROCEDURES RT890E Lowering the Cable L O W E R s w i t c h . S e e S E C T I O N 3 - O P E R AT I N G C O N T R O L S A N D P R O C E D U R E S f o r l o c a t i o n a n d Push the MAIN or AUX hoist control lever forward, away description of these switches.
  • Page 59 RT890E OPERATING CONTROLS AND PROCEDURES The luffing jib ON/OFF switch must be in the ON position. Push the luffing jib RAISE/LOWER switch to the LOWER position and hold until the extension is lowered to the desired WARNING position or a switch-off point is reached. There are no cutouts associated with the swing angle set To lower the extension at the remote stations, press switch limitation or the work area definition features.
  • Page 60 OPERATING CONTROLS AND PROCEDURES RT890E 10. Shut down the engine following the proper procedures 11. Remove the keys. specified in this Handbook and the applicable Engine 12. Close and lock all windows, covers, and doors. manual. 3-24...
  • Page 61 SECTION 4 SET-UP AND INSTALLATION TABLE OF CONTENTS GENERAL ............4-1 INSTALLING CABLE ON THE HOIST .
  • Page 62 SET-UP AND INSTALLATION RT890E Hydraulic Connection at the Boom Extension ......4-46 Electrical Connection at the Boom Extension ......4-48 Unfolding/Folding the Deflection Sheave on the 16 ft (4.9 m) Section .
  • Page 63 RT890E SET-UP AND INSTALLATION SECTION 4 SET-UP AND INSTALLATION GENERAL This section provides procedures for installing the hoist cable on the hoist drum, cable reeving, and erecting and stowing the boom extension. INSTALLING CABLE ON THE HOIST CAUTION If cable is wound from the storage drum, the reel should be rotated in the same direction as the hoist.
  • Page 64 This will allow the distortion of the rope strands, caused by the bend Manitowoc/Grove Crane specifies the size, type, class and around the wedge, to adjust themselves at the end of the line pulls for wire rope, predominately rotation resistant wire line.
  • Page 65 RT890E SET-UP AND INSTALLATION socket. It is recommended that the wedge be seated Other sources for information with which crane users should inside the socket to properly secure the wire rope by be familiar and follow is provided by the American Society of using the crane’s hoist to first apply a light load to the live Mechanical Engineers, American National Standard, ASME line.
  • Page 66 SET-UP AND INSTALLATION RT890E BOTTOM BOOM NOSE SHEAVES TO MAIN HOIST HOOK BLOCK DEAD END UPPER BOOM NOSE SHEAVE AUXILIARY NOSE HOOK BLOCK SHEAVES 6267-1 TO MAIN HOIST BOTTOM BOOM NOSE SHEAVES UPPER BOOM NOSE SHEAVE BOOM NOSE DEAD END HOOK BLOCK SHEAVES 6267-2 FIGURE 4-4...
  • Page 67 RT890E SET-UP AND INSTALLATION TO HOIST 10 M (33 FT) FIXED BOOM EXTENSION 6267-3a TO HOIST 17 M (56 FT) BI-FOLD BOOM EXTENSION 6267-4a TO HOIST 22 M (72 FT) BOOM EXTENSION 6267-5 TO HOIST 27 M (89 FT) BOOM EXTENSION 6267-6 FIGURE 4-5 6267-3/4/5/6...
  • Page 68 SET-UP AND INSTALLATION RT890E Counterweight and Auxiliary Hoist Properly attach chains with clevis to the counterweight lifting holes (see Figure 4-7) and use a crane to carefully Removal transfer the counterweight and auxiliary hoist to the frame counterweight supports over the rear outrigger Position the crane on a firm, level surface.
  • Page 69 RT890E SET-UP AND INSTALLATION 8, 9, 10, 11 6, 7 FIGURE 4-6 Item Description Item Description Counterweight Weld Washer Counterweight Pin Cylinder Bolt Counterweight Removal Cylinder Flatwasher Cylinder Support Weld Lockwasher Ball Detent Pin Hex Nut Screw IPO Counterweight...
