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CARRIER OPERATOR’S MANUAL This manual has been prepared for and is considered part of -

TM500E-2 Crane Model Number

To prevent death or serious injury: • Avoid unsafe operation and maintenance.

• This crane must be operated and maintained by trained and experienced personnel. Manitowoc is not responsible for qualifying these personnel.

• Do not drive, operate or work on this crane without first reading and understanding the Operator’s Manuals and Rating Plate supplied with crane.

• Store this Operator’s Manual in the Carrier Cab. • Attach laminated Capacity Charts supplied with crane to chain in Superstructure cab.

• If Operator’s Manuals are missing from either cab, or Capacity Charts are missing from Superstructure cab, contact your distributor for new ones.

© 2008 Manitowoc Crane Group Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Figure -1

AC-OM-041-0707-P154

To Contact Us:

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

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

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

Technical Publications

Field Service

Parts

Published 05-30-08, Control # 166-02

Factory Service

Training

TM500E-2 CARRIER OPERATOR’S MANUAL General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Diesel Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Battery Posts, Terminals, and Related Accessories . . . . . . . . . . . 3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrocution Hazard Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special Operating Conditions and Equipment. . . . . . . . . . . . . . . . 6 Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Noise Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CRANE Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cab Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Tilting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Crane Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Safety Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Dashboard Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Steering Column Switches/Controls . . . . . . . . . . . . . . . . . . . . . . 45 Miscellaneous Switches/Controls . . . . . . . . . . . . . . . . . . . . . . . . 45 Interior Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Heating and Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Cab Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Fuel Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Engine Start and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Transmission Warning Functions . . . . . . . . . . . . . . . . . . . . . . . . 60 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Brake System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FMVSS 121 Brake Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Anti-Lock Brake System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Crane Speed Retardation Devices . . . . . . . . . . . . . . . . . . . . . . . 66 General Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Battery Jump-Starting and Charging . . . . . . . . . . . . . . . . . . . . . . 68 Electrical Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Breakers and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Power Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Battery Main Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . 69 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Caging Spring Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL

GENERAL INFORMATION Figure 1

Superstructure Cab

Carrier Cab

Figure 1

Information for the Owner Please take the time to read all of the information in this manual. It has been designed to be easy to read and understand and to provide you, the driver and owner, with all of the necessary information to drive your crane as safely as possible.

If there are questions about the maintenance or performance of your crane, please discuss them with your Manitowoc CraneCARE dealer. Your authorized Manitowoc dealer is required to have trained mechanics, special tools and spare parts to fully service your crane. If necessary, your dealer will contact the manufacturer for any assistance.

In addition to this operator manual, there are other manuals and documents located in the Superstructure cab. Be sure to read, and understand, all the manuals and documents thoroughly before operating the superstructure part of the crane.

Your Grove Crane has been designed for maximum performance with minimum maintenance. With proper care, years of trouble-free service can be expected.

Constant improvement and engineering progress makes it necessary that we reserve the right to make specification and equipment changes without notice.

6977

Grove Manitowoc and our Dealer Network want to ensure your satisfaction with our products and customer support. Your local dealer is the best equipped and most knowledgeable to assist you for parts, service and warranty issues. They have the facilities, parts, factory trained personnel, and the information to assist you in a timely manner. We request that you first contact them for assistance. If you feel you need factory assistance, please ask the dealer’s service management to coordinate the contact on your behalf.

Engine operating procedures and routine maintenance procedures are supplied in a separate manual with each crane, and should be referred to for detailed information.

Information in this manual does not replace federal, state, or local regulations, safety codes, or insurance requirements.

Federal law requires manufacturers to notify owners of their products in the event that a Federal Motor Vehicle Safety Standard is violated or if a safety-related defect is discovered. If you are not the original owner of this crane, please notify us about the change in ownership at the address below or through an authorized Manitowoc dealer.

This is the only way we will be able to contact you if necessary.

Published 05-30-08, Control # 166-02

1

TM500E-2 CARRIER OPERATOR’S MANUAL Do Not Remove this manual from the crane. It contains important operational and safety information that is needed by all drivers and owners of this crane.

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

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Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL

SAFETY

Note: A note defines an operating procedure, practice, condition, etc., which is essential to proper operation of the crane.

Safety DEFINITIONS The importance of safe operation and maintenance cannot be over emphasized. Carelessness or neglect on the part of operators, job supervisors and planners, rigging personnel, and job site workers can result in their death or injury and costly damage to the crane and property.

To alert personnel to hazardous operating practices and maintenance procedures, safety messages are used throughout the manual. Each safety message contains a safety alert symbol and a signal word to identify the hazard’s degree of seriousness.

This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Read and abide by the message that follows the safety alert symbol.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

Indicates a property damage message.

Diesel Engine Exhaust

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery Posts, Terminals, and Related Accessories

CALIFORNIA PROPOSITION 65 WARNING The battery posts, terminals, and related accessories 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 handling.

General It is impossible to compile a list of safety precautions covering all situations. However, there are basic principles that MUST be followed during your daily routine. Safety is YOUR PRIMARY RESPONSIBILITY, since any piece of equipment is only as safe AS THE PERSON AT THE CONTROLS. 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 arise. It is intended to present basic safety precautions that should be followed in daily operation.

Because you, the operator, are the only part of the crane that can think and reason, your responsibility is not lessened by the addition of operational aids or warning devices. Indeed, you must guard against acquiring a false sense of security when using them. They are there to assist, not direct the operation. Operational aids or warning devices can be mechanical, electrical, electronic, or a combination thereof. They are subject to failure or misuse and should not be relied upon in place of good operating practices.

Published 05-30-08, Control # 166-02

3

TM500E-2 CARRIER OPERATOR’S MANUAL You, the operator, are the only one who can be relied upon to assure the safety of yourself and those around you. Be a PROFESSIONAL and follow the RULES of SAFETY.

Operator’s Qualifications

REMEMBER, failure to follow just one safety precaution could cause an accident that results in death or serious injury to personnel or damage to equipment. You are responsible for the safety of yourself and those around you.

IMMEDIATELY report all accidents, malfunctions, and equipment damages to your local Manitowoc distributor. Following any accident or damage to equipment the local Manitowoc distributor must be immediately advised of the incident and consulted on necessary inspections and repairs. Should the distributor not be immediately available, contact should be made directly with Grove Manitowoc Crane CARE. The crane must not be returned to service until it is thoroughly inspected for any evidence of damage. All damaged parts must be repaired or replaced as authorized by your local Grove Manitowoc distributor and/or Grove Manitowoc CraneCARE.

Operator’s Information You must READ and UNDERSTAND the Operator’s and Safety Handbook before driving the crane. The handbook must be readily available to the operator at all times and must remain in the cab while the crane is in use.

Ensure that all personnel working around the crane are thoroughly familiar with safe operating practices. You must be thoroughly familiar with the location and content of all placards and decals on the crane. Decals provide important instructions and warnings and must be read prior to any operational or maintenance function.

You must be familiar with the regulations and standards governing cranes and their operation.

Work practice requirements may vary slightly between government regulations, industry standards, and employer policies so a thorough knowledge of all such relevant work rules is necessary.

DO NOT REMOVE this Operator’s and Safety Handbook, or any decal from this crane.

Inspect the crane every day (before the start of each shift). Ensure that routine maintenance and lubrication are being dutifully performed. Don’t operate a damaged or poorly maintained crane.

You risk lives when operating faulty machinery, including your own.

Allow No One other than the operator to be on the crane while the crane is functioning or moving, unless they are seated in a two-man cab.

4

An untrained operator subjects himself and others to death or serious injury.

YOU MUST NOT OPERATE THIS MACHINE UNLESS: You have been trained in the safe operation of this machine.

You read, understand, and follow the safety and operating recommendations contained in the operator’s manuals, your employer’s work rules, and applicable government regulations.

You are sure the machine is operating properly and has been inspected and maintained in accordance with the manuals provided with this crane.

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 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 trained.

You must be mentally and physically fit to operate a crane. Never attempt to operate a crane while under the influence of medication, narcotics or alcohol. Any type of drug could impair physical, visual and mental reactions and capabilities.

Work Site Prior to any operation, you must inspect the ENTIRE work-site, including ground conditions, where the crane will travel and operate. Be sure that the surfaces will support a load greater than the crane’s weight and maximum capacity.

Barricade the area where the crane is working and keep all unnecessary personnel out of that area.

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Be aware of all conditions that could adversely affect the stability of the crane.

Use caution when operating in the vicinity of overhanging banks and edges.

Set-Up and Operation During crane use, assume that every line is energized (“hot” or “live”) and take the necessary precautions.

Set-up the crane in a position such that the load, boom or any part of the crane and its attachments cannot be moved to within 6 m (20 ft.) of electrical power lines or equipment. This includes the crane boom (fully extended to maximum height, radius and length) and all attachments (jibs, boom extensions, rigging, loads, etc.). Overhead lines tend to blow in the wind so allow for lines’ movement when determining safe operating distance.

A suitable barricade should be erected to physically restrain the crane and all attachments (including the load) from entering into an unsafe distance from electrical power lines or equipment.

Electrocution Hazard Devices The use of insulated links, insulated boom cages/guards, proximity warning devices, or mechanical limit stops does not assure that electrical contact will not occur. Even if codes or regulations require the use of such devices, failure to follow the rules listed here may result in serious injury or death. You should be aware that such devices have limitations and you should follow the rules and precautions outlined in this handbook at all times even if the crane is equipped with these devices.

Insulating links installed into the load line afford limited protection from electrocution hazards. Links are limited in their lifting abilities, insulating properties, and other properties that affect their performance. Moisture, dust, dirt, oils, and other contaminants can cause a link to conduct 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 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.

Plan ahead and always plan a safe route before traveling under power lines. Rider poles should be erected on each side of a crossing to assure sufficient clearance is maintained.

Appoint a reliable and qualified signal person, equipped with a loud signal whistle or horn and voice communication equipment, to warn the operator when any part of the crane or load moves near a power source. This person should have no other duties while the crane is working.

DO NOT store materials under power lines or close to electrical power sources.

Proximity sensing and warning devices are available in different types. Some use boom nose (localized) sensors and others use full boom length sensors. No warning may be given for components, cables, loads, and other attachments located outside of the sensing area. Much reliance is placed upon you, the operator, in selecting and properly setting the sensitivity of these devices.

Never rely solely on a device to protect you and your fellow workers from danger.

Some variables you must know and understand are: Proximity devices are supposed to detect the existence of electricity - not its quantity or magnitude.

Some proximity devices will detect only alternating current (AC) and not direct current (DC).

Published 05-30-08, Control # 166-02

5

TM500E-2 CARRIER OPERATOR’S MANUAL Some proximity devices detect radio frequency (RF) energy and others do not.

Most proximity devices simply provide a signal (audible, visual or both) for the operator and this signal must not be ignored.

Sometimes the sensing portion of the proximity devices becomes confused by complex or differing arrays of power lines and power sources.

DO NOT depend on grounding. Grounding of a crane affords little or no protection from electrical hazards. The effectiveness of grounding is limited by the size of the (wire) conductor used, the condition of the ground, the magnitude of the voltage and current present, and numerous other factors.

Electrical Contact If the crane should come in contact with an energized power source, you must: Stay in the crane cab. DON’T PANIC. Immediately warn personnel in the vicinity to stay away.

Attempt to move the crane away from the contacted power source using the crane’s controls which are likely to remain functional.

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.

Only as a last resort should an operator attempt to leave the crane upon contacting a power source. If it is absolutely necessary to leave the operator station, JUMP COMPLETELY CLEAR OF THE CRANE. DO NOT STEP OFF. Hop away with both feet together. DO NOT walk or run.

Following any contact with an energized electrical source the local, authorized Manitowoc distributor must be immediately advised of the incident and consulted on necessary inspections and repairs.

Thoroughly inspect the wire rope and all points of contact on the crane. Should the distributor not be immediately available, contact Manitowoc CraneCARE. The crane m ust not be returned to service until it is thoroughly inspected for any evidence of damage and all damaged parts are repaired or replaced as authorized by Grove Manitowoc CraneCARE or your local Manitowoc distributor.

Special Operating Conditions and Equipment

Working in the vicinity of radio frequency transmission towers and other transmission sources may cause a crane to become “electrically charged”.

When operating cranes equipped with electromagnets you must take additional precautions. Permit no one to touch the magnet or load. Alert personnel by sounding a warning signal when moving a load. Do not allow the cover of the electromagnet power supply to be open during operation or at any time the electrical system is activated. Shut down the crane completely and open the magnet controls switch prior to connecting or disconnecting magnet leads. Use only a non-conductive device when positioning a load.

Lower the magnet to the stowing area and shut off power before leaving the operator’s cab.

Travel Operation • Before travel, fully retract and lower the boom into the boom rest and engage the turntable pin swing lock.

• Secure the hook block and other items before moving the crane.

6977 • Follow the instructions in this handbook when preparing the crane for highway travel.

• If using a boom dolly/trailer, thoroughly read and understand all the steps and safety precautions in the handbook for setup and travel and in the Carrier Handbook.

• Watch overhead and side clearances and avoid running into obstructions along the travel route.

• When moving in a tight quarters, post a signal person to help guard against collisions or bumping structures.

