Chapter 1 Safety and Operation

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1 Chapter 1 Safety and Operation General The importance of safe operation cannot be over emphasized. Carelessness and neglect on the part of operators, job supervisors and planners, rigging personnel, and job site personnel can result in their death or injury and costly damage to the crane or property. The safety information in this section is intended only as a guide to assist the qualified operator in safe operation. Manitowoc Boom Trucks cannot foresee all hazards that will arise in the field; therefore, safety remains the responsibil- ity of the crane owner/user. Always refer to ANSI/ASME B30.5 for complete safety and operation regulations. The subjects and material presented here are highlights of ANSI/ASME B30.5 and are intended as general information only. Local, state, and other governmental agencies may require stricter operating practices. When a conflict in exists, follow the strictest requirements. Failing to comply with safe operating practices and safety messages in this section may result in death or serious injury to operator and job site personnel and destruction of this crane. Read and understand instructions in this chapter and in Capacity Chart on each side of pedestal before attempting to operate this crane. Note This crane has two control stations. Operate the crane from the station that provides the best view of the load and wrk area. The terms RIGHT, LEFT, FORWARD, and BACK refer to the operator's right, left, front and rear when facing the controls at either control station. Safe Operating Practices Operation Near Electric Power Lines Operation of this crane near electric power lines shall be accordance with the following requirements: For power lines rated at 50,000 volts or less, the minimum clearance between the power lines and any part of the crane or load shall be 10 feet. For power lines rated over 50,000 volts, the minimum clearance between the power lines and any part of the crane or load shall be 10 feet plus 0.4 inch for every 1,000 volts over 50,000 volts, or use twice the length of the line insulator but never less than 10 feet. While in transit with no load and the boom lowered onto the boom rest, the clearance shall be a minimum of 4 feet. Any overhead wire shall be considered to be an energized power line unless and until the person owning the wire or the electrical utility authorities indicate that the wire is not an energized power line. Before starting crane operations near electric power lines, the person responsible for the job shall notify the owner of the lines or his authorized representative providing them with all pertinent information and requesting their cooperation. For all operations where it is difficult for the operator to maintain the required clearance by visual means, a qualified signal person shall be provided. The signal person shall observe the clearance and give the operator timely warnings so as to maintain the minimum clearance. Avoid electrocution! if any part of the crane or the load contacts an energized electric power line, the operator shall not attempt to get off the crane. The operator shall remain at the controls until the contact has been cleared or the power line has been de-energized. Do not let anyone on the ground touch the crane. The above requirements shall be adhered to even if the crane is equipped with cage-type boom guards, insulating links, or proximity warning devices. Note The only exceptions to the above requirements are: 1.The power lines have been de-energized and physically grounded at the point of work. 2.Insulating barriers have been erected to prevent physical contact of any part of the crane or load with the power lines. The insulating barriers shall not be a part of or attachment of the crane. C-Series Operator Manual 1-1

2 Signals Signals to the operator shall be in accordance with the standard signals shown on the following pages unless communications equipment (telephone, radio, etc.) is used. All signals shall be easily understood by the operator at all times. The operator shall not respond to any signals which are not clearly understood. For operations not covered in standard signals illustrations, or for special situations, additional signals may be required. In those cases, the signals used shall be agreed upon in advance by the operator and the signal person. The signals used should not conflict with or have the potential to be confused with the standard signals. If it is necessary to give other than the standard signals to the operator, all crane motions shall be stopped. The signal person shall: Be qualified by experience with the operations and knowledgeable of the standard signals. Position himself in clear view of the operator. The signal person's position shall give him a clear view of the load, the crane, and the operating area. Direct the load so the load does not pass over personnel. Keep unnecessary personnel out of the crane's operating area. 1-2 C-Series Operator Manual