  • Page 70 SET-UP AND INSTALLATION RT890E Counterweight Lifting Points FIGURE 4-7 6326 Item Description Counterweight Counterweight Cylinder Assembly...
  • Page 71 RT890E SET-UP AND INSTALLATION CHECKLISTS FOR RIGGING WORK Using the control levers (left and right), simultaneously extend (lower) the counterweight onto the frame Overview of the Required Rigging Work counterweight supports. Feather individual controls as required to lower the counterweight in a level position. There are different initial states for rigging the lattice Remove the counterweight removal cylinder support extension, depending on whether...
  • Page 72 SET-UP AND INSTALLATION RT890E If necessary, connect the hose drum for hydraulic 10. If the lattice extension needs to be rigged in front of the supply. main boom, attach guide ropes to the head of the 33 ft (10.1 m) section. The other types of rigging work for the 33 ft (10.1 m) swingaway lattice extension are described in the Check List: Rigging the 33 ft (10.1 m) swingaway lattice...
  • Page 73 RT890E SET-UP AND INSTALLATION If necessary, remove hose drum connection for Establish electrical connection between the lattice hydraulic supply. extension and the main boom. Establish hydraulic electrical connection between the Checklist: Rigging the 33 Ft (10.1 m) lattice extension and the main boom. Swingaway Lattice Extension 10.
  • Page 74 SET-UP AND INSTALLATION RT890E 18. Move the lifting limit switch from the head of the main Unreeve the hoist cable from the hook block and remove boom to the head of the 33 ft (10.1 m) section. it from the lattice extension. 19.
  • Page 75 RT890E SET-UP AND INSTALLATION 13. Remove the right hand locking pin between the 33 ft (10.1 m) section and the main boom head. 20. Disconnect hydraulic connection between the lattice extension and the main boom. 14. Swing the 33 ft (10.1 m) section on the run-up rail onto the main boom.
  • Page 76 SET-UP AND INSTALLATION RT890E Remove the connection between 23 ft (7 m) section and 12. Remove the connection in the front area. If necessary, the main boom in the rear area. press down the slewing axle mechanically. Establish electrical connection between the lattice 13.
  • Page 77 RT890E SET-UP AND INSTALLATION Remove the locking pins on the left-hand side between 22. Move the lifting limit switch from the head of the main 23 ft (7 m) section and 33 ft (10.1 m) section. boom to the head of the 33 ft (10.1 m) section. Swing the 23 ft (7 m) section in front of the 33 ft (10.1 m) section.
  • Page 78 SET-UP AND INSTALLATION RT890E 17. Lower the lattice extension so that it is positioned on the 27. If necessary, remove the hose drum connection for run-up rail. hydraulic supply. DESCRIPTION OF RIGGING WORK Preparing the Crane for Rigging NOTE: The data is this section also applies to the rigging of the boom extension.
  • Page 79 RT890E SET-UP AND INSTALLATION You must therefore secure the lattice extension before you which need to be established depend on whether the lattice begin with the rigging work. extension: is folded up at the side of the main boom for transportation or DANGER is completely removed for transportation.
  • Page 80 SET-UP AND INSTALLATION RT890E FIGURE 4-8 4-18...
  • Page 81 RT890E SET-UP AND INSTALLATION Transport condition with lattice extension folded at If the main boom is used for longer periods of time, the hose the side drum’s hydraulic connections should be brought into the main boom operation position. The transport condition with the lattice extension folded at This prevents unnecessary reeling and unreeling of the the side is created when all of the following connections are hose.
  • Page 82 SET-UP AND INSTALLATION RT890E Inserting anti-twist device Position for working with the lattice extension • Turn the hose drum until a bore is in front of the • Take the strain relief out of the holder (1) and pull spring latch (3). the hydraulic hoses (2) towards the main boom head.
  • Page 83 RT890E SET-UP AND INSTALLATION 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 Connections With Folded Lattice Extension on-road driving after derigging. The lattice extension is turned sideways to the main boom in Fold out the run-up rail the folded position.
  • Page 84 SET-UP AND INSTALLATION RT890E Securing the connection • Swing the lattice extension on the run-up rail onto the main boom until the bores on the 33 ft (10.1 m) DANGER section and the main boom are aligned. Risk of accidents from lattice extension swinging of its •...