• Never back up without the aid of a signal person to verify that the area behind the crane is clear of all personnel and obstructions.

• Check load limits of bridges on the travel route and ensure they are greater than the crane’s weight.

• Always drive the crane carefully, obeying speed limits and highway regulations.

• Keep lights on, use traffic warning flags and signs, and use front and rear flag vehicles when necessary. Check state and local restrictions and regulations.

• When parking on a grade, apply parking brake and chock the wheels.

Never operate the crane during an electrical thunderstorm.

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Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL

Accidents If this crane becomes involved in a property damage and/or personal injury accident, immediately contact your local Grove Manitowoc distributor. If the distributor is unknown and/or cannot be reached, contact Product Safety and Reliability at:

ROUTINE MAINTENANCE and INSPECTION of this crane must be performed by a qualified person(s) according to the recommendations in the Grove Manitowoc Maintenance and Inspection Manual. Any questions regarding procedures and specifications should be directed to the your local, authorized Grove Worldwide Distributor.

Lubrication Grove Manitowoc Crane Group 1565 East Buchanan Trail Shady Grove, PA 17256-0021 Phone:888-777-3378 (888-PSR-DEPT) Fax:717-593-5074 E-mail:psafety@groveworldwide.com Provide a complete description of the accident, including the crane model and serial number.

Maintenance The crane must be inspected prior to use on each work shift. The owner, user and operator must ensure that routine maintenance and lubrication are being dutifully performed. NEVER operate a damaged or poorly maintained crane.

Keep the crane properly maintained and adjusted at all times. Shut down the crane while making repairs or adjustments.

Always perform a function check after repairs have been made to ensure proper operation. Load tests should be performed when structural or lifting members are involved.

Follow all applicable safety precautions in this handbook when performing crane maintenance as well as crane operations.

Before crane use: Conduct a visual inspection for cracked welds, damaged components, loose pin/bolt, and wire connections. Any item or component that is found to be loose or damaged (broken, chipped, cracked, worn-through, etc.) must be repaired or replaced.

Check for proper functioning of all controls and operator aids.

Check all braking (e.g. wheel, hoist, and swing brakes) and holding devices before operation.

Keep the crane clean at all times, free of mud, dirt, and grease. Dirty equipment introduces hazards, wears-out faster, and makes proper maintenance difficult. Cleaning solutions used should be appropriate for the job and non-flammable/toxic.

See Superstructure Operator’s Manual, located in the Superstructure Cab, for complete Lubrication Specifications. The crane must be lubricated according to the factory recommendations for lubrication points, time intervals, and types.

Lubricate at more frequent intervals when working under severe conditions.

Exercise care when servicing the hydraulic system of the crane, as pressurized hydraulic oil can cause serious injury. The following precautions must be taken when servicing the hydraulic system: Follow the manufacturer’s recommendations when adding oil to the system. Mixing the wrong fluids could destroy seals, causing machine failure.

Be certain all lines, components and fittings are tight before resuming operation.

When checking for suspected leaks, use a piece of wood or cardboard and wear appropriate personal protective equipment.

Never exceed the manufacturers recommended relief valve settings.

Tires Inspect the tires for nicks, cuts, embedded material, and abnormal wear.

Ensure all lug nuts are properly torqued.

Ensure tires are inflated to the proper pressure (Refer to the Tire Inflation Chart in the Load Chart Binder located in the Superstructure cab). When inflating tires, use a tire gauge, clip-on inflator, and extension hose which will permit standing clear of the tire while inflating.

Batteries Battery electrolyte must not be allowed to contact the skin or eyes. If this occurs, flush the contacted area with water and consult a doctor immediately.

When checking and maintaining batteries exercise the following procedures and precautions:

Published 05-30-08, Control # 166-02

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TM500E-2 CARRIER OPERATOR’S MANUAL

CAUTION To avoid possible engine fault codes and undesirable operation, ensure the keyswitch has been off 2 minutes before disconnecting batteries.

Shut down the engine and disconnect the battery before performing maintenance. If unable to do so for the task required, keep hands clear of the engine fan and other moving parts while performing maintenance.

DANGER CAUTION Battery disconnect switch does not disconnect transmission ECU.

To avoid death or serious injury, do not use ether. Engine is equipped with electric heater starting aid. Use of ether may cause explosion.

Disconnect the batteries.

Be careful of hot surfaces and hot fluids when performing maintenance on or around the engine.

Wear safety glasses when servicing batteries.

Job Preparation

Do not short across the battery posts to check charge. Short circuit, spark, or flame could cause battery explosion.

You must inspect the crane prior to your work shift checking for cracked welds, damaged components, and evidence of improper maintenance (consult Maintenance-Inspection and Service Manuals).

Maintain battery electrolyte at the proper level.

Check the electrolyte with a flashlight.

If applicable to your crane, check battery test indicator on maintenance-free batteries.

Do not break a live circuit at the battery terminal.

Disconnect the ground battery cable first when removing 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 free of flame, smoking, sparks, and fire.

You must ensure that the crane is properly equipped including access steps, covers, doors, guards, and controls.

Wear appropriate clothing and personal protective equipment whether or not required by local or job regulations. Be prepared for the work day.

Before entering the cab, you must be THOROUGHLY familiar with the planned route of travel and area of operation, including surface conditions and the presence of overhead obstructions and power lines.

Engine

Always keep the crane clean, free of dirt, debris, and grease.

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 tank cap.

Fuel the crane ONLY with the engine turned off. Do not smoke while fueling the crane. Do not store flammable materials on the crane or in the operator’s cab.

Follow standard safety precautions when refueling.

FUEL IT SAFELY. Be familiar with the location and use of the nearest fire extinguisher.

CAUTION To avoid possible engine fault codes and undesirable operation, ensure the keyswitch has been off 2 minutes before disconnecting batteries.

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.

Cold Weather Operation CAUTION Battery disconnect switch does not disconnect transmission ECU.

8

Cold weather operation requires additional caution on the part of the operator.

Don’t touch frozen metal surfaces with bare skin.

Clean the crane of all ice and snow.

Structural inspection at more frequent intervals.

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Exercising crane prior to lifting is considered good practice.

Allow ample time for hydraulic oil to warm up. The use of appripriate and approved hydraulic oil, lubricants, hoses, heaters and other cold weather ancillary items shall be considered for operation at temperatures below 00F (-180C)

CRANE ACCESS Cab Entry and Exit General

In freezing weather, park the crane in an area where it cannot become frozen to the ground. The drive line can be damaged when attempting to free a frozen crane.

Never stand on the steps or any other part of the crane while it is in motion.

The steps and the back of cab access deck plates are only for entering/exiting the crane and not for riding on. Failure to heed this warning can result in serious personal injury or death.

If applicable to your crane, frequently check all air tanks for water in freezing weather.

Do not use aerosol starting fluids. The use of aerosol spray or other types of starting fluids containing ether/volatiles can cause explosions or fire.

Steps are designed to be slip-resistant and to provide a stable surface for entering or exiting the cab. However, accumulation of ice, dirt, lubricants, etc., on the steps can make entering or exiting hazardous. Always make sure the steps are free from slippery substances.

Failure to follow this guideline may result in a fall that can cause serious personal injury or death.

Operation Below -400C / -400F Operation at full rated capacity to ambient temperature of -400F (-400C) shall be a done by compentent operators with skill, experience and dexterity to assure smooth operation without shock load.

For crane operation below -400C capacities shall be derated 3.67 percent of the rated load shown on the capacity charts for each degree below -400C without shock load.

Wearing shoes with soles that are dirty or wet increases the chance of slipping and falling. Be careful when entering the cab with dirty or wet soles.

0

For Crane operation below -40 F, capacities shall be de-rated 2 percent of the rated load shown on the capacity charts for each degree below -400F without shock load.

Both the operator and passenger should exercise caution when entering or exiting the cab. Use the steps, grab handles and/or steering wheel to safely get in and out of the cab.

Noise Emissions Figure 2

Figure -1

To avoid serious personal injury due to a slip and/or fall, observe all the guidelines explained in this manual.

Figure -2

7172

Figure 2 A Noise Emission Control label is located on the rear part of the driver’s side door frame. It is the owner’s responsibility to maintain the crane so that it conforms to EPA noise regulations and Canadian CMVSS-1106 regulations.

Figure 3

Cab Steps

Refer to your engine manufacturer’s operator’s manual for a listing on what constitutes tampering with the Noise Emission Control.

Published 05-30-08, Control # 166-02

9

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 3

General Entry Guidelines

To avoid personal injury due to a slip and/or fall, observe the following guidelines.

BE SURE TO FOLLOW ALL OF THESE INSTRUCTIONS BEFORE ENTERING OR EXITING THE CAB OR THE AREA BEHIND THE CAB. • Always have three point contact (one foot and two hands or two feet and one hand) with the crane at all times when entering or exiting the cab or the area behind the cab.

• Do not hold anything in your hands when entering or exiting the cab or the area behind the cab.

Place log books, cups, clipboards, jackets, luggage, etc., on the cab floor or rear deck plate before entering or exiting.

• Be sure to disconnect the safety belt before exiting the cab.

• Be sure that the safety belt is fully retracted and out of the way prior to entering or exiting the cab.

• Do not put your foot on any surface that does not have slip-resistant, self-cleaning material. If there is no step material, the surface may be slippery and you could fall.

• Before entering or exiting, be certain that your shoes or boot soles are free from grease, mud or any other substance which could make them slippery.

• Always put the foot flat on the top of the step. Do not place your foot on the side or edge of the step.

Driver Side Entry/Exit Figure 4

7174

2 • Be certain you have a firm hand hold and/or stable foot position before transferring weight to that position. For example, do not start to put weight on a foot until you are certain your foot is properly on the step and will not slip when you transfer your weight.

• Be certain that the grab handles are clear of snow, mud, ice or other substances that could make them slippery before using them. Do not use steps or grab handles if they are slippery or damaged.

• Be certain that all grab handles, steps and related parts are in good working condition. Any defects should be reported and repaired before using the grab handles and steps.

• Do not step on the curved surface of the fuel tanks. They may be slippery from snow, mud, ice, water, spilled fuel or other slippery substances.

• If a step is mounted to the top of the battery box, be certain that the battery box cover is properly fastened before stepping.

• Do not jump from the cab or from the steps to the ground.

• Always face the cab when entering or exiting.

10

1

3

Figure 4 Open the door. Place any hand-carried items on the cab floor or in the seat. Grasp the right grab handle (1, Figure 4) with your right hand and the left grab handle (2) with your left hand. Put the left foot fully on the bottom step (3) and pull yourself up to the opening.

Step into the cab with the right foot first.

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL To exit, reverse the process. Do not attempt to exit the cab while carrying any items in your hands.

Passenger Side Entry/Exit Figure 5

7175

2

General Remove or secure all loose articles and close all doors before raising the cab. The area above and ahead of the cab must be clear from obstructions.

Be sure to lift the boom to allow the cab to clearly tilt. Place front wheels in a straight ahead position.

Figure 6

7173

1 1

2

1

Figure 6

3

Remove the pump handle (1, Figure 6) from its storage location on the passenger side seat riser. It is held in place with two clips.

Figure 5

Figure 7

Open the door. Place any hand-carried items on the cab floor or in the seat. Grasp the cab grab handle (1, Figure 5) with your left hand and the right grab handle (2) with your right hand. Put the right foot fully on the bottom step (3) and pull yourself up to the opening.

Read the label (2, Figure 6) about cab tilting information, located on the passengers side door jam.

Raising the Cab Figure 8

Step into the cab with the left foot first.

To exit, reverse the process. Do not attempt to exit the cab while carrying any items in your hands.

Tilting the Cab Apply the parking brakes and.

Due to the danger of sustaining personal injury and/or damage to the crane, never attempt to raise the cab outdoors under extremely windy conditions. The strong wind conditions could force the cab beyond the normal limits of its travel.

Figure 7 Published 05-30-08, Control # 166-02

11

TM500E-2 CARRIER OPERATOR’S MANUAL Place the selector lever on the hydraulic pump in the RAISE (push circuit) position. Insert the pump handle into the pump and operate the handle in an up and down motion. The cab latch hooks securing the cab to the frame are automatically released with the first two to three strokes of the pump handle.

This will be evident when the pins at the rear hydraulic latch extend from the latch body. See Figure 9 The hydraulic cylinders then lift the cab until the midpoint (top) is reached. Once the cab has reached midpoint, the cab will free fall forward to the fully open position. The safety pin in the cab tilt lock device must be installed when the holes line up in the sliding bar.

Figure 10

Never rely on the hydraulic pressure to hold the cab in an open position. Always use the safety pin in the cab tilt lock tube to prevent serious personal injury or death.

AC-910-0706-01255-A

Figure 9

Figure 9

Remove the pump handle when not in use. It may stick out and could cause injury to passersby.

To stop the cab in a partially tilted position while raising the cab, stop pumping and place the flow valve selector in the HOLD position. Install the safety pin in the cab tilt lock tube wherever the holes line up.

Velocity fuses are incorporated into the cab tilt cylinder ports to control the cab's free fall past the midpoint (top) when raising and lowering the cab.

The fuses also act as a safety valve to prevent the cab from falling unchecked in the event of a hydraulic system failure.

Figure 8 Never rely on the hydraulic pressure to hold the cab in a partially open position.

