RT540E OPERATOR’S MANUAL SAFETY INFORMATION

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
Outrigger Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Load Moment Indicating (LMI) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Two-Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Special Operating Conditions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Crushing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Job Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Hand Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Transporting The Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Boom Extension/Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-i

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RT540E 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 GENERAL

be over emphasized. Carelessness or neglect on the part of
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 PERSON 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
Because you, the operator, are the only part of the crane that
or injury.
can think and reason, your responsibility is not lessened by
the addition of operational aids or warning devices. Indeed,
you must guard against acquiring a false sense of security
when using them. They are there to assist, not direct the

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

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RT540E 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 recommendations contained 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
jeopardize your own well-being or that of others 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. i m pa i r p h y s i c a l , v i s u a l a n d m e n ta l r e a c t i o n s , a n d
capabilities.

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CRANE STABILITY/STRUCTURAL Be sure the outriggers are properly extended and set, and
STRENGTH the crane is level for operation on outriggers.
All four outrigger beams must be equally extended to the mid
To avoid death or serious injury, ensure that the crane is on a
position vertical stripe or fully extended position before
firm surface with load and crane’s configuration within
beginning operation.
capacity as shown on the crane’s Load Chart and notes.
Be sure the outriggers are properly extended and set, and
Do not lift loads unless the outriggers are properly extended
the crane is level for operation on outriggers.
and the crane leveled. On models equipped with outriggers
that can be pinned at the mid-extend position, the outriggers All four outrigger beams must be equally extended to the mid
must also be pinned when operating from the mid-extend position vertical stripe or fully extended position before
position. beginning operation.
This crane should have a functional load moment indicator All four outrigger beam lock pins must be engaged before
and control lock-out system. Test daily for proper operation. operating from the mid-extend position.
Never interfere with the proper functioning of operational
aids or warning devices. The operator must select the proper Load Chart and Load
Moment Indicating (LMI) System program for the outrigger
Before swinging the superstructure over the side when the position selected.
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.
The RT535E on rubber load charts have a minimum radius of
10 feet with a load. Without a load, a radius of 9 feet is safe
for 360 degrees on rubber. A radius of less than 9 feet must
be avoided on rubber because of backward stability
considerations.
Ensure all pins and floats are properly installed and outrigger KEEP THE BOOM SHORT. Swinging loads with a long line
beams are properly extended before lifting on outriggers. can create an unstable condition and possible structural
Unless lifting within On Rubber capacities, outrigger beams failure of the boom.
must be properly extended and jack cylinders extended and
set to provide maximum leveling of the crane. On models Load Charts
equipped with outriggers that can be pinned at the mid- Load Charts represent the absolute maximum allowable
extend position, the outriggers must also be pinned when loads, which are based on either tipping or structural
operating from the mid-extend position. Tires must be clear limitations of the crane under specific conditions. Knowing
of the ground before lifting on outriggers. Remove all weight the precise load radius, boom length, and boom angle
from tires before lifting on outriggers. should be a part of your routine planning and operation.
Use adequate cribbing under outrigger floats to distribute Actual loads, including necessary allowances, should be
weight over a greater area. Check frequently for settling. kept below the capacity shown on the applicable Load Chart.

Carefully follow the procedures in this handbook when You must use the appropriate Load Chart when determining
extending or retracting the outriggers. Death or serious injury the capability of the crane in the configuration required to
could result from improper crane setup on outriggers. perform the lift.

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RT540E OPERATOR’S MANUAL SAFETY INFORMATION

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
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

4
Moderate
Breeze
21-29 (13-18) Raises dust & loose paper: moves small branches 2
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

Maximum lifting capacity is available at the shortest radius, programmed for the crane configuration. Refer to the LMI
minimum boom length, and highest boom angle. handbook supplied with the crane.
Do not remove the Load Charts from the crane. Before lifting, position the crane on a firm surface, properly
extend and set the outriggers, and level the crane.
Work Site
If the boom extension or auxiliary boom nose is to be used,
Prior to any operation, you must inspect the ENTIRE work you must ensure that the cable for the LMI system is properly
site, (including ground conditions) where the crane will travel connected at the junction box located on the boom nose.
and operate. Be sure that the surfaces will support a load
Depending on the nature of the supporting surface,
greater than the crane’s weight and maximum capacity.
adequate cribbing may be required to obtain a larger bearing
Barricade the area where the crane is working and keep all surface.
unnecessary personnel out of that area.
DO NOT OVERLOAD THE CRANE by exceeding the
Use caution when operating in the vicinity of overhanging capacities shown on the appropriate Load Chart. Death or
banks and edges. serious injury could result from the crane tipping over or
failing structurally from overload.
Be aware of all conditions that could adversely affect the
stability of the crane. Do not rely on the crane’s tipping to determine your lifting
capacity.
Wind can have a significant affect on loads that may be lifted
by a crane. Wind forces act differently on a crane depending If you should encounter a tipping condition, immediately
upon the direction from which the wind is blowing (e.g., wind lower the load with the hoist line and retract or elevate the
on the rear of the boom can result in decreased forward boom to decrease the load radius. Never lower or extend the
stability, wind on the underside of the boom can result in boom, this will aggravate the condition.
decreased backward stability, wind on the side of the boom
Be sure the load is properly rigged and attached. Always
can result in structural damages, etc.). To assist you in
determine the weight of the load before you attempt to lift it
determining prevailing wind conditions, refer to the Wind
and remember that all rigging (slings, etc.) and lifting devices
Velocity Chart (Table 2-1).
(hook block, jib, etc.) must be considered part of the load.
Lifting Operations Measure the load radius before making a lift and stay within
approved lifting areas based on the range diagrams and
If the boom extension, jib, or auxiliary boom nose is to be
working area diagrams on the crane’s load chart.
used, ensure the electrical cable and the weight for the anti-
two-block switch are properly installed and the LMI is