  • Page 85 RT890E SET-UP AND INSTALLATION • Remove the locking pin (4) from the holder (5), insert it in the bore holes and secure it with the retaining pin. Connections in the middle area When connecting in the middle area, three different joints can be established: 23 ft (7 m) section/33 ft (10.1 m) section joint 23 ft (7 m) section/main boom joint...
  • Page 86 SET-UP AND INSTALLATION RT890E • Fasten the locking bar (1) with a pin (3) onto the 23 ft (7 Secure both the pins, each with one retaining pin. m) section and with a pin (2) onto the 23 ft (7 m) section. Connections in the rear connection Connection between 23 ft (7 m) section and main boom...
  • Page 87 RT890E SET-UP AND INSTALLATION Establishing a connection • Loosen the retaining pin and remove the pins (3) from the bearing points (2). • Swivel the lattice extension into the main boom until the • Remove the retaining strut. bearing point (3) is aligned. •...
  • Page 88 SET-UP AND INSTALLATION RT890E Connections on the left side Connection on the left side The connection needs to be established after the lattice extension has been swiveled in front of the main boom head during rigging. The connection has to be removed so that the lattice extension can be swiveled onto the main boom side during unrigging.
  • Page 89 RT890E SET-UP AND INSTALLATION • Insert both pins into the holders and secure them with retaining pins. Connection on the right side 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.
  • Page 90 SET-UP AND INSTALLATION RT890E Establishing a connection DANGER Risk of accidents from falling 23 ft (7 m) section. Make sure that the connections between the 23 ft (7 m) section and the main boom (in the rear area) and between the 23 ft (7 m) section and the main boom have been made before you release the connection on the right side of the pivot point.
  • Page 91 RT890E SET-UP AND INSTALLATION The required connections among the individual lattice extension sections or the lattice extension sections and the main boom have been removed. Swinging the Lattice Extension When swung, the lattice extension rolls on the run-up rail, turns around the connection in the front area and makes contact at the front at the bearing points.
  • Page 92 SET-UP AND INSTALLATION RT890E Swing the lattice extension until it is no longer above • Remove the short-circuit plug from the dummy socket the run-up rail. and plug it in the socket on the main boom. Carefully lower the lattice extension from the control •...
  • Page 93 RT890E SET-UP AND INSTALLATION • Remove the dummy plug (2) from the socket (4) on the Establishing the Hydraulic Connection 33 ft (10.1 m) section and insert it in the dummy socket • Take the hose line (2) out of the holders (3) on the 33 ft (1) on the 23 ft (7 m) section.
  • Page 94 SET-UP AND INSTALLATION RT890E Folding Out/In the Deflection Sheaves on the • Fold the deflection sheave up and secure it with the pin in the bore (4). 33 ft (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 deflection sheaves.
  • Page 95 RT890E SET-UP AND INSTALLATION • Hold the deflection sheave by the strut (1) and remove the pin (3) from the bore (2). • Fold the deflection sheave up until the pin can be inserted through the bore (2) again. • Insert the pin through the bore and secure it with a retaining pin.
  • Page 96 SET-UP AND INSTALLATION RT890E Possible Reeving Methods on the Lattice Extension The hoist cable can be reeved once or twice. Hook tackle, max. lifting capacity: 6 U.S. Tons 1 fall maximum load bearing capacity: Single reeving 6 U.S. Tons 1-sheave hook block, max. load bearing capacity 20 t 1 fall 2 fall...
  • Page 97 RT890E SET-UP AND INSTALLATION • Connect the lifting limit switch on the socket (1). During operation • When unrigging you must insert the short-circuit plug (2) During operation the lattice extension is derricked from the back in the socket (1). crane cab.
  • Page 98 SET-UP AND INSTALLATION RT890E OPERATION WITH THE LATTICE • Always secure the lattice extension on the separate vehicle with belts as well as to prevent slipping and EXTENSION overturning. NOTE: The information in this section also applies to operation with the boom extension. Observe the CAUTION following safety instruction before working with the Risk of damaging the lattice extension.