Always use the safety pin in the cab tilt lock tube to prevent serious personal injury or death.

12

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Lowering the Cab Remove the safety lock pin. It may be necessary to remove weight from the pin by operating the cab jack pump. Do not use excessive force on either pin or pump, pin should be free to turn in order to remove it. Place the selector lever on the hydraulic pump to the LOWER (pull circuit) position. Insert the pump handle into the pump and operate the handle in an up and down motion. The hydraulic cylinders then lower the cab until the midpoint (top) is reached. Once the cab has reached midpoint, stop pumping and the cab will free fall rearward to the fully lowered position. When the cab is lowered, the crossbars of the cab brackets will automatically engage the hydraulic cab latches. The weight of the cab then triggers the hydraulic latches to lock. This will be evident when the pins in the hydraulic latches retract into the latch body.

Remove the pump handle when not in use. It may stick out and could cause injury to passersby.

Published 05-30-08, Control # 166-02

13

TM500E-2 CARRIER OPERATOR’S MANUAL

PRE-TRIP INSPECTION AND DAILY MAINTENANCE Crane Maintenance Before working on or inspecting a crane, set the parking brakes, place t he transmission in neutral and block the wheels. Failure to do so can result in unexpected crane movement and can cause serious personal injury or death.

Safety is the most important and obvious reason for doing a pre-trip inspection. Federal and state laws require that a pre-trip inspection be completed by the driver. An unsafe crane can be put “out of service” until the driver or owner corrects the deficiency. Owners and operators should familiarize themselves with sections 49 CFR 396.11 and 396.13 concerning federal requirements for vehicle inspection. Certain other laws may also apply.

The Pre-Trip Inspection Quick List in this manual shows suggested guidelines to be used in performing crane pre-trip inspections. Depending on the application in which the crane is being used, these guidelines should be modified to include other necessary inspection points.

If any component or system does not pass this inspection, it must be corrected before operating the crane. Whenever equipment requires adjustment, replacement, repair or lubrication refer to the service manuals or contact a Manitowoc dealer for the correct procedures, specifications and intervals.

Take your time going through the pre-trip inspection. Remember that a careful pre-trip inspection saves time by eliminating unscheduled stops for correcting a faulty item.

The following information has been provided by the American Trucking Association as developed by the D.O.T. Office of Motor Carriers (BMCS).

Section 49 CFR 396.13 states that all motor carrier drivers must complete a written report at the end of each workday for each crane operated, covering most of what is covered in the pre-trip list. The report should list all defects or deficiencies discovered by the driver. Performing a pre-trip inspection prepares for the end-of-work report.

14

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL

Pre-Trip Inspection Quick List Figure 11

Figure 10 Inspect the crane in a circular manner as shown in Figure 10 and Figure 11.

Approaching the Crane • Check under the crane for oil, fuel, coolant leaks or other signs of damage.

• Check body surfaces for breaks or damage.

Preparation • Chock wheels on crane.

• Open drain cocks on air tanks to let the tanks drain.

• Close air tank drain cocks.

• Start the engine and let the air pressure build up to normal. Stop engine.

• Switch on parking lights and four-way flashers.

• Apply parking brakes.

Step 1: Left Side of the Cab Left Front Wheel • Check condition of wheel rim. Especially look for cracks, missing lock rings, bent or broken studs, clamps or lugs.

• Check condition of tire: properly inflated, no serious cuts, bulges, tread wear or any signs of misalignment; valve stem not touching wheel, rim or brake drum; valve cap in place.

• Check wheel bearing and hub; no obvious leaking on the outside or inside of wheel. Verify correct oil level in hub.

• Check air filter with brackets and hoses for loose connections or damage. Check filter gauge, if mounted on filter.

Left Front Suspension • Check condition of spring, spring hangers, shackles, U-bolts; no cracks, breaks or shifting.

• Check shock absorber condition.

Left Front Brake • Chock wheels on crane.

• Check brake air hose for any chafing.

• Check brake chamber mounting bolts and bracket.

• Check slack adjuster and chamber pushrod travel. With brakes applied or released, look for conspicuously different positions of the slack adjusters.

Condition of Front Axle and Steering System, Left Side • No loose, worn, bent, damaged or missing parts.

Under Cab, Left Side (Cab Raised) • Check coolant hose condition.

• Check condition of fan drive belts.

• Check engine and surrounding areas for coolant, oil and fuel leaks.

• Check wiring for signs of damage.

Published 05-30-08, Control # 166-02

15

TM500E-2 CARRIER OPERATOR’S MANUAL Step 2: Front of Cab Area Condition of Windshield • Check for damage and clean if dirty.

• Check windshield wiper arms for proper spring tension.

• Check wiper blades for any damage, cracked, split, or dry rotted rubber and check for proper attachment to wiper arm.

Lights and Reflectors • Inspect parking, clearance and identification lights. They should be clean, operating and of the proper color.

• Reflectors should be clean and of the proper color.

• Turn on the headlights. High and low beams should be operating and lenses clean. If equipped, check daytime running lights.

• Left and right front turn signal lights should be clean, operating and of the proper color.

• Check the four-way flashers for proper operation and color.

Grille • Check that charge air cooler, radiator or bug screens are clean and undamaged.

• If equipped with an oil cooler, check for leaks or that cooler fins are not blocked.

Step 3: Right Side of Cab Area Right Front Area • Check condition of wheel rim. Especially look for cracks, missing lock rings, bent or broken studs, clamps or lugs.

• Check condition of tire: properly inflated, no serious cuts, bulges, tread wear or any signs of misalignment; valve stem not touching wheel, rim or brake drum; valve cap in place.

• Check wheel bearing and hub; no obvious leaking on the outside or inside of wheel. Verify correct oil level in hub.

16

Right Front Suspension • Check condition of spring, spring hangers, shackles, U-bolts; no cracks, breaks or shifting.

• Check shock absorber condition.

Right Front Brake • Chock wheels on crane.

• Check brake air hose for any chafing.

• Check brake chamber mounting bolts and bracket.

• Check slack adjuster and chamber pushrod travel. With brakes applied or released, look for conspicuously different positions of the slack adjusters.

Condition of Front Axle and Steering System, Right Side • No loose, worn, bent, damaged or missing parts.

Under Cab, Right Side (Cab Raised) • Check coolant and heater hose condition.

• Check condition of fan drive belts.

• Check engine and surrounding areas for coolant, oil and fuel leaks.

• Check fuel separator sight glass and drain if necessary. Check for leaks.

• Check wiring harnesses for signs of damage.

Fluid Levels • Check the engine oil level using the dipstick.

• Check the transmission oil level using the dipstick.

• Inspect the coolant reserve tank to verify the coolant is visible in the sight glass.

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL

Figure 12

Figure 11

Step 4: Right Saddle Tank Area Right Fuel Tank(s) • Tanks securely mounted and not damaged or leaking.

• Fuel lines secure and not leaking.

• Check that tank(s) is full of fuel; cap on and secure.

Condition of Visible Components • Check rear of engine for leaks.

• Check transmission for leaks.

• Check drive shaft.

• Check that exhaust system is secure and has no leaks, and is not touching wires, fuel or air tubing.

• Check frame and crossmembers for bends, cracks or breaks.

• Check that air tubing and electrical wiring are secured against snagging and chafing.

Step 5: Right Rear Crane Area Dual Wheels, One or Two Axles • Check condition of wheels and rims. Especially look for cracks, missing lock rings, bent or broken spacers, studs, clamps or lugs.

• Check condition of tires: properly inflated, no serious cuts, bulges, tread wear or any signs of misalignment; valve stems not touching wheels, rims or brake drums; valve caps in place and no objects stuck between the wheels.

• Check that both tires are of the same type, i.e., not mixed radial and bias type, and that their circumferences are matched.

• Check wheel bearing and hub: no obvious leaks on the outside or inside of wheel.

Suspension • Check condition of springs (leaf or air), spring hangers, shackles and U-bolts for cracks, breaks or shifting.

• Check axle alignment.

Right Rear Brake • Chock wheels on crane.

• Release the parking brake and look for a noticeable gap between lining and drum. (This check cannot be made if dust covers are in place.) Reapply parking brake.

• Check brake air hose for any chafing.

• Check brake chamber mounting bolts and bracket.

• Check slack adjuster and chamber pushrod travel. With brakes applied or released, look for conspicuously different positions of the slack adjusters.

• Check spring brakes.

Published 05-30-08, Control # 166-02

17

TM500E-2 CARRIER OPERATOR’S MANUAL Step 6: Rear of Crane Area Frame Area • Frame or crossmembers not bent, cracked, or otherwise damaged or missing.

• Check that air tubing and electrical harnesses are properly secured to the frame with no damage or chafing.

Lights and Reflectors • Taillights, brake lights and turn signal lights operating, clean and of proper color.

• Check the four-way flashers for proper operation and color.

Air Tubing and Electrical Lines Visible from this Point • Should be secure from dangling.

• Both air lines and electric harnesses should be free from damage, oil and grease.

Step 7: Left Saddle Tank and Left Rear Wheels Dual Wheels, One or Two Axles • Check condition of wheels and rims. Especially look for cracks, missing lock rings, bent or broken spacers, studs, clamps or lugs.

• Check condition of tires: properly inflated, no serious cuts, bulges, tread wear or any signs of misalignment; valve stems not touching wheels, rims or brake drums; valve caps in place and no objects stuck between the wheels.

• Check that both tires are of the same type, for example, not mixed radial and bias type, and that their circumferences are matched.

• Check wheel bearing and hub: no obvious leaks on the outside or inside of wheel.

Suspension • Check condition of springs (leaf or air), spring hangers, shackles and U-bolts for cracks, breaks or shifting.

• Check axle alignment.

Left Rear Brake • Chock wheels on crane.

• Release the parking brake and look for a noticeable gap between lining and drum. (This check cannot be made if dust covers are in place.) Reapply the parking brake.

• Check brake air hose for any chafing.

18

• Check brake chamber mounting bolts and bracket.

• Check slack adjuster and chamber pushrod travel. With brakes applied or released, look for conspicuously different positions of the slack adjusters.

• Check spring brakes.

Condition of Visible Components • Check that transmission is not leaking.

• Check transmission oil cooler for leaks, secure mounting and free air passage.

• Check that drive shaft looks OK. • Check that exhaust system is secure, not leaking, not touching wires, fuel or air tubing.

• Check frame and crossmembers for bends, cracks or breaks.

• Check that air tubing and electrical wiring is secured against snagging and chafing.

Left Fuel Tank(s) • Tanks securely mounted and not damaged or leaking.

• Fuel lines secure and not leaking. Check that shut-off valves are open.

• Check that tank(s) is full of fuel; cap on and secure.

Battery Area • Open the battery box. Battery box securely mounted to the crane.

• Batteries secured against movement.

• Battery cases not broken or leaking. Battery cables free from damage.

• Tops of batteries and terminals clean and free from foreign material.

• Install battery lid and make sure it is securely fastened.

• Check the windshield washer fluid reservoir to ensure an adequate level of washer solution.

In the Cab • Check steps and grab handles for looseness or breakage. Also, clean them if there is any substance that makes them slippery, which makes cab entry/exit hazardous.

• Start the engine. If equipped, check that exhaust rain cap opens when accelerating engine.

• Check gauge and telltale light function.

• Check function of the low air warning.

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL • Check the warning light indicator panel for any malfunctions.

• Check windshield wipers, washers and horns, including back-up alarm, if equipped.

• Clean inside windshield, door windows and instruments. Clean mirrors.

• Check climate control and defroster. If equipped, check mirror heater.

• Check the condition of warning triangles, fire extinguisher and flares. Ensure that safety devices are properly secured in the cab.

• Adjust the seat. Check mirror adjustment.

• Check safety belts for function and damage.

• Apply service brakes. After the initial drop, pressure should hold steady or increase slightly, with engine at idle.

• Check steering for excessive free play.

• Check for loose items in the cab. Secure them if necessary.

Before Leaving the Parking Area • Remove chocks from the wheels.

• Test the service brakes before leaving the parking area.

Daily Maintenance Before working on or inspecting a crane, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected crane movement and can cause serious personal injury or death.

The following should be checked daily in addition to doing the pre-trip inspection.

Figure 13

AC-180-0705-01244-A

Figure 12 • Check coolant level in the coolant tank. Coolant should be visible in the sight glass on the side of the coolant surge tank.

• If coolant is not visible through sight glass, add coolant through the fill cap on top of the tank.

Only add enough coolant until visible through sight glass. See arrow in Figure 12.

Do not remove the cap to the coolant surge tank while the engine and radiator are still hot and under pressure.

Scalding fluid and/or steam may be blown out under pressure if the cap is taken off too soon.

Use only Texaco Extended Life Coolant #20358716 or Etheleyne Glycol Base standard coolant #20469513 or equivalent.

When checking the fluid levels, visually inspect hoses, pipes and their connections for signs of leakage. Inspect the ground under engine, transmission and rear axle(s) for signs of leakage.

Published 05-30-08, Control # 166-02

19

TM500E-2 CARRIER OPERATOR’S MANUAL • Check level in the windshield washer reservoir. If washer fluid needs to be added, use a commercially reputable washer fluid that has good cleaning capability and does not freeze in cold weather.