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Verify the crane’s capacity by checking the Load Chart Load Chart capacities are based on freely suspended loads.
against the weight of the load. Then, lift the load slightly at Do not pull posts, pilings, or submerged articles. Be sure the
first to ensure stability before proceeding with the lift. load is not frozen or otherwise attached to the ground before
lifting.
Always keep the load as near to the crane and as close to
the ground as possible. Use only one hoist at a time when lifting loads.
The crane can tip over or fail structurally if: Always use enough parts-of-line to accommodate the load to
be lifted. Lifting with too few parts-of-line can result in failure
• The load and crane’s configuration is not within the
of the wire rope.
capacity as shown on the applicable load rating chart
and notes. Never operate the crane with less than two wraps of wire
rope on the hoist drum.
• The ground is soft and/or the surface conditions are
poor. Counterweight
• Outriggers are not properly extended and set. On
On cranes equipped with removable counterweights, ensure
models equipped with outriggers that can be pinned at
the appropriate counterweight sections are properly installed
the mid-extend position, the outriggers must also be
for the lift being considered.
pinned when operating from the mid-extend position.
To reduce the crushing hazard and to prevent death or
• Cribbing under the outrigger pads is inadequate.
seriou s injury, always clear all personne l from the
• The crane is improperly operated. counterweight and superstructure area before moving the
counterweight or rotating the superstructure.
Wind forces can exert extreme dynamic loads. Grove
recommends that a lift not be made if the wind can cause Do not add material to the counterweight to increase
a loss of control in handling the load. Grove recommends capacity.
if the wind speed (velocity) is between 32 km/h (20 mph) to
Federal law prohibits modification or additions which affect
48 km/h (30 mph), that the load capacities shall be reduced
the capacity or safe operation of the equipment without the
to account for the size and shape of the load and the wind
manufacturer’s written approval. [29CFR 1926.550]
direction in relation to the machine for all boom, boom
extension, and jib lengths. Further, operation of the crane in Outrigger Lift Off
wind velocities over 48 km/h (30 mph) is not recommended.
To assist you in determining prevailing wind conditions, refer Regarding “Lifting” of an outrigger pad on Grove cranes
to the Wind Velocity Chart (Table 2-1). during craning activities, please be advised that the rated
loads for these cranes, as indicated on the crane’s in-cab
The crane cab is equipped with a sight level bubble that
load chart, do not exceed 85% of the tipping load on
should be used to determine whether the crane is level. The
outriggers as determined by SAE J765 OCT80 “Cranes
load line can also be used to estimate the levelness of the
Stability Test Code”. An outrigger pad may lift off the ground
crane by checking to be sure it is in-line with the center of the
during operation of the crane within the capacity limits of the
boom at all points on the swing circle.
load capacity chart, yet the crane will not have reached
Use tag lines whenever possible to help control the instability. The “balance point” for stability testing according
movement of the load. to SAE and Grove criteria is a condition of loading wherein
the load moment acting to overturn the crane is equal to the
When lifting loads, the crane will lean toward the boom and
maximum moment of the crane available, t o re sist
the load will swing out, increasing the load radius. Ensure the
overturning. This balance point or point of instability for a
load capacity chart is not exceeded when this occurs.
crane does not depend on “lifting” of an outrigger but rather
Be sure the hoist line is vertical before lifting. Do not subject on comparison of the “opposing” load moments.
the crane to side loading. A side load can tip the crane or
The occurrence of an outrigger lifting from the ground is often
cause it to fail structurally.
attributed to natural flex in the crane’s frame. This may
Do not strike any obstruction with the boom. If the boom happen when lifting a load in certain configurations within the
should accidentally contact an object, stop immediately. capacity limits of the load capacity chart and is not
Inspect the boom. Remove the crane from service if the necessarily an indication of an unstable condition.
boom is damaged.
Provided the crane is properly set-up, as indicated within the
Never push or pull with the crane boom. accompanying documentation with the crane, is in good
working condition, and all operator’s aids are properly
Avoid sudden starts and stops when moving the load. The programmed and qualified crane operators adhere to the
inertia and an increased load radius could tip the crane over instructions and parameters of the applicable load capacity
or cause it to fail structurally.

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chart, the Operator’s and Safety Handbook, the decals on Never interfere with the proper functioning of operational
the machine, and follow established safe crane operating aids or warning devices.
practices, the subject cranes should not be unstable.
For detailed information concerning the operation and
maintenance of the load moment indicating system installed
MULTIPLE CRANE LIFTS
on the crane see the manufacturer’s manual supplied with
the crane.
Multiple crane lifts are not recommended.
Any lift that requires more that one crane must be precisely Two-Blocking
planned and coordinated by a qualified engineer. Two-blocking occurs when the load block (hook block,
If it is necessary to perform a multi-crane lift, the operator headache ball, rigging, etc.) comes into physical contact with
shall be responsible for assuring that the following minimum the boom (boom nose, sheaves, jib, etc.). Two-blocking can
cause hoist lines (wire rope) rigging, reeving, and other
safety precautions are taken.
1. Secure the services of a qualified engineer to direct the
components to become highly stressed and overloaded in 2
which case the wire rope may fail allowing the load, block,
operation. etc. to free fall.
2. Use one qualified signal person. Two-blocking is more likely to occur when both the main and
3. Coordinate lifting plans with the operator, engineer, and auxiliary hoist lines are reeved over the main boom nose and
signal person prior to beginning the lift. boom extension/jib nose respectively. An operator,
concentrating on the specific line being used, may telescope
4. Communication between all parties must be maintained or lower the boom allowing the other hoist line attachment to
throughout the entire operation. If possible, provide contact the boom or boom extension/jib nose, thus causing
approved radio equipment for voice communication damage to the sheaves, or causing the wire rope to fail,
between all parties engaged in the lift. dropping the lifting device to the ground and possibly injuring
5. Use cranes and rigging of equal capabilities and use the personnel working below.
same boom length. Caution must be used when lowering or extending the boom.
6. Use outriggers on cranes so equipped. Let out load line(s) simultaneously to prevent two-blocking
the boom tip(s) and the hook block, etc. The closer the load
7. Be certain cranes are of adequate lifting capacity. is carried to the boom nose the more important it becomes to
8. Calculate the amount of weight to be lifted by each crane simultaneously let out wire rope as the boom is lowered.
and attach slings at the correct points for proper weight Keep load handling devices a minimum of 107 cm (42 in)
distribution. below the boom nose at all times.