3 HOIST. With forearm vertical, forefinger pointing up, move hand in small horizontal circles. LOWER. With arm extended downward, forefinger pointing down, move hand in small horizontal circles. USE MAIN HOIST. Tap fist on head; then use regular signals. USE WHIPLINE. (Auxiliary Hoist.) Tap elbow with one hand; then use regular signals. RAISE BOOM. Arm extended, fingers closed, thumb pointing upward. LOWER BOOM. Arm extended, fingers closed, thumb pointing downward. MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist slowly shown as an example.) RAISE BOOM & LOWER LOAD. With arm extended, thumb pointing up, flex fingers in and out as long as load movement is desired. LOWER BOOM & RAISE LOAD. With arm extended, thumb pointing down, flex fingers in and out as long as load movement is desired. SWING. Arm extended point with finger in direction of swing of boom. STOP. Arm extended, palm down, move arm back and forth horizontally. EMERGENCY STOP. Both arms extended, palms down, move arms back and forth horizontally. TRAVEL. Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel. DOG EVERYTHING. Clasp hand in front of body. TRAVEL. (Both Tracks.) Use both fists in front of body, making a circular motion about each other, indicating direction of travel; forward or backward. TRAVEL. (One Track.) Lock the track on side indicated by raised fist. Travel EXTEND BOOM. opposite track in direction (Telescoping Booms.) indicated by circular Both fists in front of body motion of other fist, with thumbs pointing outward. rotated vertically in front of body. RETRACT BOOM. (Telescoping Boom.) Both fists in front of body with thumbs pointing toward each other. EXTEND BOOM. (Telescoping Boom.) One Hand Signal. One fist in front of chest with thumb tapping chest. RETRACT BOOM. (Telescoping Boom.) One hand signal. One fist in front of chest, thumb pointing outward and heel of fist tapping chest. Figure 1-1 Hand Signals C-Series Operator Manual 1-3

4 Preparing for Road Travel The following steps shall be taken before the truck is traveled after crane operations: The jib shall be stored, If equipped. The boom shall be lowered onto the boom rest before the outriggers and stabilizers are retracted. The load block or the overhaul ball shall be secured to the rear of the subframe. The tires shall be inflated to the proper pressure. The outriggers and stabilizers shall be fully retracted. Important Always retract front bumper stabilizer before retracting outriggers or rear stabilizers. The PTO shall be disengaged. All loose items shall be secured to the flatbed. The total weight of the truck, the crane, and any load carried on the flatbed shall not exceed the allowable gross vehicle weight. 1-4 C-Series Operator Manual

5 Crane Operating Controls 1. Power Take-Off (PTO) Control 2. Boom Hoist Control 3. Winch Control 3a. Speed-Lift Control 4. Telescope Control 5. Swing Control 6. Hydraulic Accessory Valve Control 7. Hydraulic System Pressure Gauge 8. Bubble Level 9. Horn Switch 10. Engine Start/Stop 11. Foot Throttle 12. Boom Angle Indicator 13. Load Moment Indicator (LMI) Display 14. Warning Horn 15. Anti-Two-block Shutdown (Not Shown) 16. Overload Shutdown (Not Shown) 17. Boom Bypass Switch 18. Hydraulic Capacity Alert System (HYCAS) (Not Shown) Figure 1-2 Typical Crane Operating Controls 1 Manual PTO Control & Light 1 11 Air PTO Control and Light Figure 1-3 View in Truck Cab Figure 1-4 View Both Platforms Figure 1-5 View Both Sides of Boom Figure 1-6 Load Moment Indicator Display (LMI) Figure 1-7 View Inside Pedestal C-Series Operator Manual 1-5