The windshield washer reservoir is located just behind the grille and is accessed through the hatch, centered above the grille where the reservoir filler neck is located.

Figure 14

Figure 15

AC-180-0705-01232-B

Figure 14

AC-185-0506-G500

1 – Engine Oil Dipstick 2 – Oil Cap 3 – Transmission Oil Dipstick

Total reservoir capacity is approximately 1.0 gallon (4 liters). Check that windshield wipers and washer are working properly.

Figure 13 • Check oil level in the engine with the dipstick Figure 13 (1) located on the right side behind the cab. The oil level should be between the minimum and maximum marks on the dipstick. Do not overfill!

Use Chevron Delo #400 15W40 engine oil or equivalent.

The windshield washer spray should cover the windshield well. The wipers should clean the windshield in a couple of strokes and should not leave any streaks.

If the windshield needs an overall cleaning, use a long-handled cleaning sponge and squeegee.

Figure 16

To add oil to the engine, remove the oil cap Figure 14 (2) on the filler tube (below the oil dipstick) and fill through the tube.

Make sure the oil added is the same type of oil that is in the engine. The wrong type of oil could accelerate engine wear if not suited for application.

• Check the transmission oil level with the dipstick Figure 13 (3) located on the right side behind the cab. The oil level should be between the minimum and maximum marks on the dipstick.

See Page 57 - Oil Level Sensor for procedure to check the transmission oil. (Use Castrol Transynd transmission oil ONLY.)

20

Figure 15 • Clean the side windows in the same way with a long-handled sponge and squeegee.

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL

SAFETY FEATURES

Figure 17

7179

Safety Belts General

Safety belts must be properly worn at all times by the driver and passenger while the crane is in motion. Failure to do so can result in serious personal injury or death in the event of a collision.

Fasten the safety belt before starting to drive. Trying to fasten the safety belt while the crane is moving may lead to an accident, and can cause serious personal injury or death.

Figure 16 • Check all lights for proper function: • Headlights •

Daytime running lights

•

Parking and marker lights

•

Stoplights

•

Turn signals

Figure 19

Figure 18

Figure 18 Safety belt assemblies installed in this crane meet FMVSS 209, “Type 1” and “Type 2” requirements.

They are recommended for all persons weighing over 50 lbs (25kg).

Figure 17

When draining the air tanks, do not look into the area of the draining air. Dirt or sludge particles may be expelled in the air stream and can cause eye injury.

• Empty out the air tanks daily. With the air system fully charged and with the engine shut off, listen for air leaks. Air tank drains are located under the battery box.

Published 05-30-08, Control # 166-02

21

TM500E-2 CARRIER OPERATOR’S MANUAL Tether straps are installed on some suspension-type seats. Tether straps help secure the seat to the floor and are intended to restrain the seat and safety belt in case of an accident or sudden stop.

Figure 20

The tethers are not adjustable.

Operating the Safety Belt Figure 22

AC-884-0508-G008

Figure 19 Safety belts must be worn by the driver and passenger at all times. Before adjusting or fastening the safety belt, move the seat forward or rearward and adjust the seat height as necessary.

Sit erect and adjust the seat cushion and seat back for a comfortable driving position. In the event of a collision, a correct driving position maximizes the effectiveness of the safety belt.

Fasten the safety belt before starting to drive. Trying to fasten the safety belt while the crane is moving creates a hazard.

Figure 21

AC-884-0508-G009

Figure 21 To fasten the safety belt, pull the belt out from the retractor and insert the latch into the buckle. Verify proper lock of the latch by pulling on the latch.

Adjust the slack by pulling on the top part of the belt until the lower part, or the part that crosses the lap, is snugly adjusted. Release the top part and let the retractor pull the belt in.

The lap portion of the safety belt should be worn low across the pelvic region (hip bone) and adjusted snugly. Never adjust the lap belt across the abdomen. A push button on the buckle is used to release the safety belt latch by pushing in the button release on the buckle.

Figure 20

22

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 23

Figure 24

Figure 23 Note: After the crane has been started, a telltale indicator light Figure 24 on the dashboard will remain illuminated until the driver’s safety belt is secured. Additionally, an audible tone will be emitted until the safety belt is secured, or until two minutes’ time has elapsed.

AC-884-0508-G010

Figure 22 If a Komfort Latch™ is used on the safety belt, always adjust the belt so that there is a maximum of 1" (25 mm) of slack between the belt and chest (about two fingers’ width). If a larger slack is allowed, in the event of a collision, the effectiveness of the safety belt is decreased. Operation of the clip is described in Komfort Latch™ Operation on page 32.

Make sure the safety belt is completely retracted and out of the way when not in use.

Inspection Check the belts, buckles, latch plates, retractors, anchors and guide loops to ensure that they are working properly. Look for loose/damaged parts (without disassembling) that could keep the restraint system from working properly. If the safety belt, retractor and hardware were in use during a collision, they must be replaced. The restraint system anchoring fasteners must be replaced if necessary. If there is any doubt about the restraint system’s effectiveness, replace the entire safety belt assembly.

Failure to properly inspect and maintain the safety belts can cause serious personal injury or death.

It is critical that any time a crane has been involved in an accident, the entire safety belt system must be replaced in the crane if they were in use at the time of the accident. Failure to replace the safety belt system may result in serious injury or death.

A damaged safety belt, whether visibly damaged or not, could result in serious personal injury in the event of an accident. The safety belt systems should be replaced at least every five years.

Do not bleach or re-dye the color webbing because it may cause a severe loss of belt strength. This loss of strength could allow the safety belt to break under stress, thus resulting in severe personal injury or death.

The following maintenance guidelines detail how to inspect safety belts and tethers for cuts, fraying, extreme or unusual wear of the webbing, etc., and damage to the buckle, retractor, hardware or other factors which indicate that safety belt system replacement is necessary.

Published 05-30-08, Control # 166-02

23

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 25

Figure 27

Figure 24

Figure 26

Check the web wear at the buckle/latch area. The webbing must be closely examined to determine if there are any cuts, fraying or extreme wear in the webbing. Cuts, fraying or excessive wear would indicate the need for replacement of the safety belt system.

Check to make sure that the D-loop web guide is rotating properly. If the guide is not rotating properly, the webbing will pull at the wrong angle through the guide, accelerating wear.

If equipped, check the Komfort Latch™ for cracks or possible damage. Make sure that it works properly.

Figure 26 Figure 28

Figure 25 The D-loop web guide is an area where almost constant movement of the safety belt webbing occurs because of the relative movement between the seat and the cab. This constant movement forms an area where wear will often occur. The webbing must be closely examined to determine if there are any cuts, fraying or extreme wear in the webbing. Cuts, fraying or excessive wear would indicate the need for replacement of the safety belt system.

24

Figure 27 Check the buckle by inserting the latch and verifying proper operation. Determine if the latch plate is worn or deformed. Check the buckle and latch casing for cracks or breakage.

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Check the web in areas exposed to ultraviolet rays from the sun or extreme dust or dirt. If the original color of the web in these areas is extremely faded, the physical strength of this web may have deteriorated. If this condition exists, replace the safety belt system.

Figure 29

Important Facts About Safety Belts in Heavy Crane Driving

Figure 28 The retractor web storage device is mounted on the B-pillar, just behind the door in the cab. The retractor is the heart of the safety belt system and can be damaged if abused, even unintentionally.

Check the retractor web storage device operation to ensure that it is not locked and that it spools out and retracts the webbing properly.

If tethers are being used to anchor the safety belts to the floor, make sure that they are properly attached to the seat. Tethers must also be inspected for web wear and proper tightness of mounting hardware.

Figure 30

Figure 29 All hardware for safety belt mounting points should be evaluated for corrosion. All attachment points of the system should be checked for tightness of mounting hardware.

The high mileage associated with some crane uses, the continual relative movement of the seat with the cab, the possible contact with the crane seat or other parts of the cab structure, and the potential exposure of this safety belt to severe environmental conditions make it crucial to inspect the safety belt system regularly. It is recommended that the system is inspected every 15,000 miles (24,000 km) or more often if the crane is exposed to severe environmental or vocational conditions. Any safety belt system that shows cuts, fraying, extreme or unusual wear, significant discoloration due to ultra-violet exposure, dusty or dirty conditions, abrasion to the safety belt webbing, or damage to the buckle, latch plate, retractor, hardware or any other obvious problem should be replaced immediately, regardless of the mileage.

Once replacement of the safety belt has been determined necessary, be certain that it is replaced only with a Manitowoc original replacement safety belt. See your authorized Manitowoc dealer for replacement. Your Manitowoc safety belt system has been developed and tested specifically for your crane. Replace it only with the exact same design that the crane was equipped with.

If the inspection indicates that any other part of the safety belt system requires replacement, the entire belt system must be replaced. An installation guide is attached to every replacement system, entitled “Three-Point Safety Belt Installation Guide.” There are separate safety belt instruction guides for suspension and stationary seats. Use the proper guide for your type of seat and follow the instructions very closely. It is vitally important that all components are mounted back in the same position as the original components that were removed. This will maintain the design integrity of the mounting points for the safety belt assembly.

Published 05-30-08, Control # 166-02

25

TM500E-2 CARRIER OPERATOR’S MANUAL Komfort Latch™ Operation

Figure 32

Figure 31

AC-884-0508-G010

Figure 31

AC-884-0508-G011

Figure 30

Always adjust the clip so that there is a maximum of 1" (25 mm) of slack between the belt and chest (about two fingers’ width). If a larger slack is allowed, the effectiveness of the safety belt is decreased in the event of a collision.

When provided, the Komfort Latch™ is located on the shoulder strap just below the D-ring.

When adjusting the Komfort Latch™, the following procedure must be followed for proper adjustment: 1. Pull out only enough webbing to allow slight pressure to the shoulder and chest. There should be a maximum of 1" (25 mm) of slack (approximately two fingers’ width) when measured between the chest and the belt. See Figure 31.

2. To activate the clip mechanism feature, lift the lever up to clamp the webbing in place.

Note: When the safety belt is not in use, the clip should be in the open position to allow the safety belt to retract to its proper position. Also make sure that the adjustment of the Komfort Latch™ does not interfere with the operation of the safety belt.

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Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL

INSTRUMENTS AND CONTROLS Dashboard Overview Figure 33

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1 – Main Instrument Cluster Page 28 2 – Telltale Warning Center Page 34

3 – Center Switch Panel Page 40 4 – Transmission Selector Page 55

Figure 32

Operating Before driving this crane, locate instruments and controls, and become thoroughly familiar with their operation. After starting and when driving, always check that the instrument readings are normal.

A Battery Main Disconnect switch is standard on this unit.

Note that outside marker lights on the cab stay lite to warn to disconnect the switch.

Note: When the ignition key is turned to the ON position the gauge indicators on all instruments with the exception of the speedometer and tachometer will perform a self test sweep through the full range to verify the instrument is working.

Published 05-30-08, Control # 166-02

27

TM500E-2 CARRIER OPERATOR’S MANUAL

Main Instrument Cluster Figure 34

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1 – Tachometer & Hourmeter Page 29 2 – Speedometer & Odometer Page 29 3 – Engine Oil Pressure Page 30

4 – Engine Coolant Temperature Page 31 5 – Fuel Level Page 32 6 – Reserve Pressure “A” Page 32 7 – Reserve Pressure “B” Page 32 8 – Telltale Warning Indicators Page 34

Figure 33

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Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Tachometer

Speedometer

Figure 35

Figure 36

Figure 34

7004

The tachometer is electrically driven by a signal forwarded from the speedometer. Monitor the tachometer to guide correct gear shifting (manual transmission) and to prevent engine overspeed when descending steep grades. Each engine has its ideal operating ranges for power and economy.

Read the engine manufacturer’s operator’s manual to determine the best operating range for your engine.

Figure 35

7002

The speedometer is driven by a signal from the gateway module. The speedometer shows the crane speed in both miles per hour (mph) and kilometers per hour (kph). Additional information sent from the gateway module to the speedometer then uses the speedometer to forward information to the appropriate gauge. Recalibration of the ECU can be made to compensate for any change to tire size or other changes in the crane driveline. This is done by recalibration of the ECU by your local Manitowoc dealer.

Always keep an eye on the tachometer during downhill runs. Do not allow the engine to overspeed. Excessive engine overspeed could result in serious engine damage.

Engine Hour Meter The engine hour meter is a liquid crystal display (LCD) mounted in the lower tachometer face. The hour meter only accumulates hours when the engine is running.

Published 05-30-08, Control # 166-02

29

TM500E-2 CARRIER OPERATOR’S MANUAL Odometer

The gauge indicates oil pressure from a signal from the engine ECU forwarded via the speedometer which monitors the engine lubrication system.

Normal oil pressure is 30 - 70 psi (210 - 480 kPa) when the engine is at normal operating temperature. At idle speed, the pressure may drop to 5 - 20 psi (35 - 140 kPa). When first starting a cold engine, oil pressure may exceed 90 psi (620 kPa). If the oil pressure remains below the normal operating range, the engine should be checked for problems by your authorized Manitowoc dealer.

Figure 37

Figure 39

Figure 38 Figure 36

7003

Figure 40

The odometer is a liquid crystal display (LCD) mounted in the lower speedometer face. The odometer registers up to 999,999.9 miles or kilometers.