9. Ensure the load lines are directly over the attach points Two-blocking can be prevented. Operator awareness of the
to avoid side loading and transfer of loading from one hazards of two-blocking is the most important factor in
crane to the other. preventing this condition. An anti two-block system is
intended to assist the operator in preventing dangerous two-
10. DO NOT TRAVEL. Lift only from a stationary position. block conditions. It is not a replacement for operator
awareness and competence.
LOAD MOMENT INDICATING (LMI)
To avoid death or serious injury, keep load handling devices
SYSTEMS away from boom/jib tip when extending or lowering the boom
Electronic equipment on this crane is intended as an aid to and when hoisting up.
the operator. This crane should have a functional ANTI-TWO-BLOCK and
Under NO CONDITION should it be relied upon to replace CONTROL LOCK-OUT system. Test daily for proper
the use of capacity charts and operating instructions. Sole operation.
reliance upon these electronic aids in place of good Do not pass loads or boom over ground personnel.
operating practices can cause an accident.
Barricade the area where the crane is working and keep all
Know the weight of all loads and always check the capacity unnecessary personnel out of that area. DO NOT allow
of the crane as shown on the Load Chart before making any personnel to be under the load or boom.
lifts.
Never pass loads, load handling devices, or the crane boom
NEVER exceed the rated capacity shown on the Load Chart. over people on the ground.
Always check the Load Chart to ensure the load to be lifted
at the desired radius is within the rated capacity of the crane. Never operate the crane with less than two wraps of wire
rope on the hoist drum.

Published 3-17-2008, Control # 100-02 2-7

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Never interfere with the proper functioning of operational positive and absolute assurance that the power has been
aids or warning devices. turned off.
This machine is NOT INSULATED. Always consider all parts
ELECTROCUTION HAZARD of the load and the crane, including the wire rope, hoist
To avoid death or serious injury, keep all parts of this cable, pendant cables, and tag lines, as conductors.
machine, the rigging, and materials being lifted at least 6 m Most overhead power lines ARE NOT insulated. Treat all
(20 ft) away from all electrical power lines and equipment. overhead power lines as being energized unless you have
Keep all personnel away from this machine if it is being reliable information to the contrary from the utility company
operated near electrical power lines or equipment. or owner.

Before operating this crane in the vicinity of electrical power

lines or equipment, notify the power utility company. Obtain

The rules in this Operator’s Manual must be followed at all Even if the crane operator is not affected by an electrical
times, even if the electrical power lines or equipment have contact, others in the area may become seriously injured or
been de-energized. killed.
Crane operation is dangerous when close to an energized It is not always necessary to contact a power line or power
electrical power source. Exercise extreme caution and source to become electrocuted. Electricity, depending on
prudent judgement. Operate slowly and cautiously when in magnitude, can arc or jump to any part of the load, load line,
the vicinity of power lines. or crane boom if it comes too close to an electrical power
source. Low voltages can also be dangerous.
If the load, wire rope, crane boom, or any portion of the crane
contacts or comes too close to an electrical power source, Thoroughly read, understand, and abide by all applicable
everyone in, on, and around the crane can be seriously federal, state, and local regulations.
injured or killed.
Federal law prohibits the use of cranes closer than 3 m (10 ft)
The safest way to avoid electrocution is to stay away from to power sources up to 50,000 volts and greater distances for
electrical power lines and electrical power sources. higher voltages [29CFR1910.180 and 29CFR1926.550].
Manitowoc/Grove recommends keeping cranes twice the
You, the operator, are responsible for alerting all personnel of
minimum distance [e.g., 6 m (20 ft)] as specified by US
dangers associated with electrical power lines and
Department of Labor - Occupational Safety and Health
equipment. The crane is not insulated. Do not allow
Administration (OSHA) standards.
unnecessary personnel in the vicinity of the crane while
operating. Permit no one to lean against or touch the crane. Set-Up and Operation
Permit no one, including riggers and load handlers, to hold
the load, load lines, tag lines, or rigging gear. During crane use, assume that every line is energized (“hot”
or “live”) and take the necessary precautions.