6 Controls and Functions Control and Position (Figures 1-5 through 1-9) Function 1. Power Take-Off (PTO) Control Operation of the PTO will vary; refer to the manufacturer s manual in the truck cab for operating instructions. Important Do not drive truck while PTO is engaged; hydraulic pump may be damaged. 2. Boom Hoist Control 3. Winch Control 3a. Speed-Lift Control Button DOWN 4. Telescope Control DOWN (lower boom). UP (raise boom). OFF (counterbalance valve holds boom in position). Important Return control lever to OFF as soon as boom is fully raised or fully lowered, otherwise, oil will flow over relief valve possibly causing damage to hydraulic system from overheating. DOWN (lower load). UP (raise load). OFF (spring-applied brake holds load in position). HIGH SPEED winch operation. Note When Speed-Lift is activated, the excess oil from the main control valve is diverted to the winch valve, and winch speed increases. Speed-Lift will not operate if system pressure exceeds 2,500 psi or if another function is being operated at full speed. OUT (extend boom sections). IN (retract boom sections). OFF (counterbalance valve holds boom sections in position. Important Return control lever to OFF as soon as boom is fully extended or fully retracted; otherwise, oil will flow over relief valve, possibly causing damage to hydraulic system from overheating. Note Due to variations in loading, boom angle and slider pad friction, the maximum load which can be telescoped cannot be specified. It is safe, however, to attempt to telescope the boom within the limits of the Capacity Chart. 1-6 C-Series Operator Manual

7 Controls and Functions Control and Position (Figures 1-5 through 1-9) 5. Swing Control 372º Uninterrupted Swing Function Swing LEFT (counterclockwise). Swing RIGHT (clockwise). OFF (spring-applied brake holds boom in position). Note This crane has 372º uninterrupted swing in both directions. When the boom swings 372º a mechanical swing stop will automatically pull the swing control lever OFF and the swing brake will apply to stop the swing motion. C L Truck C L Rotation 12º Important Do not disable swing stop. If boom swings more than 372º hydraulic lines will break. Always move swing control lever gradually toward OFF to bring boom to a smooth stop. If swing control lever is suddenly released to OFF, swing brake will bring boom to an abrupt stop. This action will cause load to swing out from under boom point or jib point, possibly resulting in damage to boom or jib from side loading. Figure 1-8 Swing Limit 6. Hydraulic Accessory Valve Control (If Equipped) HI Pressure to Port B of accessory valve. HI Pressure to Port A of accessory valve. Control valve blocks flow to work Ports A and B. 7. Hydraulic System Pressure Gauge Indicates the pressure (0-2,800 psi) in the circuit operating under the most load. 8. Bubble Level Indicates how level the crane is from side to side and from front to rear. 9. Horn Switch Button IN 10. Engine Start/Stop Switch Toggle LEFT (Momentary) Toggle RIGHT (Momentary) Signal horn ON. START engine. STOP engine Always stop engine before leaving crane unattended and before servicing crane. 11. Engine Foot Throttle Pedal DOWN Pedal UP (spring returned) INCREASE engine speed in relation to how far the pedal is depressed. DECREASE engine speed. Note The speed of any crane function depends on engine speed and on how far the control lever is moved in either direction. C-Series Operator Manual 1-7

8 Controls and Functions Control and Position (Figures 1-5 through 1-9) 12. Boom Angle Indicator Main Boom Only Main Boom with Jib Erected 13. Load Moment Indicator (LMI) Control/Display 14. Warning Horn Anti-Two-Block, Overload Warning and Outrigger/Stabilizer (Not Shown) Function Indicates the angle of the boom (in degrees) above or below horizontal. Loaded boom angles at specified boom lengths give only an approximation of the operating radius. The boom angle before loading should be greater to account for deflections. Do not exceed the operating radius for rated loads. The operating radius shown in the jib rating chart is for fully extended boom only. When boom is not fully extended, use only loaded boom angle to determine load rating of jib. For function, controls and display information, refer to LMI Handbook provided with crane. The horn BEEPS to warn the operator and surrounding personnel when any of the following conditions occur. The load block or the overhaul ball is hoisted too high (against two-block weight on load line). Important Always pay out load line while extending boom to prevent load block or overhaul ball from contacting two-block weight. Do not hoist load so high that load block or overhaul ball contacts two-block weight. The crane outriggers and/or stabilizers are being operated. Note Warning horn will stop sounding when the outrigger and stabilizer set-up is completed. If warning horn comes on due to overload, immediately correct overload condition; failing to do so may result in structural damage or tipping. Do not rely on warning horn to alert operator to an overload condition when jib is being used. Jib's capacity can be exceeded before warning horn comes on. To correct a two-block condition Lower the load or retract the boom. To correct an overload condition Lower the load to the ground, retract the boom, or raise the boom 15. Anti-Two Block Shutdown (Not Shown) Automatically STOPS and prevents further operation of the WINCH UP and TELESCOPE OUT and BOOM DOWN functions when warning horn comes on. Important Always pay out load line while extending boom to prevent load block or overhaul ball from contacting two-block weight. Do not hoist load so high that load block or overhaul ball contacts two-block weight. 1-8 C-Series Operator Manual