Engine Oil Pressure Figure 38

Figure 39

Figure 37

The low oil pressure warning limit is dependent on the engine manufacturer’s electronic program. With low oil pressure, the Check Engine telltale Figure 38 will illuminate and sound an alarm. The engine is at risk of damage. The engine controller reacts by de-rating the engine’s power. The engine will lose power gradually as long as the oil pressure is below the activation pressure and will, given time, decrease output to 50% of full power. When the pressure has increased to above the activation point, the power will gradually increase to full power again. Stop at the first safe place where the problem can be checked.

Do not attempt to drive the crane or run the engine until a qualified service technician can diagnose the problem.

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Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Note: The Stop Engine telltale remains on even when the oil pressure returns to normal. The ignition key switch must be turned off and then on again to clear the warning mode.

Failure to observe correct precautions when the Stop Engine telltale lights up solidly could result in serious damage to the engine and/or other components.

Engine Coolant Temperature Figure 41

Figure 40 The gauge indicates engine coolant temperature.

For normal engine operating temperature reading, refer to your engine manufacturer’s operator’s manual. The temperature range for the coolant will vary depending on the type of engine, load, grade, ambient air temperature and operating conditions.

If the temperature remains below or exceeds the normal temperature range, the cooling system should be checked for problems by by a qualified service technician.

Figure 43

Figure 42 The high temperature warning limit is dependent on the engine manufacturer’s electronic program. With high temperature, the Check Engine telltale Figure 41 will illuminate and sound an alarm. The engine is at risk of damage. The engine controller reacts by de-rating the engine’s power. The engine will lose power gradually as long as the temperature is over the activation temperature and will, given time, decrease output to 50% of full power. When the temperature has decreased to under the activation point, the power will gradually increase to full power again. Stop at the first safe place where the problem can be checked.

If the high temperature condition remains, and if your engine electronic control module has been programmed for engine shutdown, the Stop Engine telltale Figure 42 will illuminate and sound an alarm for 30 seconds. In this time, safely pull the truck off of the road and away from traffic. The engine electronic control module will shut the engine down.

After allowing the engine to cool, an engine restart can be attempted. The engine electronic control module will determine whether to allow a restart, based on whether or not the engine temperature has returned to the normal operating range.

Do not attempt to drive the crane or run the engine until a qualified service technician can diagnose can diagnose the problem.

Figure 42

Figure 41

Published 05-30-08, Control # 166-02

31

TM500E-2 CARRIER OPERATOR’S MANUAL Note: The Stop Engine telltale remains on even when the temperature returns to normal. The ignition key switch must be turned off and then on again to clear the warning mode.

Failure to take necessary action when the Stop Engine telltale is on can result in automatic engine shutdown and loss of power steering assist. Crane crash can occur causing serious personal injury or death.

Figure 45

Figure 44 If the fuel level is depleted to a specific level, the Low Fuel telltale will illuminate. An alarm will sound to indicate that the fuel level is low.

Failure to observe correct precautions when the Stop Engine telltale lights up solidly could result in serious damage to the engine and/or other components.

Use ultra low sulfur diesel fuel only.

Using a diesel fuel that is not ultra low sulfur will damage the diesel particulate filter and can damage the other emission system components.

Fuel Level

Reserve Pressure “A” & “B”

Figure 44

Figure 46

E

ULTRA LOW SULFUR FUEL ONLY

FUEL LEVEL

F D

AC-380-0701-01155-A

Figure 43

AC-382-0505-00863-B

The gauge is connected to a sending unit in the fuel tank via the gateway module on the right-side frame rail.

Figure 45 Figure 47

AC-382-0505-00884-B

Figure 46 32

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL The system air gauges are connected to the front and rear circuit tanks via the gateway module on the right-side frame rail. The two gauges should register equal air pressure. Air brake system pressure should be between 90 - 135 psi (620 - 930 kPa) for normal operation.

By observing the gauge pointers, the operator can detect a pressure drop if an air leak develops and can readily identify the circuit affected.

Figure 48

Figure 47 There is a low-pressure warning switch connected to each air circuit. If the pressure in a brake circuit air tank drops below approximately 65 psi (450 kPa), the telltale Figure 47 will illuminate and sound an alarm. If the air pressure is allowed to drop below 30 - 40 psi (205 - 275 kPa) in both systems, the parking brakes will automatically engage to stop the vehicle.

Failure to observe these precautions can result in the loss of braking performance and personal injury or death can occur as a result of a crane crash.

Published 05-30-08, Control # 166-02

33

TM500E-2 CARRIER OPERATOR’S MANUAL

Telltale Warning Indicators Figure 49

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1 – DPF (Diesel Particulate Filter) Page 35 2 – Check Engine Page 35 3 – Stop Engine Page 35 4 – Brake Pressure Page 36 5 – High Beams Page 36 6 – Transmission Temperature Page 36 7 – Transmission Warning Page 37 8 – ABS, Front Page 37 9 – ABS, Back Page 37

10 – Air Filter Page 37 11 – HEST (High Exhaust System Temperature)

Page 37 12 – Parking Brake Page 38 13 – Neutral Page 38 14 – Wait to Start Page 38 15 – Communication Error Page 38 16 – Charging System Page 38 17 – Traction Control Page 38 18 – Fuel Page 39 19 – Safety Belt Page 39

Figure 48 Note: The telltales are located above the tachometer and speedometer.

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Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Diesel Particulate Filter Figure 50

AC-384-0701-01156-A

Figure 49 The Diesel Particulate Filter (DPF) telltale will illuminate when the DPF system must undergo a regeneration cycle. The regeneration cycle is necessary to burn off the accumulated soot particles trapped in the diesel particulate filter system. The regeneration cycle is an automatic process and should occur when the exhaust heat reaches a sufficient temperature to begin the process.

If the DPF lamp begins blinking once per second, then the need for the regeneration cycle has become urgent but has not started. At this point it is recommended that the operator take the crane for a short drive at a minimum speed of 25 mph. This will increase the exhaust heat, and should help trigger the regeneration cycle.

The Check Engine telltale only illuminates when there is a problem in the electronics, wiring or sensors. The engine or crane electronic units not only monitor component operating levels but also do self-monitoring. If a problem is found that is not component-related, the Check Engine telltale will light up. The Check Engine telltale will stay illuminated for two minutes, go dark for eight minutes, and repeat the cycle until the ignition is switched off. If the problem still exists when the ignition is turned on, the Check Engine telltale will illuminate again.

The problem is also logged in the diagnostic memory for later viewing. The problem is typically not of any immediate danger to the crane. Drive safely to the next service shop to have the problem rectified.

If the Check Engine telltale comes on after the Diesel Particulate Filter telltale has been blinking, the problem could be with the exhaust system. The operator may need to take the crane for a drive at a minimum speed of 20 mph to increase exhaust gas heat in order to trigger an active regeneration cycle, or return the crane to the shop.

Stop Engine Figure 52

Reference Engine Start and Operation Page 50 for further information on the DPF System regeneration process.

Failure to take necessary action when the Stop Engine telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist. Crane crash can occur leading to serious personal injury or death.

Check Engine Figure 51

Figure 51 For high coolant temperature or low oil pressure, the Stop Engine telltale will light up solid with a steady-on audible alarm. The engine is at risk of damage and the engine controller reacts by de-rating the engine power. The engine will lose power gradually as long as the oil pressure or temperature are outside of the normal operating range and, given time, decrease output down to 50% of full power. If the oil pressure or coolant temperature return to normal operating range, power will gradually increase to full again. Stop at the first safe place where the problem can be checked.

Figure 50

Published 05-30-08, Control # 166-02

35

TM500E-2 CARRIER OPERATOR’S MANUAL For low coolant level or low oil pressure with the Extended Protection, the engine will be forced to idle speed within 30 seconds from when the light came on, followed by a forced shutdown. Pull off of the road as soon as possible without being a safety hazard. When the crane speed falls below 1.5 mph (3 km/h), the engine shuts down.

When the master warning telltale comes on and before the parking spring brakes engage, stop the crane in a controlled manner at an off-road location so as not to be a hazard to other vehicles on the road.

If the Stop Engine telltale illuminates after the Check Engine light illuminates and the Diesel particulate Filter lamp is out, the crane must be returned to the shop to have the DPF removed and cleaned.

Failure to observe these precautions can result in the loss of braking performance and personal injury or death can occur as a result of a crane crash.

High Beams Figure 54

Failure to take necessary action when the Stop Engine telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist. Crane crash can occur, leading to serious personal injury or death.

Brake Pressure

Figure 53

Figure 53

Any time the high beams are activated by the high/low beam switch, the High Beams telltale illuminates blue. For information on switching high/low beam, see Steering Column Switches/Controls Page 44.

Transmission Temperature Figure 55

Figure 52 The Brake Pressure telltale will illuminate when either front or rear air brake system pressure drops below 65 psi (450 kPa). The alarm will also sound when the telltale lights up. When the pressure goes above 65 psi (450 kPa) in both primary and secondary brake circuits, the telltale automatically goes out and the audible alarm stops.

Air brake system pressure should be between 90 135 psi (620 - 930 kPa) for normal operation. The air pressure telltale comes on and the buzzer sounds when air pressure has dropped to 65 psi or lower. If the air pressure is allowed to drop below 30 - 40 psi (200 - 275 kPa) in both systems, the parking spring brakes will automatically engage and stop the crane.

Figure 54 The Transmission Temperature telltale will illuminate when the transmission sump temperature reaches a point where transmission damage is possible. The Transmission Temperature telltale will illuminate with a steady-on audible alarm when the transmission temperature reaches 250°F (121°C). When the transmission temperature has decreased to 240°F (116°C), the telltale indicator and the audible alarm will stop.

For more information, see Transmission Warning Functions Page 60.

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Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Transmission Warning

If the ABS telltale illuminates during driving, the ABS self-test has detected a fault in the system.

Figure 56

The crane can still be driven with a problem in the ABS. However, the ABS will not be operating and standard air braking is in effect. For more information on operation of the ABS, see Anti-Lock Brake System (ABS) Page 65.

Figure 55 The Transmission Warning telltale will illuminate when a fault within the transmission is detected.

The Transmission Warning telltale will illuminate with a steady-on audible alarm when a fault is detected. The tone will stop after 15 seconds and the telltale indicator will remain illuminated.

For more information, see Transmission Warning Functions Page 60.

Operating the crane without ABS can result in loss of control of the crane in an emergency braking situation or on low traction conditions. A loss of crane control can lead to an accident, which may result in serious injury or death.

Air Filter Figure 59

Anti-Lock Brake System Figure 57

Figure 58 The Air Filter Restriction telltale will illuminate when the air filter becomes clogged.

High Exhaust System Temperature Figure 56

Figure 60

The Anti-Lock Brake System telltale will illuminate amber if the Anti-Lock Brake System (ABS) senses a problem under the following conditions: The system will go through its self-test when the ignition switch is turned on, and the telltale should continue to be on until the self-test is over. If the telltale stays on, there is a problem with the ABS.

AC-384-0701-01157-A

Figure 59 The High Exhaust System Temperature (HEST) telltale will illuminate when the exhaust system is operating above normal temperatures, or when the exhaust system is going through the active regeneration phase.

Figure 58

Figure 57 Published 05-30-08, Control # 166-02

37

TM500E-2 CARRIER OPERATOR’S MANUAL Parking Brake

Communication Error

Figure 61

Figure 64

Figure 63 Figure 60 The Parking Brake telltale will illuminate when the parking brake is applied. The indicator will darken when the parking brake is released.

For more information, see Parking Brake Valve Page 63.

If the telltale indicator panel on the dashboard loses communication with the engine, transmission or ABS, the Comm Error telltale will illuminate. An audible alarm will sound when the Comm Error telltale illuminates, and will stop after 15 seconds.

Charging System Figure 65

Neutral Figure 62

Figure 61 The Neutral telltale is driven by the transmission's neutral circuit and will activate when the crane is at risk of rolling, i.e., the Neutral position is engaged and the parking brake is not applied. The Neutral telltale also illuminates any time the transmission is switched to neutral, or when the Auto Neutral switch is activated and the crane comes to a stop without the parking brakes applied.

Wait to Start

Figure 64 The No Charge telltale will illuminate to indicate the alternator is not charging the crane’s batteries.

Note: Not all alternators will support the No Charge telltale function.

For more information, see General Safety Guidelines General Safety Guidelines.

Figure 63

Fuel Figure 66

Figure 62 The Wait to Start telltale is driven by the engine’s electronic control unit (ECU). If the Wait to Start telltale is illuminated, DO NOT START THE ENGINE. If the Wait to Start telltale remains illuminated, contact an authorized Manitowoc service center for further assistance.

38

Figure 65 If the fuel level is depleted to a specific level, the Low Fuel telltale will illuminate. It will be accompanied by an audible tone for the first two seconds that the telltale is illuminated.

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Safety Belt Figure 67

Figure 66 The Safety Belt telltale illuminates red each time the ignition is turned on to remind the driver to fasten the safety belt. It stays on for a set period of time and then goes out automatically.

Before adjusting the safety belt, make sure the crane is stationary and that the seat has been adjusted as required. Do not attempt to adjust the safety belt or seat while the crane is in motion.