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Set up the crane in a position such that the load, boom, or outlined in this handbook at all times even if the crane is
any part of the crane and its attachments cannot be moved to equipped with these devices.
within 6 m (20 ft) of electrical power lines or equipment. This
Insulating links installed into the load line afford limited
includes the crane boom (fully extended to maximum height,
protection from electrocution hazards. Links are limited in
radius, and length) and all attachments (jibs, boom
their lifting abilities, insulating properties, and other
extensions, rigging, loads, etc.). Overhead lines tend to blow
properties that affect their performance. Moisture, dust, dirt,
in the wind so allow for lines’ movement when determining
oils, and other contaminants can cause a link to conduct
safe operating distance.
electricity. Due to their capacity ratings, some links are not
effective for large cranes and/or high voltages/currents.
The only protection that may be afforded by an insulated link
is below the link (electrically downstream), provided the link
has been kept clean, free of contamination, has not been
scratched or damaged, and is periodically tested (just before 2
use) for its dielectric integrity.
Boom cages and boom guards afford limited protection from
electrocution hazards. They are designed to cover only the
boom nose and a small portion of the boom. Performance of
boom cages and boom guards is limited by their physical
size, insulating characteristics, and operating environment
(e.g. dust, dirt, moisture, etc.). The insulating characteristics
of these devices can be compromised if not kept clean, free
of contamination, and undamaged.
Proximity sensing and warning devices are available in
A suitable barricade should be erected to physically restrain different types. Some use boom nose (localized) sensors
the crane and all attachments (including the load) from and others use full boom length sensors. No warning may be
entering into an unsafe distance from electrical power lines given for components, cables, loads, and other attachments
or equipment. located outside of the sensing area. Much reliance is placed
Plan ahead and always plan a safe route before traveling upon you, the operator, in selecting and properly setting the
under power lines. Rider poles should be erected on each sensitivity of these devices.
side of a crossing to assure sufficient clearance is Never rely solely on a device to protect you and your fellow
maintained. workers from danger.
Appoint a reliable and qualified signal person, equipped with Some variables you must know and understand are:
a loud signal whistle or horn and voice communication
equipment, to warn the operator when any part of the crane • Proximity devices are supposed to detect the existence
or load moves near a power source. This person should of electricity and not its quantity or magnitude.
have no other duties while the crane is working. • Some proximity devices will detect only alternating
Tag lines should always be made of non-conductive current (AC) and not direct current (DC).
materials. Any tag line that is wet or dirty can conduct • Some proximity devices detect radio frequency (RF)
electricity. energy and others do not.
DO NOT store materials under power lines or close to • Most proximity devices simply provide a signal (audible,
electrical power sources. visual, or both) for the operator and this signal must not
be ignored.
Electrocution Hazard Devices
• Sometimes the sensing portion of the proximity devices
The use of insulated links, insulated boom cages/guards, becomes confused by complex or differing arrays of
proximity warning devices, or mechanical limit stops does power lines and power sources.
not assure that electrical contact will not occur. Even if codes
or regulations require the use of such devices, failure to DO NOT depend on grounding. Grounding of a crane affords
follow the rules listed here may result in serious injury or little o r no prote ction f rom e lec tric al haz ards. The
death. You should be aware that such devices have effectiveness of grounding is limited by the size of the (wire)
limitations and you should follow the rules and precautions conductor used, the condition of the ground, the magnitude
of the voltage and current present, and numerous other
factors.

Published 3-17-2008, Control # 100-02 2-9

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Electrical Contact CRUSHING HAZARDS

If the crane should come in contact with an energized power
source, you must:
1. Stay in the crane cab. DON’T PANIC.
2. Immediately warn personnel in the vicinity to stay away.
3. Attempt to move the crane away from the contacted
power source using the crane’s controls which are likely
to remain functional.
4. Stay in the crane until the power company has been
contacted and the power source has been de-energized.
NO ONE must attempt to come close to the crane or
load until the power has been turned off.
Death or serious injury could result from being crushed by
Only as a last resort should an operator attempt to leave the
moving machinery.
crane upon contacting a power source. If it is absolutely
necessary to leave the operator station, JUMP Clear all personnel from the counterweight and
COMPLETELY CLEAR OF THE CRANE. DO NOT STEP superstructure area before removing the counterweight or
OFF. Hop away with both feet together. DO NOT walk or run. rotating the superstructure.
Following any contact with an energized electrical source, Barricade the entire area where the crane is working and
the local, authorized, Grove distributor must be immediately keep all unnecessary personnel out of the work area.
advised of the incident and consulted on necessary
Never allow anyone to stand or work on or near the
inspections and repairs. Thoroughly inspect the wire rope
superstructure while the crane is in operation.
and all points of contact on the crane. Should the distributor
n o t b e i m m e d i a t e l y a v a i l a b l e , c o n ta c t M a n i t o w o c Always barricade the tail-swing of the rotating
CraneCARE. The crane must not be returned to service until superstructure.
it is thoroughly inspected for any evidence of damage and all
damaged parts are repaired or replaced as authorized by Before actuating swing or any other crane function, sound
Manitowoc CraneCARE or your local Manitowoc/Grove the horn and verify that all personnel are clear of rotating and
distributor. moving parts.
Watch the path of the boom and load when swinging. Avoid
Special Operating Conditions and lowering or swinging the boom and load into ground
Equipment personnel, equipment, or other objects.
Never operate the crane during an electrical thunderstorm. Always be aware of your working environment during
operation of the crane. Avoid contacting any part of the crane
Working in the vicinity of radio frequency transmission with external objects.
towers and other transmission sources may cause a crane to
become “electrically charged.” You must always be aware of everything around the crane
while lifting or traveling. If you are unable to clearly see in the
When operating cranes equipped with electromagnets you direction of motion, you must post a look out or signal person
must take additional precautions. Permit no one to touch the before moving the crane or making a lift. Sound the horn to
magnet or load. Alert personnel by sounding a warning warn personnel.
signal when moving a load. Do not allow the cover of the
electromagnet power supply to be open during operation or Clear all personnel from the outrigger area before extending
at any time the electrical system is activated. Shut down the or retracting the outriggers.
crane completely and open the magnet controls switch prior
Carefully follow the procedures in this handbook when
to connecting or disconnecting magnet leads. Use only a
extending or retracting the outriggers. Death or serious injury
non-conductive device when positioning a load. Lower the
could result from improper crane set up on outriggers.
magnet to the stowing area and shut off power before
leaving the operator’s cab. Be sure the outriggers are properly extended, set and the
crane is level for operation on outriggers.
All four outrigger beams must be equally extended to the mid
position vertical stripe or fully extended position before
beginning operation.

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• The crane operator shall be qualified to operate the

specific type of hoisting equipment used in the
personnel lift.
• The crane operator and occupants have been instructed
in the recognized hazards of personnel platform lifts.
• The crane is in proper working order.
• The crane is equipped with a functional anti-two block
device.
• The crane's load capacity chart is affixed inside the
crane's cab, readily accessible to the operator. The total