  • Page 99 RT890E SET-UP AND INSTALLATION DRIVING WITH RIGGED CRANE AND Retracting the Outrigger INSTALLED LATTICE EXTENSION • Retract the outrigger cylinders until the wheels are just above the ground. This section describes how you can move the crane with an installed counterweight and rigged lattice extension (e.g. when the lattice extension cannot be rigged on the site due DANGER to lack of space).
  • Page 100 SET-UP AND INSTALLATION RT890E MALFUNCTION WHEN WORKING WITH NOTE: The information in the following table applies to malfunctions during operation with the 33/56 ft LATTICE EXTENSION (10.1/17.1 m) lattice extension. Malfunction Cause Remedy No function of the lifting limit switch Lifting limit switch not connected Connect the lifting limit switch.
  • Page 101 RT890E SET-UP AND INSTALLATION the control box at the front of the 23 ft (7 m) section Lubricating Joint on 33 ft (10.1 m) Section both the control units (5). Maintenance Work M1, Monthly Pins Lubricate all attach, securing and retaining pins, in other words: the pins for the pin connection on the lattice extension,...
  • Page 102 For technical reasons a crane may only be set with one boom extension. If you wish to use the boom extension on several Manitowoc/ Grove cranes, the parts of the boom extension must be adjusted for these cranes and labeled with all of the respective serial numbers.
  • Page 103 RT890E SET-UP AND INSTALLATION ASSEMBLY OF BOOM EXTENSIONS FIGURE 4-11 CHECKLISTS FOR RIGGING WORK NOTE: The lengths of 72 ft (22.0 m) and 89 ft (27.1 m) respectively equal the distance between the center Rigging the 72/89 Ft (22.0/27.1 m) Boom of the locking pin (on the main boom head) and the front edge of the head sheave.
  • Page 104 SET-UP AND INSTALLATION RT890E If necessary, connect the hose drum for hydraulic 10. Swinging the 23 ft (7 m) section in front of the 33 ft (10.1 supply. m) section. Check the transport of the two-stage swingaway lattice extension. Install 16 ft (4.9 m) sections in front of the main boom: One 16 ft (4.9 m) section for the 72 ft (22.0 m) boom extension, Both 16 ft (4.9 m) sections for the 89 ft (27.1 m) boom...
  • Page 105 RT890E SET-UP AND INSTALLATION 15. Place hoist rope on all deflection sheaves and the head Telescoping; sheave of the 23 ft (7 m) section. Unrigging the 72/89 Ft (22/27.1 m) Boom Extension Prerequisites The crane is on outriggers or the main boom is placed on the boom support.
  • Page 106 SET-UP AND INSTALLATION RT890E Detach the hydraulic connection. 11. Remove the locking pins on the left-hand sided between 23 ft (7 m) section and 33 ft (10.1 m) section. Detach electrical connections. 12. Swinging the 23 ft (7 m) section in front of the 33 ft (10.1 m) section.
  • Page 107 RT890E SET-UP AND INSTALLATION 16. Remove 16 ft (4.9 m) sections from the main boom: The securing pins (1) for the connection are secured with retaining pins in the holders at the foot of the 16 ft (4.9 m) One 16 ft section for a 72 ft (22.0 m) boom extension; sections.
  • Page 108 SET-UP AND INSTALLATION RT890E • Lift the two-stage swingaway lattice extension until the bearing points are relieved. • Release the pins and knock them out of the bearing points on both sides. • Insert the pins into the holders on the 33 ft (10.1 m) section and secure them with retaining needles.
  • Page 109 RT890E SET-UP AND INSTALLATION At the 72 ft (22.0 m) Boom Extension All connections are made via quick-action couplings. Half couplings which belong together are color coded. Establishing a Connection Disconnecting • Connect the rear hose ends (1) of the 126 ft (38.4 m) •...
  • Page 110 SET-UP AND INSTALLATION RT890E • Connect rear hose ends (1) of the 16 ft section to the For transport, the cable is wound around the holders (2) and quick-action couplings (2) at the main boom head. the plug is inserted in the dummy socket (2). •...