For proper use of the safety belt, see Safety Belts Safety Belts.

Published 05-30-08, Control # 166-02

39

TM500E-2 CARRIER OPERATOR’S MANUAL

Center Switch Panel Figure 68

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1 – Ignition/Start Key Page 41 2 – Engine Diag Active Reg Page 42 3 – Headlights Page 41 4 – Engine (Exhaust) Brake Page 43 5 – Cruise Control Page 42 6 – Parking Brake Page 63 7 – Heater and A/C Controls Page 46

40

8 – Transmission Gear Selector Page 55 9 – Cross Axle (Differental) Lock Page 43 10 – Interaxle Lock (Optional) Page 43 11 – Deflate Air Ride Suspension Page 43 12 – Pusher Axle (Optional) Page 44 13 – Windshield Wiper/Washer Page 41 14 – Interior Lights - Page 46 15 – Instrument Light Dimmer Switch Page 43

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Ignition/Start Key

Figure 71

7179

Figure 69

AC-334-0705-01240-A

Figure 67 The starter switch consists of a keyed ignition switch. Key positions are OFF, ACC (accessories), IGN (ignition) and STR (start) for all engines. See Engine Start and Operation Page 58 for proper starting and preheating procedures.

The key switch enables the engine when turned to the ON position. To shut the engine off, turn the key to the OFF position.

Figure 69 Daytime Running Lights (DRL) are automatically switched on when the parking brakes are released (ignition must be on) and will stay on until the parking brakes are engaged or the headlights are switched on.

Windshield Wiper/Washer

Headlights

Figure 72 Figure 70

AC-364-0701-01165-A

Figure 68

Figure 70

The Headlight switch controls parking lights and headlights. It is a three-position toggle switch, turning on parking lights, cab marker lamps and taillights in the middle position and turning on headlights in the upper position. The lower position turns all lights off.

The wiper/washer functions are operated by the Windshield Wiper/Washer switch. The wipers are equipped with intermittent wipe function as standard. Push the switch upward from the OFF position to activate the wiper delay function. In the intermittent mode, there are six different levels of delay.

The headlights are of a halogen sealed beam type.

If one of the lights is not functioning, replace the whole lamp.

Pushing the switch upward past the sixth intermittent wiper setting will active the low wiper speed. The next detent will activate the high wiper speed.

Published 05-30-08, Control # 166-02

41

TM500E-2 CARRIER OPERATOR’S MANUAL Note: The wiper motor contains a built-in protective thermal switch that will shut down the motor if it is overloaded. The continued operation of the wipers over a dry windshield for an extended period may overload the wiper motor sufficiently to trip the thermal switch.

The electric windshield washer is also operated by the Windshield Wiper/Washer switch. Depress and hold the rocker switch to operate the washer.

Release the switch to stop.

Cruise Control Figure 73

To engage the cruise control and set the crane speed: 1. Set the cruise control ON/OFF switch to the ON position.

2. When the desired crane speed has been reached, move the SET/RES switch to the SET position.

3. If the crane speed needs to be increased, push the SET/RES switch upward to accelerate the crane. The crane speed will increase as long as the switch is held. Release the switch when the desired speed has been reached.

4. To reduce the crane speed, push the SET/RES switch downward to decelerate the crane. The crane speed will decrease as long as the switch is held. Release the switch when the desired speed has been reached.

Note: As an option, some cranes may be equipped with Base PTO Mode. Base PTO Mode allows the crane to be operated with the cruise control engaged below 30 mph.

This feature is a function of the electronic engine control unit. Refer to the engine manufacturer’s operator’s manual for more information.

Note: The Cruise Control switches may be used to control more functions than just the cruise control. Ensure that you are familiar with the operating characteristics of the crane and any additional functions the Cruise Control switches have control over.

Figure 71 Figure 74

Engine Diagnostic Active Regeneration Figure -3

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Figure 72 The Cruise Control switches are located on the center switch panel.

Figure 73

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Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL This switch is a dual function switch. It enables the operator to turn on or off the engine diagnostic testing mode or to initiate stationary exhaust regeneration. If engine RPM is zero - it functions as the regeneration initiate switch. The switch must be cycled on and off ti initiate regeneration. The brake pedal must be released. The engine will automatically change speed as needed. The cycle will take approximately 20 minutes.

A cross axle lock should be used only on a slippery surface and not when driving on good road conditions. See Axles and Wheels Page 72 for information on how to properly engage and drive with cross axle locks engaged.

Interaxle Lock (optional) Figure -4

Instrument Light Dimmer Switch Figure 75

Figure 76

Figure 74 The Instrument Light Dimmer switch controls the instrument light. The instrument lights are activated by the headlight switch. Light intensity can be adjusted between bright and dim by pressing the rocker switch to increase or decrease light intensity in increments.

Cross (Differential) Axle Locks (Optional) Figure 76

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The interaxle lock is used to provide additional traction in conditions where all drive wheels are slipping. The interaxle lock switch, when engaged locks the forward-rear and rear-rear axle together, ensuring that both axles receive motive power.

Use the interaxle lock switch only to move the truck out of conditions where all drive wheels are slipping. Once suitable traction has been achieved, disengage the interaxle lock.

Note: Do not engage the interaxle lock while the vehicle is in motion or when the wheels are turning.

The interaxle lock can be disengaged while the vehicle is in motion.

Figure 75 The cross axle lock eliminates one-wheel spin on slippery surfaces and improves traction. When the wheel lock is engaged, a telltale illuminates in the Cross Axle Lock switch.

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TM500E-2 CARRIER OPERATOR’S MANUAL Exhaust Brake

Deflate Air Ride Suspension

Figure 77

Figure -5

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Figure 78 Figure 77 The suspension system air bags are inflated by pressing UP on the switch, to deflate the air bags press the word LOWER. A crane speed retardation device, “Exhaust Brake,” is not intended to replace the service brake system on your crane, nor is it intended to bring your crane to a stop. A crane speed retardation device is only intended to retard the speed of your crane under certain conditions.

Pusher Axle (Optional) Figure -6

7176-7

Note: It is normal for there to be a slight delay in the application of a crane speed retardation device. When using a device of this type, be sure to think ahead and analyze conditions in order to use the device properly.

Failure to observe these precautions can result in loss of crane control and serious personal injury or death can occur.

Turning the Engine Brake switch to the ON position activates the crane's engine brake system.

44

Figure 79 The Pusher Axle is an option and may not be included on your crane. The pusher axle provides the crane with the capability to meet additional highway weight requirements for over the road travel. Press DOWN on the switch to lower the axle, flip the switch up to raise the axle to the stowed position.

Published 05-30-08, Control # 166-02

TM500E-2 CARRIER OPERATOR’S MANUAL Cigar Lighter

The headlight beam change is done by a switch at the end of the turn signal switch. Depress the button fully for changing between low beam and high beam.

Figure 78

Hazard Light Switch Figure 80

Figure 80 To operate the cigar lighter, press in the center until it stays in. The heater element heats up and the lighter pops out when it is ready for use.

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The ashtray is located on top of the center panel.

Steering Column Switches/Controls Turn Signal/Headlight Beam Change Figure 79

Figure 82 The hazard or four-way warning circuit is activated by pulling out the tab under the turn signal lever until it locks in place. The hazard lights function independently from the ignition switch. To cancel the hazard lights, move the turn signal lever either up or down.

Activate this function only when the crane is stopped where it might be a danger to other cranes or to alert others of a problem that changes the traffic rhythm.

Miscellaneous Switches/Controls Horn Button Figure 81

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Figure 81 The turn signal is activated by the lever under the left side of the steering wheel. The turn signal switch is not self-canceling. It must be manually returned to the neutral position after making a turn.

For lane changes, the lever does not need to be moved to a locking position. Move the lever partway off the normal position until resistance is felt. The turn signal is now activated and the lever will return to normal position when it is released.

Figure 83 An electric horn is standard equipment. It is operated by the button in the middle of the steering wheel.

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TM500E-2 CARRIER OPERATOR’S MANUAL

Cab Ventilation

Air Horn Figure 82

Ventilation Guidelines If at any time it is believed that exhaust fumes are entering the cab, have the cause of the fumes determined and corrected as soon as possible. If the crane must be driven under these conditions, drive only with all windows open.

AC-362-0705-01241-A

Figure 84 The air horn control is located above the driver side door. The cord is pulled to activate the air valve feeding air to the horn(s).

INTERIOR LIGHTS Figure -7

7176-9

Protect against carbon monoxide entry into the cab.

Keep the engine exhaust system, cab and cab ventilation system properly maintained. It is recommended that the exhaust system and cab are inspected by a competent technician: • At every oil change • Whenever a change is noticed in the sound of the exhaust system • Whenever the exhaust system, underbody or cab is damaged

Do not breathe the engine exhaust gas. It contains carbon monoxide, which has no color or odor. Carbon monoxide is a dangerous gas which can cause unconsciousness or death.

To allow for proper operation of the crane ventilation system, keep the inlet grille at the front of the cab clear of snow, ice, leaves and other obstructions at all times.

Figure 85 The interior light switch turns the two cab interior overhead lights on and off.

HEATING AND AIR CONDITIONING General The standard heater controls for the Carrier cab are mounted on the center console and consist of three sliding adjustment knobs that control air distribution, fresh air and temperature and an adjustment knob for setting the fan speed (OFF-Low-Medium-High).

The air conditioning system consists of a roof mounted unit with an overhead console where the temperature control knob and the four position (OFF-Low-Medium-High) fan speed knob are set.

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Do not park the crane and let the engine run or idle for more than 10 minutes with the ventilation system control switch in the OFF position. Even with the ventilation system on, running the engine while parked or stopped for long periods of time is not recommended. Entry of carbon monoxide into the cab is possible with a poorly repaired, damaged or corroded exhaust system or cab.

Do not run the engine in confined areas, such as garages or next to a building, any more than necessary. The area must be properly ventilated.

When the crane must be stopped with the engine running for more than a few minutes: • Adjust the heating or cooling system to force outside air into the cab. Do this by setting the fan to medium or high speed and with the controls set in any position except for recirculation of air inside of the cab.

• Keep the exhaust pipe area clear to help reduce the buildup of exhaust gas under the crane.

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TM500E-2 CARRIER OPERATOR’S MANUAL

SEATS

Figure 85

General All adjustments are to be made while the operator is seated and the crane is stationary. Do not adjust seat position while driving the crane. Failure to follow this warning can result in loss of crane control, which can result in serious personal injury or death in the event of a crash.

Before adjusting or fastening the safety belt, move the seat forward or rearward and adjust the seat height as necessary. Sit erect and adjust the seat cushion and seat back to obtain a comfortable driving position.

1 – Backrest tilt: By rotating the round handle, the backrest recline angle can be adjusted within 12 degrees. By lifting the adjustment lever, leaning back as if reclining the seat and then releasing, the adjustment lever will adjust the backrest tilt as well.

2 – Lumbar support adjustment: Push the switch up to inflate the support for firmer support. Push the switch down to deflate the support.

3 – Ride height adjustment: Push the switch up to increase ride height. Push the switch down to deflate the airbag and lower the ride height.

4 – Fore and aft movement: Press the lever sideways to unlock the seat. Move seat fore or aft to a new position.

5 – Cushion front tilt and length: Pulling the handle up and out adjusts the tilt and length of the seat cushion.

Seat Adjustments Figure 83

AC-852-0312-G843-A. Figure 84

Figure 86

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TM500E-2 CARRIER OPERATOR’S MANUAL

FUEL ECONOMY DRIVING

A good indication of an axle or wheel out of alignment is uneven tire wear. Check the tires often.

Fuel Economy

Engine

The absolute fuel consumption (counted in miles per US gallon (mpg) or liters per 100 kilometers (L/100 km) for highway driving and gallons per hour (gph) or liters per hour (lph) for off-road is determined by a large number of circumstances which can be related to one of the following main areas:

Faulty or incorrectly adjusted engine components increase fuel consumption. The list below gives some typical components that can influence fuel consumption:

1. Build specification and equipment 2. Service and maintenance 3. External environment 4. Driving habits Due to these factors, fuel consumption can vary considerably within what is called “normal fuel consumption.” Fuel consumption can vary widely between easy driving conditions with a light load to driving with a maximum permitted GVW on hilly or slushy winter roads.

• Air blockage (on the outside charge air cooler/radiator package) • Faulty thermostats • Blocked fuel filter • Blocked air intake filter • Faulty injectors • Dirty turbocharger • Air in fuel system • Faulty fuel supply pump • Faulty fuel relief valve • Faulty fan thermostat/clutch

Tires

External Environment

Heavy duty treaded tires increase rolling resistance considerably. For standard hauling duties, choose a smoother, ribbed-type tire. Choose a lugged-type tire only when the added traction in mud and/or snow is needed.

Under unfavorable conditions, the external environment can have a negative effect on fuel consumption. This can be separated into two main groups: weather and wind, and the nature of the roads. Rain, snow, icy conditions and headwinds have a negative impact on fuel economy, as do hilly roads and uneven road surfaces.

If the tire pressure is too low, the rolling resistance increases and, thereby, the fuel consumption. The overall economy is also affected as tire wear increases considerably.