All four outrigger beam lock pins must be engaged before

weight of the loaded personnel platform and related
rigging shall not exceed 50 percent of the rated capacity 2
operating from the mid-extend position. for the radius and configuration of the crane.
The operator must select the proper Load Chart and LMI • The crane is uniformly level within one percent of level
program for the outrigger position selected. grade and located on a firm footing. Cranes with
outriggers shall have them all fully deployed following
Only the crane operator shall occupy the crane when
manufacturer's specifications.
traveling or in operation.
• The crane's Operator's And Safety Handbook and other
PERSONNEL HANDLING operating manuals are inside the crane's cab, readily
accessible to the operator.
The American Society of Mechanical Engineers issued a
new American National Standard entitled, Personnel Lifting • The platform meets the requirements as prescribed by
Systems, ASME B30.23-1998. This standard provides, applicable standards and regulations.
“lifting and lowering of personnel using ASME B30 Standard • For wire rope suspended platforms, the crane is
hoisting equipment shall be undertaken only in equipped with a hook that can be closed and locked,
circumstances when it is not possible to accomplish the task eliminating the throat opening.
by less hazardous means. Unless all of the applicable
requirements of this volume are met, the lifting or lowering of • The platform is properly attached and secure.
personnel using ASME B30 Standard equipment is To avoid death or serious injury:
prohibited." This new standard is consistent with the U.S.
Department of Labor, Occupational Safety and Health NEVER use this crane for bungee jumping or any form of
Administration (OSHA) regulations for Construction that amusement or sport.
state, in 29CFRI926.550(g)(2): "General requirements. The NEVER permit anyone to ride loads, hooks, slings or other
use of a crane or derrick to hoist employees on a personnel rigging for any reason.
platform is prohibited, except when the erection, use, and
dismantling of conventional means of reaching the worksite, NEVER get on or off a moving crane.
such as a personnel hoist, ladder, stairway, aerial lift, NEVER allow anyone other than the operator to be on this
elevating work platform or scaffold, would be more crane while the machine is operating or traveling.
hazardous or is not possible because of structural design or
worksite conditions." Additional requirements for crane Manitowoc CraneCARE continues to recommend that
op e ra tio ns ar e s ta te d in AS ME B3 0. 5, Mo bile An d cranes be properly maintained, regularly inspected and
Locomotive Cranes, and in OSHA regulations repaired as necessary. Manitowoc CraneCARE reminds
29CFRI910.180 for General Industry and 29CFRI926.550 crane owners to ensure that all safety decals are in place
for Construction. and legible. Manitowoc CraneCARE continues to urge Grove
crane owners to upgrade their cranes with load moment
Use of a Grove crane to handle personnel is acceptable indicator (LMI) and control lever lockout systems for all lifting
provided: operations.
• The requirements of the applicable national, state and The following standards and regulations are available by
local regulations and safety codes are met. mail at the following addresses:
• A determination has been made that use of a crane to • ASME (formerly ANSI) B30 Series American National
handle personnel is the least hazardous means to Safety Standards For Cableways, Cranes, Derricks,
perform the work. Hoists, Hooks, Jacks, And Slings; ASME B30.5, Mobile
And Locomotive Cranes, and ASME B30.23, Personnel

Published 3-17-2008, Control # 100-02 2-11

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SAFETY INFORMATION RT540E OPERATOR’S MANUAL

Lifting Systems, are available by mail from the ASME, Phone: 888-777-3378 (888-PSR-DEPT)
22 Law Drive, Fairfield, New Jersey, 0700-2900 Fax: 717-593-5102
E-mail: [email protected]
• US DOL/OSHA Rules and Regulations are available by
mail from the Superintendent of Documents, PO Box Provide a complete description of the accident, including the
371954, Pittsburgh, PA, 15250-7954. crane model and serial number.

TRAVEL OPERATION MAINTENANCE

• Strictly adhere to the guidelines and restrictions in the The crane must be inspected prior to use on each work shift.
Load Chart for pick and carry operations. The owner, user, and operator must ensure that routine
maintenance and lubrication are being dutifully performed.
• Before travel, fully retract and lower the boom into the
NEVER operate a damaged or poorly maintained crane.
boom rest and engage the turntable pin swing lock. See
SECTION 3 for Traveling with Boom Extension Erected. Keep the crane properly maintained and adjusted at all
times. Shut down the crane while making repairs or
• Secure the hook block and other items before moving
adjustments.
the crane.
Always perform a function check after repairs have been
• Follow the instructions in this handbook when preparing
made to ensure proper operation. Load tests should be
the crane highway travel.
performed when structural or lifting members are involved.
• If using for a boom dolly/trailer, thoroughly read and
Follow all applicable safety precautions in this handbook
understand all the steps and safety precautions in the
when performing crane maintenance as well as crane
handbook for setup and travel.
operations.
• Watch clearances when traveling. Do not take a chance
Before crane use:
of running into overhead or side obstructions.
• Conduct a visual inspection for cracked welds, damaged
• When moving in tight quarters, post a signal person to
components, loose pin/bolt, and wire connections. Any
help guard against collisions or bumping structures.
item or component that is found to be loose or damaged
• Never back up without the aid of a signal person to verify (broken, chipped, cracked, worn-through, etc.) must be
the area behind the crane is clear of obstructions and/or repaired or replaced.
personnel.
• Check for proper functioning of all controls and operator
• Check load limit of bridges. Before traveling across aids (e.g. LMI).
bridges, ensure they will carry a load greater than the
• Check all braking (e.g. wheel, hoist, and swing brakes)
crane’s weight.
and holding devices before operation.
• Always drive the crane carefully, obeying speed limits
Keep the crane clean at all times, free of mud, dirt, and
and highway regulations.
grease. Dirty equipment introduces hazards, wears-out
• Keep lights on, use traffic warning flags and signs, and faster, and makes proper maintenance difficult. Cleaning
use front and rear flag vehicles when necessary. Check solutions used should be non-flammable, non-toxic and
state and local restrictions and regulations. appropriate for the job.
• When parking on a grade, apply the parking brake and ROUTINE MAINTENANCE and INSPECTION of this crane
chock the wheels. must be performed by a qualified person(s) according to the
recommendations in the Grove Maintenance and Inspection
ACCIDENTS Manual. Any questions regarding procedures and
specifications should be directed to the your local,
If this crane becomes involved in a property damage and/or authorized Grove Distributor.
personal injury accident, immediately contact your local
Manitowoc/Grove distributor. If the distributor is unknown Service and Repair
and/or cannot be reached, contact Product Safety and
Reliability at: Service and repairs to the crane must only be performed by a
qualified person. All service and repairs must be performed
Manitowoc Crane Group in accordance with manufacturer’s recommendations, this
1565 East Buchanan Trail handbook, and the service manual for this machine. All
Shady Grove, PA 17256-0021 replacement parts must be approved by Manitowoc
CraneCARE.