  • Page 111 RT890E SET-UP AND INSTALLATION Disconnecting • Pull the pin (2) out of the bore (3). • Fold the deflection sheave on the strut (1) upwards until • Detach the electrical connection between the 33 ft (10.1 the locking positions are aligned with the bore hole (3). m) and front 16 ft (4.9 m) section.
  • Page 112 SET-UP AND INSTALLATION RT890E Positioning/Removing the Hoist Cable DANGER Risk of accidents due to falling parts. Always secure the hoist cable holding rollers and rods with retaining pins. This prevents elements from becoming loose, falling down and injuring people. • Remove the hoist rope holding rollers and rods (1).
  • Page 113 RT890E SET-UP AND INSTALLATION Traveling with Hydraulic Luffing or Manually Offsettable Boom Extension and/or Inserts Item Description Erected Bolt 33 ft (10.1 m)/56 ft (17.1 m) Extension Plus 16 ft (4.9 m) Flatwasher or 32 ft (10 m) Inserts Rear Hanger Assembly Travel is permissible under the following conditions.
  • Page 114 Installing Auxiliary Single-Sheave Boom Top boom top that has the identical serial number. If you wish to use the auxiliary single-sheave boom top on several Manitowoc/Grove cranes, it needs to be adapted to the corresponding crane and marked with all the serial numbers.
  • Page 115 RT890E SET-UP AND INSTALLATION • Secure the auxiliary single-sheave boom top to the • Remove the retaining pins and draw all the pins out of holding device using a pin (1). the bores and bearing points. • Secure the pin with a retaining pin. •...
  • Page 116 SET-UP AND INSTALLATION RT890E • Using the thin pin (1), fasten the auxiliary single-sheave boom top to the bearing point (2). • Secure the pin with a retaining pin. • The auxiliary single-sheave boom top is now in transport position. Rigging in Working Position On the left side of the main boom head, there is a holding device.
  • Page 117 RT890E SET-UP AND INSTALLATION • Swing the auxiliary single-sheave boom top in front of • When reeving, guide the hoist cable over the left head the main boom head. sheave of the main boom. • Insert the rope holding rod into the appropriate bore holes and secure them with the corresponding retaining pins.
  • Page 118 SET-UP AND INSTALLATION RT890E Setting the Folding Swingaway Extension If, additionally, a hook block is reeved on the main boom, connect the lifting limit switch of the main hoist to the socket Offset on the right side of the main boom head. DANGER Ensure any blocking material used is adequate to support the weight of the extension assembly without tipping or...
  • Page 119 RT890E SET-UP AND INSTALLATION 6438-2 SHOWN AT 0° OFFSET TO OBTAIN MAXIMUM DEGREE OFFSET, REMOVE OFFSET PIN AND STOW IN LUG. LINK OFFSET LINK SHOWN AT 40° OFFSET SHOWN AT 20° OFFSET 6438-1 6438-3 FIGURE 4-14 unnecessary reeling and unreeling of the hose (see Figure 4- 15).
  • Page 120 SET-UP AND INSTALLATION RT890E Disconnect the hydraulic connection between the Remove the hoses from the boom nose. Retract the hydraulic hoses to the holder on the boom base section. lattice extension and the main boom. Engage the hose drum lock pin into hole on the drum. DANGER Wind the hoses onto the boom extension for storage.
  • Page 121 RT890E SET-UP AND INSTALLATION Establish an electrical connection between the lattice boom. Make the connection at the front stowage bracket extension and anti-two block switch and support with lifting device (see detail A). NOTE: The anti-two block switch supplied with the boom Refer to detail A (front stowage bracket) and pivot the extension is used for operation of the 33 ft (10.1 m) boom extension on the front support bracket.
  • Page 122 SET-UP AND INSTALLATION RT890E THIS PAGE BLANK 4-60...
  • Page 123 SECTION 5 LUBRICATION TABLE OF CONTENTS GENERAL ............5-1 Arctic Conditions - Below -18°C (0°F).
  • Page 124 LUBRICATION RT890E 5-ii...
  • Page 125 For information on bottom edge of the fill plug hole. extreme condition lubrication, contract your local Manitowoc/ On all hoists with a check plug in the drum, the fill plug shall Grove distributor or Manitowoc CraneCARE.