Service and Maintenance A crane requires regular and preventive maintenance in order to ensure that all its components function as they should.

Brakes Dragging brakes increase fuel consumption. They should be checked regularly. It is important that the release action of the air valves is fast and that the moving parts of the wheel brakes are checked for good adjustment and operation.

Axles

Headwinds Headwinds have a large negative impact on fuel consumption. With following winds, fuel saving is only marginal.

Air Temperature Low ambient temperature contributes to increased fuel consumption.

Rain, Snow and Road Surface A wet road surface increases rolling resistance and, thereby, fuel consumption. Slush will increase consumption even more. In certain cases, the surface structure of the road can also have a negative effect on fuel consumption.

An axle out of alignment will increase rolling resistance. Regularly check the front wheel alignment and axle alignment. If they are correct, there will be less rolling resistance, and therefore, lower fuel consumption.

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TM500E-2 CARRIER OPERATOR’S MANUAL Gradients A hilly road with a lot of bends demands a higher output from the engine. The difference between flat, straight roads and hilly, winding roads can amount to as much as a 50 percent increase in fuel consumption.

When choosing your route, avoid hills, rough roads and frequent stops. Every stop from 45 mph (70 km/h) can cost up to an extra one quart (one liter) of fuel to get up to speed again.

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TM500E-2 CARRIER OPERATOR’S MANUAL Driving Habits How a crane is driven is the one factor which has the greatest influence on fuel consumption. Correct driving saves fuel and reduces crane wear. To achieve optimal running economy, the driver should always remember to:

ENGINE START AND OPERATION Starting the Engine Start Procedure

• Start the engine correctly (especially important in winter season) • Maintain an even and correct speed • Keep the engine in its optimum speed range • Use the correct uphill and downhill driving technique

Note: For cold weather starting, see Cold Weather Operation Page 52.

Note: These starting and operating procedures should be followed for all engines. For more detailed information over design and function, read the engine manufacturer’s operator’s manual.

Starting the Engine

Note: Before starting the engine, see Operating Page 27 for detailed information on how the gauges and telltales work.

Start the engine according to the instructions in the engine manufacturer’s operator’s manual. A proper start, especially during the cold season, saves fuel and reduces engine wear.

Sluggish lubricating oil in the engine makes cold starting more difficult. Therefore it is important to always use engine oil with the correct viscosity. (For the sake of the overall fuel economy it is also important to have the right viscosity of transmission and rear axle oils.)

Avoid High Engine Speeds High engine speeds mean high fuel consumption.

Erratic driving also increases fuel consumption when the crane is constantly accelerated and slowed down. Avoid higher consumption by steady, even driving.

Refer to each engine manufacturer’s operator’s manual for information on the engine’s optimum operating range.

Never operate the starter without first placing the transmission in NEUTRAL. Failure to follow these instructions may result in the unintentional movement of the crane causing property damage personal injury or death.

1. Before starting the engine, perform the engine pre-trip inspection and daily maintenance checks in Pre-Trip Inspection and Daily Maintenance Page 14.

2. Make sure the parking brakes are engaged.

3. Place the transmission in NEUTRAL. Figure 86

Hill Driving Technique Use the inertia of the crane to go over the crest of a hill under reduced power. Use gravity to help with acceleration when going down the hill. Build up speed before reaching the next uphill.

High Crane Speed

AC-334-0705-01240-A

With higher speed comes an increasing wind resistance that negatively affects fuel consumption.

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Figure 87

TM500E-2 CARRIER OPERATOR’S MANUAL 4. Turn on the ignition by turning the key switch to IGN. (See Ignition/Start Key Page 41 for ignition switch information.) Some telltales light up in a routine check that shows that bulbs and systems are OK. If any of the telltales stay lit after the crane has been started, that function of the crane may not be operable. Do not operate crane until problem is repaired.

Do not crank the engine for more than 30 seconds at a time; wait two minutes after each try to allow the starter to cool.

Failure to follow these instructions could cause starter damage.

Note: Some starters are equipped with an optional thermostat. If over-cranking occurs, the thermostat breaks the electrical circuit to the starter motor until the motor has cooled.

5. Turn the key to STR to start the engine.

Release as soon as the engine has started.

7. During warm-up, apply load gradually until the oil temperature reaches 140°F (60°C). To pull away in a crane, the minimum coolant temperature must be approximately 120°F (50°C).

If at start-up, or thereafter, the oil pressure gauge indicates any drop in oil pressure, the engine must be shut down immediately. Failure to stop engine may cause major engine damage.

Starting After Extended Shutdown or After Oil Change If an engine has been sitting unused for more than four days or if an oil change has been performed, it is recommended that the oil pressure be established before starting the engine. This can be done by cranking the engine without fuel delivered to the cylinders. Let an experienced technician carry out the following: Figure 88

Figure 87

Figure 89

Figure 88 6. When the engine has started, it takes a while to send lubricating oil to all bearings, shafts and between pistons and liners. Wait for the oil pressure gauge to settle at a normal level, then bring engine speed up gradually. Increase speed as the engine warms up. Check all gauges during warm-up.

1. Separate the in-line fuse(s) feeding the engine electronic control unit. The fuse(s) is located in the battery box.

2. Use the starter to turn the engine over for eight seconds. Wait for four seconds, then repeat the sequence.

3. Reconnect the fuse(s).

4. Start the engine.

Note: Check all engine fluids before attempting to crank the engine to establish oil pressure. Top off any fluids that may be below the minimum acceptable amount.

Replace any fluids that show signs of contamination.

Note: This procedure will log a fault code that shows up in the diagnostic message retrieval. It will not affect driving or compromise engine operation.

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TM500E-2 CARRIER OPERATOR’S MANUAL Note: The oil pressure gauge will not show oil pressure during starter motor cranking, as removing the electronic engine control fuse(s) cuts power to the instrument cluster.

Stopping the Engine Allow the engine to slow down and idle for three to five minutes before shutting it off. This allows the turbocharger to slow down and the cooling system to dissipate the engine heat. Switch the engine off by turning the ignition key to the OFF position.

Shutting off an engine immediately after high-speed or full-load operation can damage the turbocharger and cause heat stress in the engine. Always let the engine idle for three to five minutes before shutting it off.

Ignition Switch Figure 89

AC-334-0705-01240-A

Figure 90 The ignition switch is located on the center switch panel.

The key can only be removed when in the OFF position.

For full starting instructions, see Start Procedure Page 50.

Cold Weather Operation

If satisfactory engine temperature is not maintained, increased engine wear will result in higher maintenance cost. Accessories should be designed to be easily disconnected when switching to driving in warmer weather so they do not affect the operation of the engine.

Recommendations for cold weather operations: • When starting the engine in temperatures below 32°F (0°C), use engine lubricants of lower viscosity.

• When the temperature is below freezing, make sure the concentration of antifreeze in the coolant is sufficient to prevent freezing.

• During cold weather, give more attention to the condition of the batteries. Test them frequently to ensure sufficient power for starting. A dead battery may freeze.

• Fuel cloud point is the temperature at which wax crystals become visible in the fuel. The cloud point is generally at a higher temperature than the pour point of the fuel. To keep the fuel filter from clogging with wax crystals, the cloud point should be below the lowest ambient temperature at which the engine will be expected to operate.

To prevent wear and possible damage to the engine when it is cold, gradually bring it up to operating temperature before operating at high engine speeds or full load. After starting and before moving the crane, run the engine at 800 - 1000 RPM for three to five minutes. Operate at partial engine load until the coolant temperature reaches 165°F (75°C).

Engine Block Heater An electric engine block heater can be installed for keeping the coolant hot when the crane is parked.

The heater is mounted through the side of the engine block with the heater coils in the coolant jacket. The heater does not interfere with normal operation and can be permanently installed.

Figure 90

If the engine is in good mechanical condition and the necessary preparations are taken for cold weather operation, ordinary cold weather will not cause difficulty in starting or loss of efficiency.

Cold weather operation does require changes in operating practices, maintenance procedures, lubrication and fuel. Additions to the crane, such as heated fuel filters, fuel tank heater, engine block heater, etc., can make winter operation easier.

Contact your Manitowoc dealer for the correct accessories and installation information.

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120 V, 20 A

120 V, 30A AC-333-0509-G016

Figure 91

TM500E-2 CARRIER OPERATOR’S MANUAL The engine block heater runs on 120 V and has an easily accessible plug, typically located around the grille area. The plug will hook up to a normal extension cable. Your engine may be equipped with a 20 amp or 30 amp power receptacle.

Be sure that any supply circuits are adequately protected against short or open wiring conditions that may occur to the block heater wiring circuit.

Cold Weather Shielding Today’s electronically controlled engines are designed to operate in cold temperature environments without winter fronts, shutters or any other type of cold weather shielding. Manitowoc does not recommend the use of such devices.

Higher exhaust temperatures, power loss, excessive fan usage and reductions in fuel economy can result from improper use of cold weather shielding.

Engine Operation General Proper operation, driving techniques and maintenance are key factors in obtaining the maximum life and economy from a modern turbocharged diesel engine. This section has operational information about the components that make up the engine. For the best operation economy, see Fuel Economy Page 48.

When operating on a level highway or cruising, hold the engine speed at approximately 75 to 85 percent of governed speed (1400 to 1600 RPM for large displacement engines) to achieve power and economical fuel consumption.

The operator should understand the operating characteristics of the engine the crane is equipped with. Modern diesel engines have maximum torques at much lower engine speeds than in the past. As such, these engines are designed to perform satisfactorily at a lower engine speed.

Excessive exhaust smoke may be due to the type of fuel used, a restricted air cleaner, a malfunctioning fuel system, or the way in which the crane is operated. Increase or decrease the engine speed as necessary to obtain the engine speed/transmission gear combination which will prevent smoking. Excessive smoke is wasted fuel which creates carbon deposits in the engine and turbocharger. This causes excessive engine wear and oil consumption. Excessive smoke not only pollutes the atmosphere but can also cause engine oil contamination and shortened exhaust system life.

Engine Break-In The engines used your crane are run on dynamometers before being shipped from the manufacturer. In most applications, the engine can be put to work immediately, but the operator should be extra observant of the operating conditions shown on the gauges during the initial 100 hours or 3000 miles (5000 km).

A more frequent check of the engine compartment for fluid leaks, fluid levels and fastener tightness is also recommended during the initial period.

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TM500E-2 CARRIER OPERATOR’S MANUAL Engine Overspeed

Low Idle Adjustment

This crane is equipped with a diesel engine and should not be operated in an area with a high concentration of hydrocarbon vapors (gasoline or diesel fuel fumes). Be especially cautious of low-lying or closed-in areas. The vapors may be drawn into the engine through the air intake and cause the engine to overspeed. Hot carbon and other sparks may come from the exhaust system, and can cause an explosion and fire.

Figure 91

If the crane is in an area where hydrocarbon vapors may be present, shut the engine off immediately if any abnormalities are experienced. Do not leave it unattended.

Figure 92 The diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may overspeed during start-up. Engine damage and severe injury and/or death from burns or explosion can occur.

The engine idle speed can only be adjusted by a certified technician.

Base PTO Mode Figure 92

Idling The engine in your crane is electronically governed.

The idle speed is pre-programmed from the manufacturer. Low idle speed is adjustable (by a certified technician only) within certain limits (for most engines between 600 - 750 RPM).

The common belief that idling a diesel engine does not cause any engine damage is wrong. Idling produces sulfuric acid, which breaks down the oil and erodes bearings, rings, valve stems and internal engine surfaces.

Note: Avoid excessive idling. If the crane is parked for more than five minutes, stop the engine. An engine can burn from 0.5 - 1.0 gallons (2 - 4 liters) of fuel per hour while idling. During long engine idling periods, the engine coolant temperature may fall below the normal operating range. The incomplete combustion of fuel in a cold engine will cause dilution of the oil in the crankcase, formation of lacquer or gummy deposits on the valves, pistons and rings, and rapid accumulation of oil sludge in the engine.

54

Figure 93 The engine speed can be adjusted with the use of the cruise control function for raised idle during PTO operation.

1. Set the cruise control to the ON position by pressing the ON/OFF switch up.

2. If the crane is equipped with preset PTO speeds, move the switch to the SET position for the first set speed by pushing the SET/RES switch up. Move the switch to the RESUME position (down) for the second preset speed.

Once one of these two presets has been selected, the ON/OFF switch must be turned off and back on before the other preset can be selected.

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TM500E-2 CARRIER OPERATOR’S MANUAL 3. After the preset engine speed has been set, the speed can be adjusted up or down. To increase the engine speed, hold the SET/RES switch in the ACCEL position (up) until engine speed is correct, then release it. To decrease the engine speed, hold the switch in the COAST position (down) until engine speed is correct, then release it.

Uphill Operation Your crane is equipped with a 6 speed automatic transmission. When driving uphill it is best to let the transmission shift automatically, however the gears may also be selected manually if desired.

Transmission Selector The transmission push-button shift selector is located on the right side console. When the engine is first started, the ECU will automatically initialize the transmission to neutral.

Digital Display Monitor Mode Indicator Mode ID Mode LED

Range Buttons

CAUTION (D) drive may not be attained due to an active inhibitor.