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Any modification, alteration, or change to a crane which Ensure pneumatic tires are inflated to the proper pressure
affects its original design and is not authorized and approved (refer to the Load Chart Book in the crane cab). When
by Manitowoc CraneCare is STRICTLY PROHIBITED. Such inflating tires, use a tire gauge, clip-on inflator, and extension
action invalidates all warranties and makes the owner/user hose which will permit standing clear of the tire while
liable for any resultant accidents. inflating.
Before performing any maintenance, service or repairs on Wire Rope
the crane:
U s e O N LY t h e w i r e r o p e s p e c i f i e d b y M a n i t o w o c
• The boom should be fully retracted and lowered and the
CraneCARE as indicated on the crane’s load capacity chart.
load placed on the ground.
Substitution of an alternate wire rope may require the use of
• Stop the engine and disconnect the battery. a different permissible line pull and, therefore, require
different reeving.
• Controls should be properly tagged. Never operate the
crane if it is TAGGED-OUT nor attempt to do so until it is NOTE: Wire rope may be purchased by contacting the 2
restored to proper operating condition and all tags have Manitowoc CraneCARE Parts Department.
been removed by the person(s) who installed them.
Always make daily inspections of the wire rope, keeping in
Recognize and avoid pinch-points while performing mind that all wire rope will eventually deteriorate to a point
maintenance. Stay clear of sheave wheels and holes in where it is no longer usable. Wire rope shall be taken out of
crane booms. service when any of the following conditions exist:
After maintenance or repairs: 1. For rotation-resistant running ropes-more than two (2)
broken wires in a length of rope equal to six (6) times the
• Replace all guards and covers that have been removed.
rope diameter, or more than four (4) broken wires in a
• Remove all tags, connect the battery, and perform a length of rope equal to thirty (30) times the rope
function check of all operating controls. diameter.
• Perform load tests when a structural or lifting member is 2. For running ropes other than rotation resistant-six (6)
involved in a repair. broken wires in one rope lay or three (3) broken wires in
one strand.
Lubrication 3. One valley break where the wire fractures between
The crane must be lubricated according to the factory strands in a running rope is cause for removal.
recommendations for lubrication points, time intervals, and
4. Abrasion of the rope resulting in wear of the individual
types. Lubricate at more frequent intervals when working
outside wires of 1/3 of the original wire diameter.
under severe conditions.
5. Any kinking, bird caging, crushing, corrosion, or other
Exercise care when servicing the hydraulic system of the
damage resulting in distortion of the rope structure.
crane, as pressurized hydraulic oil can cause serious injury.
The following precautions must be taken when servicing the 6. Rope that has been in contact with a live power line or
hydraulic system: has been used as a ground in an electric circuit (e. g.
welding) may have wires that are fused or annealed and
1. Follow the manufacturer’s recommendations when
must be removed from service.
adding oil to the system. Mixing the wrong fluids could
destroy seals, causing machine failure. 7. In standing ropes, more than three (3) breaks in one
rope lay in sections beyond the end connection or more
2. Be certain all lines, components, and fittings are tight
than two (2) broken wires at an end connection.
before resuming operation.
8. Core deterioration is usually observed as a rapid
3. When checking for suspected leaks, use a piece of
reduction in rope diameter and is cause for immediate
wood or cardboard and wear appropriate personal
removal of the rope.
protective equipment.
Refuse to work with worn or damaged wire rope.
4. Never exceed the manufacturer’s recommended relief
valve settings. When installing and inspecting wire ropes and attachments,
keep all parts of your body and clothing away from rotating
Tires hoist drums and all rotating sheaves.
Inspect the tires for nicks, cuts, embedded material, and Never handle the wire rope with bare hands.
abnormal wear.
Periodic rope inspection records are required by law. Make
Ensure all lug nuts are properly torqued. sure these records have been reviewed and are up to date.

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When installing a new rope: BATTERIES

• Follow proper instructions for removing rope from a reel. Battery electrolyte must not be allowed to contact the skin or
• Apply back tension to the storage/payoff reel of the new eyes. If this occurs, flush the contacted area with water and
rope to insure tight, even spooling onto the hoist drum. consult a doctor immediately.

• Operate the new rope - first through several cycles at When checking and maintaining batteries exercise the
light load and then through several cycles at following procedures and precautions:
intermediate load to allow the rope to adjust to operating • Disconnect the batteries.
conditions.
• Wear safety glasses when servicing batteries.
When using a wedge socket:
• Do not short across the battery posts to check charge.
• Always inspect socket, wedge, and pin for correct size Short circuit, spark, or flame could cause battery
and condition. explosion.
• Do not use parts that are damaged, cracked, or • Maintain battery electrolyte at the proper level. Check
modified. the electrolyte with a flashlight.
• Assemble the wedge socket with live end of rope aligned • If applicable to your crane, check battery test indicator
with the centerline of pin and assure proper length of tail on maintenance-free batteries.
(dead end) protrudes beyond the socket.
• Do not break a live circuit at the battery terminal.
Never overload or shock load a wire rope. Lubricate the wire Disconnect the ground battery cable first when removing
rope periodically as the lubricant becomes depleted. a battery and connect it last when installing a battery.
• Check battery condition only with proper test equipment.
Batteries shall not be charged except in an open, well-
ventilated area that is free of flame, smoking, sparks,
and fire.

ENGINE
Be careful when checking the engine coolant level. The fluid
may be hot and under pressure. Shut down the engine and
allow the radiator time to cool before removing the radiator
cap.