9 Controls and Functions Control and Position (Figures 1-5 through 1-9) Function 16. Overload Shutdown (Not Shown) The overload shutdown automatically stops and prevents further operation of the WINCH UP, TELESCOPE OUT, and BOOM DOWN functions when warning horn comes on. If warning horn comes on due to overload, immediately correct overload condition; failing to do so may result in structural damage or tipping. Do not rely on warning horn to alert operator to an overload condition when jib is being used. Jib's capacity can be exceeded before warning horn comes on. 17. Boom Down Bypass Switch (Not Shown) Button IN 18. Hydraulic Capacity Alert System (HYCAS) (Not Shown) Not used with cranes equipped with LMI units. This switch is used to bypass the overload shutdown system so the boom can be lowered from the maximum boom angle (80 ). Button located on electrical enclosure inside the crane pedestal. Hold the button in and lower the boom. Once the boom has lowered a few degrees, the warning horn should shutoff. Release the button and continue to lower the boom to the desired angle. Bypass switch to be used only for lowering boom from maximum angle. Do not use for any other reason. Bypass switch must be in its normal position (OUT) during operation; otherwise, overload shutdown system will not work properly, and crane's capacity may be exceeded. Hydraulic monitoring system provides an audible warning when the crane's rated capacity is exceeded. The system will disable Winch Up, Telescope Out and Boom Down crane functions until the overload condition has been corrected. The HYCAS system is designed to monitor Main Boom operation only. Do not rely on shutdown feature or warning horn to alert operator to an overload condition when the jib is being used. The jib's capacity can be exceeded before the shutdown feature or warning horn is activated. C-Series Operator Manual 1-9

10 Setting Outriggers and Stabilizers Outrigger Operation and Warnings Avoid injury to personnel or damage to crane and property by adhering to the following safety precautions when operating outriggers and stabilizers. Warn all personnel to stand clear of outriggers and stabilizers before operating them. Operator do not place hands and arms between outriggers and platform back guard. Set outrigger and stabilizer pads on flat, firm foundation that will support load placed on pads. Do not set pads in holes, on rocky ground, or on extremely soft ground. Use wood blocking or steel plates under pads, if necessary, to properly distribute loading on foundation. Fully retract outriggers and stabilizers before traveling in the truck. Return control levers to OFF as soon as outriggers or stabilizers are fully extended or fully retracted, otherwise, oil will flow over relief valve, possibly causing damage to hydraulic system from overheating. Crane operations with outriggers or stabilizers jack cylinders retracted is prohibited. Cranes with Link type Outriggers (full spread only) To level the crane Step 1 First, extend the outriggers to level the crane from side to side Step 2 (A-frame Stabiizers) Then, extend the stabilizers to level from the crane from front to rear. Step 2 (Out -Down Stabiizers) a.) Fully extend the stailizer beams. b.) Then, extend the stabilizer jack cylinders to level the crane from front to rear. Important Do not operate crane with stabilizers beams partially extended. Crane operations with outriggers retracted is prohibited. Step 3 Finally, extend the front bumper stabilizer, if equipped, until oil flows over the relief valve. At this point, the stabilizer will stop extending, ensuring the stabilizer is properly loaded C-Series Operator Manual