  • Page 126 LUBRICATION RT890E Table 5-1 Lube Symbol Chart Symbol Description EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2. SSGL-5 Semi-Synthetic Gear Lubricant - SAE Grade 80W-90, API Service Designation GL-5. 50/50 Blended Fully Formulated Antifreeze/Coolant, SAE J1941, ASTM D6210 Hydraulic Oil - Must meet John Deere Standard JDM-J20C (Anti-brake chatter) and ISO 4406 cleanliness HYDO level 17/14...
  • Page 127 T P - 9 5 3 9 a v a i l a b l e Lube Interval - 500 hours or 3 months www.arvinmeritor.com or by contacting Manitowoc CraneCARE. Lube Amount - Until grease extrudes Lube Amount - Capacity - 24.6 liters (51.9 pints) Normal Application - 8 grease fittings makeup - less than 0.23 liter (0.5 pint)
  • Page 128 LUBRICATION RT890E 6265-1 FIGURE 5-1...
  • Page 129 RT890E LUBRICATION Item Description Item Description Steering Cylinder Pivot Pins Jack Cylinder Support Tubes King Pins (Upper and Lower) Hook Block Swivel Bearing Fifth Wheel Pivots Hook Block Sheaves - 80 Ton Lockout Cylinder Pivot Pins Headache Ball Tie Rod Pivot Pins Telescope Cylinder Wear Pads Differentials Internal Side and Bottom Wear Pads -...
  • Page 130 LUBRICATION RT890E 6265-3 6265-2 FIGURE 5-1 continued...
  • Page 131 RT890E LUBRICATION Planetary Hubs and Wheel Bearings should be accomplished by engaging the shift lever in forward high range with the brakes applied and Lube Type - SSGL-5 then accelerating the engine to half or three- quarter throttle. Hold the stall until the required Lube Interval - Check fluid level every 500 hours or 3 converter temperature is reached and stabilized.
  • Page 132 LUBRICATION RT890E 15. Fuel Strainer 21. Pillow Block Change strainer every 500 hours or 6 months Lube Type - EP-MPG 16. Turntable Gear Box Lube Interval - 500 hours or 3 months Lube Type - SSGL-5 Lube Amount - Until grease extrudes NOTE: Remove one valve to equalize the pressure before Application - 2 grease fittings...
  • Page 133 RT890E LUBRICATION 27. Telescope Cylinder Wear Pads 32. Retract Cable Sheaves Lube Type - EP-MPG Lube Type - EP-MPG Lube Interval - Every boom teardown. Lube Interval - 250 hours or 3 months Lube Amount - Thoroughly coat all areas the wear pad Lube Amount - Until grease extrudes moves on.
  • Page 134 LUBRICATION RT890E 39. Boom Extension Sheaves 42. Hydraulic Reservoir Lube Type - EP-MPG Lube Type - HYDO Lube Interval - 250 hours or 3 months Lube Interval - Check fluid level every 10 hours or daily, using sight gauge on side of tank, with boom down and Lube Amount - Until grease extrudes all outrigger cylinders retracted;...
  • Page 135 SECTION 6 MAINTENANCE CHECKLIST TABLE OF CONTENTS GENERAL ............6-1 INSTRUCTIONS .
  • Page 136 MAINTENANCE CHECKLIST RT890E 6-ii...
  • Page 137 RT890E MAINTENANCE CHECKLIST SECTION 6 MAINTENANCE CHECKLIST GENERAL INSTRUCTIONS This section contains a list of daily inspection and S e e S e r v i c e M a n ua l f or s pe c i f i c m a i nt e n an c e an d maintenance checks.
  • Page 138 MAINTENANCE CHECKLIST RT890E INSPECTION SERVICE LOG DAY OF INSPECTION Items to be Inspected Daily December Verify Outrigger Float Pads are properly installed & show no signs of structural damage Verify Tire Condition has no excessive wear and Pressure is at the proper level Visually check machine for any Hydraulic Components (including Hoses) with excessive wear, loose fittings, or leaks...
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