Inspect the boom nose and hook block sheaves for wear. Shut down the engine and disconnect the battery before
Damaged sheaves cause rapid deterioration of wire rope. performing maintenance. If unable to do so for the task
required, keep hands clear of the engine fan and other
To attain maximum wire rope life and minimize hook block moving parts while performing maintenance.
rotation, it is recommended that even numbers of parts-of-
line be used in multiple-part reeving whenever possible. Be careful of hot surfaces and hot fluids when performing
maintenance on or around the engine.
If applicable to your crane, the use of nylon (nylatron)
sheaves, as compared with metallic sheaves, may change WORK PRACTICES
the replacement criteria of rotation- resistant wire rope.
NOTE: If applicable to your crane, the use of cast nylon Crane Access
(nylatron) sheaves, as compared with steel You must take every precaution to ensure you do not slip
sheaves, will substantially increase the service life and/or fall off the crane. Falling from any elevation could
o f w i 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 result in serious injury or death.
retirement criteria based only upon visible wire
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.
Do not step on surfaces on the crane that are not approved
or suitable for walking and working. All walking and working

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RT540E OPERATOR’S MANUAL SAFETY INFORMATION

surfaces on the crane should be clean, dry, slip-resistant, Working

and have adequate supporting capacity. Do not walk on a
surface if slip-resistant material is missing or excessively Never operate the crane when darkness, fog, or other
worn. visibility restrictions make operation unsafe. Never operate a
crane in thunderstorms or high winds.
Do not use the top of the boom as a walkway.
Keep unauthorized personnel clear of the working area
Do not step on the outrigger beams or outrigger pads (floats) during operation.
to enter or exit the crane.
Operate the crane only from the operator’s seat. Do not
Wear shoes with a highly slip-resistant sole material. Clean reach in a window or door to operate any controls.
any mud or debris from shoes before entering the crane cab
or climbing onto the crane superstructure. Excessive dirt and Operate the crane slowly and cautiously, looking carefully in
debris on the hand-holds, access steps, or walking/working the direction of movement.
surfaces could cause a slipping accident. A shoe that is not
clean might slip off a control pedal during operation.
“Stunt” driving and “horse-play” are strictly prohibited. Never
allow anyone to hitch a ride or get on or off a moving crane.
2
Do not make modifications or additions to the crane’s access A good practice is to make a “dry run” without a load before
system that have not been evaluated and approved by making the first lift. Become familiar with all factors peculiar
Manitowoc CraneCARE. to the job site.

Job Preparation Ensure the wire rope is properly routed on the hook block
and boom nose and that all rope guards are in place.
You must inspect the crane prior to your work shift - checking
for cracked welds, damaged components, and evidence of USE ENOUGH PARTS OF LINE FOR ALL LIFTS AND
improper maintenance (consult Maintenance-Inspection and CHECK ALL LINES, SLINGS, AND CHAINS FOR
Service Manual). CORRECT ATTACHMENT. To obtain maximum lifting
capacities, the hook block must be set up with enough parts
You must ensure that the crane is properly equipped of line. NO LESS THAN TWO WRAPS of wire rope should
including access steps, covers, doors, guards, and controls. remain on the hoist drum. When slings, ties, hooks, etc., are
You must ensure that the outriggers are properly extended used, make certain they are correctly positioned and
and set before performing any lifting operations. On models secured before raising or lowering the loads.
equipped with outriggers that can be pinned at the mid- Be sure the rigging is adequate before lifting. Use tag lines
extend position, the outriggers must also be pinned when when possible to position and restrain loads. Personnel
operating from the mid-extend position. using tag lines should be on the ground.
Wear appropriate clothing and personal protective Be sure good rigging practices are being used. Refuse to
e qu i p m e nt w h e t h er o r n o t r e q u i r e d b y l o c a l o r j o b use any poorly maintained or damaged equipment. Never
regulations. Be prepared for the work day. wrap the hoist cable around a load.
Before entering the cab, you must be THOROUGHLY
familiar with the planned route of travel and area of Lifting
operation, including surface conditions and the presence of Operate the crane at or near governed RPM during all lifting
overhead obstructions and power lines. operations.
Always keep the crane clean, free of dirt, debris, and grease. Check the hoist brake by raising the load a few inches,
Fuel the crane ONLY with the engine turned off. Do not stopping the hoist and holding the load. Be sure the hoist
smoke while fueling the crane. Do not store flammable brake is working correctly before continuing the lift.
materials on the crane or in the operator’s cab. When lowering a load always slow down the load’s descent
Follow standard safety precautions when refueling. FUEL IT before stopping the hoist. Do not attempt to change speeds
SAFELY. on multiple-speed hoists while the hoist is in motion.

Be familiar with the location and use of the nearest fire LIFT ONE LOAD AT 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.

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SAFETY INFORMATION RT540E OPERATOR’S MANUAL

Keep everyone away from suspended loads. Allow no one to

walk under a load. Ensure that all slings, ties, and hooks are
correctly placed and secured before raising or lowering the
load.
Use tag lines (as appropriate) for positioning and restraining
loads. Check the load slings before lifting.
Be sure everyone is clear of the crane and work area before
making any lifts.
Never swing over personnel, regardless of whether load is
suspended from or attached to the boom.
Be sure the load is well secured and attached to the hook
with rigging of proper size and in good condition.
Use only slings or other rigging devices rated for the job and
use them properly. Never wrap the hoist cable around a load.
Check all tackle, hardware, and slings before use. Refuse to
use faulty equipment.
Never work the crane when darkness, fog, or other visibility
restrictions make such operations unsafe.

Hand Signals
A qualified signal person shall be used at all times when:
Never leave the crane with a load suspended. Should it • Working in the vicinity of power lines.
become necessary to leave the crane, lower the load to the
• The crane operator cannot clearly see the load at all
ground and stop the engine before leaving the cab.
times.
Remember - all rigging equipment must be considered as
• Moving the crane in an area or direction in which the
part of the load. Lifting capacities vary with working areas.
operator cannot clearly see the path of travel.
Permissible working areas are posted in the crane cab.
When swinging from one working area to another, ensure At all times use standardized hand signals - previously
load chart capacities are not exceeded. Know your crane! agreed upon and completely understood by the operator and
signal person.
Never swing or lower the boom into the carrier cab.
If communication with the signal person is lost, crane
Stop the hook block from swinging when unhooking a load.
movement must be stopped until communications are
Swinging rapidly can cause the load to swing out and restored.
increase the load radius. Swing the load slowly. Swing with
Keep your attention focused on the crane’s operation. If for
caution and keep the load lines vertical.
some reason you must look in another direction, stop all
Look before swinging your crane. Even though the original crane movement first.
setup may have been checked, situations do change.