11 Cranes with Out-Down Outriggers (multiple spread settings) Each outrigger extension setting has its own Load Chart and Range Diagram. Use only the Load Chart and Range Diagram specified for your crane and outrigger settings. All outriggers must be identically set to the same extension. Attempting to use different beam extensions can result in equipment damage, personal injury, and injuries to others. Note Ensure that the outrigger pin is in the correct position for the desired outrigger spread configuration before extending the outrigger or stabilizer beams. Refer to the following pages for illustrations of the various C- series outrigger configurations and controls. Full and Retracted Settings Ensure the Outrigger/Stabilizer Pin for each outrigger is in the stowed position with the pin resting in the upper part of the slot as shown in Figure 1-11 or Intermediate Extension Double-stage Outriggers pins will engage when fully retracted without extending. Lower the Outrigger Pin to the lower position in the slot as shown in Figure 1-11 or Single-Stage Stabilizers With the stabilizers retracted, lift the stabilizer pin, rotate and drop into long slot until pin stops against inner box top plate. Extend inner beams slowly until pin drops into hole in each beam. To level the crane Step 1 Extend the outrigger beams to the desired spread position. Step 2 Then, extend the outrigger jack cylinders to level the crane from side to side. Step 3 Next, extend the stabilizer beams to the desired spread position. Step 4 Then, extend the outrigger jack cylinders to level the crane from front to rear. Step 5 Finally, extend the front bumper stabilizer until oil flows over the relief valve. At this point, the stabilizer will stop extending, ensuring the stabilizer is properly loaded. C-Series Operator Manual 1-11

12 Figure 1-9 Conventional Link Type Outriggers and A-frame Stabilizers Typically both sets are fully extended to lift the truck off the ground and adjusted to ensure crane is level in all directions. Controls and Functions - Link Type Outrigger and A-Frame Stabilizer Control and Position 1. This Side Outrigger 2. Other Side Outrigger 3. This Side Stabilizer 4. Other Side Stabilizer 5. Front Bumper Stabilizer (Optional) Function Note THIS SIDE refers to the side of the truck that is nearest the operator when standing at either control station. OTHER SIDE refers to the opposite side of the truck. DOWN (extend outrigger or stabilizer to raise truck). UP (retract outrigger or stabilizer to lower truck). OFF (valves hold outriggers and stabilizers in position) C-Series Operator Manual

13 Jack Cylinder Figure 1-10 Conventional Link Type Outriggers and Out-Down Stabilizers Typically both sets are fully extended to lift the truck off the ground and adjusted to ensure crane is level in all directions. Stabilizer Beams Both beams on stabilizers must be fully extended before jack cylinders are extended to level the crane. Controls and Functions - Link Type Outrigger and Out-Down Stabilizer Control and Position 1. Stabilizer Select Switch Toggle CENTERED (spring returned) Toggle held LEFT Toggle held RIGHT 2. This Side Outrigger 3. Other Side Outrigger 4. Stabilizer Up-Down 5. Stabilizer In-Out Function The position of this switch selects which cylinder operates (Left, Right or Both) when operating stabilizer controls. BOTH sides operate in conjunction with stabilizer controls 4-5. Only LEFT cylinders operate in conjunction with stabilizer controls 4-5. Only RIGHT cylinders operate in conjunction with stabilizer controls 4-5. Note THIS SIDE refers to the side of the truck that is nearest the operator when standing at either control station. OTHER SIDE refers to the opposite side of the truck. DOWN (extend outrigger to raise truck). UP (retract outrigger to lower truck). OFF (valves hold outriggers in position). Note The position of selector switch 1 (Left, Right or Both) determines the action of stabilizer controls 4 and 5. DOWN (extend stabilizer jack to raise truck). UP (retract stabilizer jack to lower truck). OFF (valves hold stabilizer jacks in position). Note The position of selector switch 1 (Left, Right or Both) determines the action of stabilizer controls 4 and 5. OUT (extend stabilizer beam outward). IN (retract stabilizer beam inward). OFF (valves hold stabilizer beams in position). 6. Front Bumper Stabilizer (Optional) DOWN (extend outrigger or stabilizer to raise truck). UP (retract outrigger or stabilizer to lower truck). OFF (valves hold outriggers and stabilizers in position). C-Series Operator Manual 1-13