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RT540E OPERATOR’S MANUAL SAFETY INFORMATION

• Engage the parking brake.

• Fully retract and lower the boom.
• Engage the pin swing lock or 360 degree swing lock.
• Place controls in neutral position.
• Shut down the engine and remove the ignition key.
• Chock the wheels.
• Lock the operator’s cab and install vandal guards, if
used.
In cold weather, never park the crane where the tires can
become frozen to the ground. 2
BOOM EXTENSION/JIB

When vision is obscured, use and follow the directions of a

single qualified signal person.
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 To avoid death or serious injury, follow proper procedures
vehicle. during erection, stowage, and use of the boom extension/jib.

If it is necessary to take the crane on a road or highway, first Install and secure all pins properly.
check state and local restrictions and regulations. Control movement of boom extension/jib at all times.
Check load limits of bridges on the travel route and ensure Do not remove right side boom nose pins unless boom
they are greater than the combined weight of the crane and extension is properly pinned and secured on front and/or
transporting vehicle. rear stowage brackets.
Always drive the crane carefully, obeying speed limits and Do not remove all the pins from both front and rear stowage
highway regulations. Keep lights on and use traffic warning brackets unless the boom extension is pinned to the right
flags and signs and front and rear flag vehicles as applicable. side of the boom nose.
See the appropriate section of this handbook for the proper
SHUT-DOWN
boom extension/jib erection and stowage procedure.
Never leave the crane with a load suspended. Lower the
Properly inspect, maintain, and adjust boom extension/jib
load to the ground before shutting down the crane.
and mounting.
Use the following steps when shutting down the crane:
Sling jib sections from the main chords or the end fittings.

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SAFETY INFORMATION RT540E OPERATOR’S MANUAL

When assembling and disassembling jib sections, use The change in the length of a cylinder is proportional to the
blocking to adequately support each section and to provide extended length of the cylinder and to the change in
proper alignment. temperature of the oil in the cylinder. For example, a cylinder
extended 25 feet in which the oil cools 60°F would retract
Stay outside of jib sections and lattice work.
approximately 7 3/4 inches (see chart below). A cylinder
Watch for falling or flying pins when they are being removed. extended 5 feet in which the oil cools 60°F would only retract
approximately 1 1/2 inches. The rate at which the oil cools
COLD WEATHER OPERATION depends on many factors and will be more noticeable with a
larger difference in oil temperature verses the ambient
Cold weather operation requires additional caution on the temperature.
part of the operator.
Thermal contraction coupled with improper lubrication or
Check operating procedures for cold weather starting. improper wear pad adjustments may, under certain
During cold weather operation, it is recommended that a cold conditions, cause a “stick-slip” condition in the boom. This
engine be started from the carrier cab with the pump “stick-slip” condition could result in the load not moving
disconnected. smoothly. Proper boom lubrication and wear pad adjustment
Don’t touch metal surfaces that could freeze you to them. is important to permit the boom sections to slide freely. Slow
movement, of the boom may be undetected by the operator
Clean the crane of all ice and snow. unless a load is suspended for a long period of time.
Allow ample time for hydraulic oil to warm up. If a load and the boom is allowed to remain stationary for a
In freezing weather, park the crane in an area where it period of time and the ambient temperature is cooler than the
cannot become frozen to the ground. The drive line can be trapped oil temperature, the trapped oil in the cylinders will
damaged when attempting to free a frozen crane. cool. The load will lower as the telescope cylinder(s) retracts
allowing the boom to come in. Also, the boom angle will
If applicable to your crane, frequently check all air tanks for decrease as the lift cylinder(s) retracts causing an increase
water in freezing weather. in radius and a decrease in load height.
If applicable to your crane, always handle propane tanks This situation will also occur in reverse. If a crane is set up in
according to the supplier’s instructions. the morning with cool oil and the daytime ambient
temperature heats the oil, the cylinders will extend in similar
Never store flammable materials on the crane.
proportions.
If cold weather starting aids are provided on your crane, use
Figure 2-2 has been prepared to assist you in determining
them. The use of aerosol spray or other types of starting
the approximate amount of retraction/extension that may be
fluids containing ether/volatiles can cause explosions or fire.
expected from a hydraulic cylinder as a result of change in
the temperature of the hydraulic oil inside the cylinder. The
TEMPERATURE EFFECTS ON HYDRAULIC chart is for dry rod cylinders. If the cylinder rod is filled with
CYLINDERS hydraulic oil, the contraction rate is somewhat greater.
Hydraulic oil expands when heated and contracts when NOTE: Operators and service personnel must be aware
cooled. This is a natural phenomena that happens to all that load movement, as a result of this phenomena,
liquids. The coefficient of expansion for API Group 1 can be easily mistaken as leaking cylinder seals or
hydraulic oil is approximately 0.00043 cubic inches per cubic faulty holding valves. If leaking seals or faulty
inch of volume for 1°F of temperature change. Thermal holding valves are suspected to be the problem,
contraction will allow a cylinder to retract as the refer to Service Bulletin 98-036 dealing with testing
hydraulic fluid which is trapped in the cylinder cools. telescope cylinders

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

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RT540E OPERATOR’S MANUAL SAFETY INFORMATION

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
45
2.06
2.32
4.13
4.64
6.19
6.97
8.26
9.29
10.32
11.61
12.38
13.93
14.45
16.25
16.51
18.58
18.58
20.90
20.64
23.22
2
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

Published 3-17-2008, Control # 100-02 2-19

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