14 BEAMS FULLY RETRACTED BEAMS AT INTERMEDIATE SPREAD PIN POSITION IS NOT CRITCAL, BUT PREFER- ABLY DISENGAGED. ALL OUTRIGGER AND STABILIZER BEAMS FULLY RETRACTED. BOTH OUTRIGGER BEAMS MUST BE EXTENDED TO THE MID EXTEND MARKS. PINS MUST BE ENGAGED FOR THIS SPREAD CONFIGURATION BOTH STABILIZER BEAMS MUST BE FULLY EXTENDED. Full or Retracted Outrigger Spread Pin Position Disengaged Intermediate Outrigger Spread Pin Position Engaged BOTH OUTRIGGER BEAMS MUST BE EXTENDED TO THE FULL EXTEND MARKS. PINS MUST BE DISENGAGED FOR THIS SPREAD CONFIGURATION BOTH STABILIZER BEAMS MUST BE FULLY EXTENDED. BEAMS FULLY EXTENDED Figure 1-11 Out-Down Outriggers and Out-Down Stabilizers Typically both sets are fully extended to lift the truck off the ground and adjusted to ensure crane is level in all directions. Set-up as illustrated BEAMS FULLY RETRACTED 3000 Series Cranes Do not attempt to operate the crane with the outriggers and stabilizers fully retracted. The LMI programming does not support this configuration nor is a load chart available. Failure to comply will cause equipment to fail possibly resulting in serious injury to personnel. Full Outrigger Spread Pin Position Disengaged Intermediate Outrigger Spread Pin Position Engaged BEAMS AT INTERMEDIATE SPREAD BOTH OUTRIGGER BEAMS MUST BE EXTENDED TO THE MID EXTEND MARKS. BOTH STABILIZER BEAMS MUST BE EXTENDED TO THE MID EXTEND MARKS. BOTH OUTRIGGER BEAMS MUST BE EXTENDED TO THE FULL EXTEND MARKS. PINS MUST BE ENGAGED FOR THIS SPREAD CONFIGURATION PINS MUST BE DISEN- GAGED FOR THIS SPREAD CONFIGURATION BOTH STABILIZER BEAMS MUST BE EXTENDED TO THE FULL EXTEND MARKS. BEAMS FULLY EXTENDED Figure 1-12 Out-Down Outriggers and 18-6 Out-Down Stabilizers Typically both sets are fully extended to lift the truck off the ground and adjusted to ensure crane is level in all directions. Set-up as illustrated 1-14 C-Series Operator Manual

15 Controls and Functions - Out-Down Outrigger and Out-Down Stabilizer Control 1. Outrigger/Stabilizer Select Switch Toggle CENTERED (spring returned) Toggle held LEFT Toggle held RIGHT 2. Stabilizer Up-Down 3. Outrigger Up-Down 4. Stabilizer In-Out 5. Outrigger In-Out Function Note The position of this switch selects which cylinder operates (Left, Right or Both) when used in conjunction with outrigger or stabilizer controls. BOTH sides operate when outrigger or stabilizer controls 2-5 are moved. Only LEFT cylinders operate when outrigger or stabilizer controls 2-5 are moved. Only RIGHT cylinders operate when outrigger or stabilizer controls 2-5 are moved. Note The position of selector switch 1 (Left, Right or Both) determines the action of outrigger or stabilizer controls 2-5. DOWN (extend jack cylinder to raise truck). UP (retract jack cylinder to lower truck). OFF (valves hold jack cylinders in position). Note The position of selector switch 1 (Left, Right or Both) determines the action of outrigger or stabilizer controls 2-5. OUT (extend outrigger/stabilizer beam outward). IN (retract outrigger/stabilizer beam inward). OFF (valves hold all beams in position). 6. Front Bumper Stabilizer (Optional) DOWN (extend outrigger or stabilizer to raise truck). UP (retract outrigger or stabilizer to lower truck). OFF (valves hold outriggers and stabilizers in position). C-Series Operator Manual 1-15

16 1-16 C-Series Operator Manual

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