Always apply the service brakes when selecting (D) drive to prevent unexpected crane movement and because a service inhibit may be present. When the (D) is flashing, it indicates the shift to D drive is inhibited. Check for active diagnostic codes if drive is not attained.

CAUTION

Automatic Transmission

Operation Mode Indicator

(D) Push-button

Mode Button

Do not idle in (D) drive for more than five minutes.

Extended idling in (D) drive can cause transmission overheating and damage. Always select (N) neutral whenever time at idle exceeds five minutes.

Press the (D) push-button to select drive. The highest forward range available will appear as the first digit in the display window. The transmission will start out in the l o w e s t a v a i l a b l e fo r w a r d r a n g e a n d a d va n c e automatically to the highest range. The second digit in the display window indicates the range the transmission is currently operating in. As travel speed is decreased, the transmission will automatically select lower ranges.

If the engine speed is too high, the shift to (D) will not occur. When (D) is flashing, it indicates the shift to (D) drive is inhibited. Check for active diagnostic codes if (D) drive is not attained.

Up and Down Arrow Buttons

Up and Down Arrows

6840

NOTE: If fault codes cannot be retrieved, contact your local distributor or Manitowoc CraneCARE for fault code diagnostics procedures.

NOTE: Visually check the display window whenever a bu t to n i s pu s h ed to en s u re th e ra n g e i s selected. A flashing display indicates the selection is inhibited

When a lower range is desired after (D) drive has been pressed, press the (Ú) down arrow button until the desired range is shown as the second digit in the display window. Likewise, if the transmission is held in a low range by the (Ú) down arrow, press (Ò) up arrow button to request the next higher range. Continuous pressing of either the (Ò) up or (Ú) down arrow buttons will request the highest or lowest range available.

NOTE: If engine speed is too high, pressing the (Ú) down arrow button may not result in a lower range until the engine speed is reduced.

Mode Button During normal operation, the MODE button selects a preprogrammed shifting schedule. The default mode uses provides a schedule programmed for economy.

P r e s s i n g t h e M O D E bu t t o n s e l e c t s a s c h e d u l e programmed for performance. When operating in the secondary mode, the LED in the upper right corner of the

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TM500E-2 CARRIER OPERATOR’S MANUAL push pad illuminates and the schedule name appears in the Mode ID display.

The MODE button is also used while troubleshooting to retrieve diagnostic codes. Simultaneously pressing the (Ò) up and (Ú) down arrow buttons twice displays the error codes.

NOTE: Fluid level information is displayed after pressing both the (Ò) up or (Ú) down arrow buttons simultaneously. Press both buttons again simultaneously to obtain diagnostic data.

To advance to the next code in the list, press the MODE button. The Mode LED illuminates to indicate active codes.

Oil Level Sensor T h e tra ns m i s s i o n s h i f t s e l e c to r c a n d i s pl ay t h e transmission fluid level. By pressing both the (Ò) up or (Ú) down arrow buttons simultaneously, the shifter display indicates if the transmission fluid level is OK. To obtain an accurate reading: 1. Park the crane on a level surface, shift to neutral (N) and set the park brake. Allow 2 minutes for the fluid to settle.

2. Press the (Ò) up and (Ú) down arrow buttons on the shift selector panel simultaneously. The following conditions must be met before a valid level check is displayed:

To clear active and inactive codes from memory, press and hold the MODE button for approximately 10 seconds.

To exit the diagnostic mode, press the (Ò) up or (Ú) down arrow buttons or wait until the unit automatically exits the diagnostic mode.

-

Engine is at idle.

-

Transmission fluid temperature is between 60 and 104° C (140 and 220° F).

-

Transmission output shaft must be stopped.

(R) Push-button

-

Transmission must be in neutral (N).

CAUTION (R) reverse may not be attained due to an active inhibitor. Always apply the ser vice brakes when selecting (R) reverse to prevent unexpected crane movement and because a service brake inhibit may be present. When the (R) is flashing, it indicates the shift to R reverse is inhibited. Check for active diagnostic codes if R reverse is not attained.

3. The shift selector display will indicate the status of the oil level. The alternately displays “oL” to indicate oil level check mode and a code. An example code is “oL HI 02” indicating a the fluid level is 2 quarts above recommended. The possible codes are displayed as follows Table 1-1: Table 1-1: Transmission Fluid Fill Codes Display

Description

The fluid level check is delayed where n indicates a countdown number between 8 and 1. Possible reasons for delay:

CAUTION

• Temperature is below 60° C (140° F).

Do not idle in (R) reverse for more than five minutes.

Extended idling in (R) reverse can cause transmission overheating and damage. Always select (N) neutral whenever time at idle exceeds five minutes.

• Temperature is above 104° C (220° C). oL, –n

• Transmission is not in neutral (N).

Completely stop the crane and let the engine return to idle before shifting from a forward range to (R) reverse or from (R) reverse to a forward range. The digital display will display (R) when reverse is selected.

• Transmission output shaft is not stopped.

• Fluid is not settled. Crane has not been stationary for 2 minutes.

Push the (R) push-button for reverse travel. oL, oK

(N) Neutral Push-button Use (N) neutral when starting the engine, checking accessories and for extended periods of engine idle operation (longer than five minutes). (N) neutral is selected by the ECU during start-up. The digital display will show (N) when neutral is selected. Always select (N) neutral before turning off the engine.

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• Engine speed is too high (above idle).

oL, Lo, 02

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Fluid Level is OK. Fluid Level is Low by x number of quarts. In this case, 2 quarts.

TM500E-2 CARRIER OPERATOR’S MANUAL Display

Description

oL, HI, 01

Fluid Level is High by x number of quarts.

In this case, 1quart.

oL, – –, nn

A fault code exists preventing the fluid level check and n n indicates a fault code.

Refer to Fluid Level Fault Codes.

Check Transmission Indicator When the CHECK TRANSMISSION indicator on the right hand console in the carrier cab is illuminated and the ignition switch is turned off, the transmission will remain in (N) neutral until the condition causing the indicator to illuminate is corrected.

Generally while the CHECK TRANSMISSION indicator is illuminated, upshifts and downshifts will be restricted and direction changes will not occur. Push-button shift selectors do not respond to any operator shift requests while the CHECK TRANSMISSION indicator is illuminated.

Transmission Lubrication Lube Type - TranSynd™ - Automatic Transmission Fluid Lube Interval - Check fluid level every 3000 hours.

Drain, fill, and replace filter every 120,700 km (75,000 miles) or 3 years.

Lube Amount - Capacity - 27.2 liters (29.0 quarts) Application - Fill through dipstick fill tube.

Transmission fluid level may be checked more frequently without the risk of contamination by using the Electronic Transmission Fluid Level display on Shift Control Panel.

Downhill Operation

Do not let your crane coast downhill with the transmission in the NEUTRAL position. With the crane transmission in NEUTRAL there is no engine braking and loss of control of the crane resulting in serious injury or death could occur.

Engine braking and service brakes are each good methods of controlling the crane's speed on a long downgrade. Pre-selecting a lower gear range on the transmission is another good method of governing speed on a downhill grade. Care should be taken not to overspeed the engine. For more specific information on these methods refer to the transmission operator’s manual, and the engine operator’s manual supplied with the crane.

High Altitude Operation Engines lose power when operated at high altitude because the air is too thin to allow burning as much fuel as at sea level. Most turbocharged engines are rated for higher altitudes and will not lose as much power as a naturally aspirated engine.

An engine will produce excessive exhaust smoke at high altitude unless a lower gear is used. Shift gears as needed to avoid excessive exhaust smoke.

The gauges should be closely monitored when operating at high altitude, as the thinner air reduces the efficiency of the engine cooling system. Engine overheating or cylinder damage could occur if the engine is operated under full load for extended periods during hot weather at high altitude.

Downshifting and reducing speed helps reduce the load on the engine when driving on long grades under these conditions. This will also help keep the engine's operating temperature within safe limits.

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TM500E-2 CARRIER OPERATOR’S MANUAL

Cruise Control

Engage and Set Desired Crane Speed

Do not use the cruise control in heavy traffic, with ice/snow on the road, or other unfavorable conditions, as this may lead to loss of crane control causing a crane crash and result in personal injury or death.

Figure 93

1. Set the Cruise Control ON/OFF switch to the ON position by pushing it upward.

2. When the desired crane speed has been reached, move the Cruise Control SET/RES switch to the SET position by pushing it upward.

3. If the speed needs to be increased, hold the SET/RES switch in the up position to accelerate. The crane speed will increase as long as the switch is held. Release the switch when desired speed has been reached.

Note: The cruise control cannot be engaged at crane speeds below approximately 30 mph (45 km/h).

Reducing and Resuming Crane Speed The cruise control disengages if the brake pedal is depressed. The previously selected cruise speed is retained in the memory. When the switch is pushed down to the RESUME position, the crane resumes the previously set speed (providing crane speed is exceeding approximately 10 mph (15 km/h) when the switch is pushed) unless the Cruise Control ON/OFF switch had been turned to OFF, in which case the resume function will not work.

Figure 94 Figure 94

Figure 95 The cruise control switches are located on the center switch panel.

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TM500E-2 CARRIER OPERATOR’S MANUAL Diesel Particulate Filter (DPF) Procedures

The operator should be aware that increased exhaust gas temperatures during the regeneration cycle may cause a fire if the crane is in an area where the exhaust might come in contact with trees, brush or other flammable objects.

The operator should avoid physical contact with the exhaust system at all times as extreme heat is often generated from the system, which could cause severe burns resulting in serious personal injury or death.

The Diesel Particulate Filter (DPF) telltale will illuminate when the DPF system must undergo a regeneration cycle. The regeneration cycle is necessary to burn off the accumulated soot particles trapped in the DPF system. The regeneration cycle is an automatic process and should occur when the exhaust heat reaches a sufficient temperature to begin the process.

If the DPF telltale begins blinking once per second, then the need for the regeneration cycle has become urgent but has not started. At this point it is recommended that the operator take the crane for a short drive at a minimum speed of 25 mph. This will increase the exhaust heat, and should help trigger the regeneration cycle. If the High Exhaust System Temperature (HEST) telltale is lit at this time it indicates that enough exhaust heat is now present in the DPF and the regeneration cycle has been initiated.

If the HEST telltale still has not lit and the Check Engine telltale has, the operator should continue driving the crane, until either the HEST telltale illuminates indicating that the regeneration cycle has begun, or the Stop Engine telltale comes on and the DPF telltale de-illuminates. If the Stop Engine telltale comes on and the DPF telltale de-illuminates, the crane must be taken back to the shop for a manual DPF cleaning.

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TM500E-2 CARRIER OPERATOR’S MANUAL

TRANSMISSION Before starting the engine, set the parking brakes and place the transmission in neutral. Failure to do so can result in unexpected crane movement and can cause serious personal injury or death.

Automatic Transmission General Your crane comes equipped with an automatic transmission. See Page 55 for detailed information on your transmission’s operation.

Figure 95

Transmission Warning Functions Figure 96

Figure 96 The transmission is equipped with an oil sump temperature sensor and Oil Sump Temperature telltale. A transmission temperature gauge is optional. The telltale will illuminate if the oil temperature exceeds the setting point.

Figure 97

Figure 97 If there is a problem with the transmission electronic control unit or its sensors, the Transmission Warning telltale illuminates. This is usually a problem that must be rectified by a qualified service facility.

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BRAKES Safety Guidelines The brake system is a critical crane safety system. For the safety of you and others around you, follow the recommended preventive maintenance checks. If any problems occur, have them investigated immediately by an authorized service facility. Failure to properly maintain the brake system can result in compromised brake efficiency and lead to loss of control of the crane resulting in severe personal injury or death.

Do not inspect or adjust parts or components in the brake system without setting the parking brake and securely chocking the wheels. If the crane is not secured to prevent uncontrolled crane movement, it could roll and cause severe personal injury or death.

Do not release the parking brake or attempt to move the crane until brake air pressure in both circuits is at least 100 psi (700 kPa). Failure to follow this procedure may lead to uncontrolled crane movement and cause severe personal injury or death.

Never release or drive a crane on the road that has a brake discrepancy – no matter how minor – until it has been repaired or corrected. Failure to repair brake discrepancies can result in compromised brake efficiency and lead to loss of control of the crane resulting in severe personal injury or death.

Do not operate the crane when there is a malfunction in the compressed air system. An air brake system with leaks or other malfunctions may prevent the brake system from operating properly.

The crane should not be operated until the system is repaired and all brake circuits are working properly. Failure to repair the system can lead to loss of control of the crane resulting in severe personal injury or death.

Do not use replacement parts anywhere in the brake system unless they conform exactly to original specifications. A nonconforming part in your crane’s brake system could cause a malfunction, leading to loss of control of the crane resulting in severe personal injury or death.

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General

Before operating the crane, check the air gauges which indicate air pressure. They should not register less than 105 psi (725 kPa). Maximum pressure at any time should not exceed 150 psi (1035 kPa).

Figure 98

Both circuits are plumbed into a dual brake valve, which simultaneously applies front and rear axle service brakes during each brake application. In the event of a failure in either one of the circuits, the other circuit becomes the emergency circuit for applying the brakes.

AC-382-0505-00863-B

Figure 98 Figure 99

An important feature of the brake system is that an automatic spring brake application does not take place as a result of an air loss in only one of the two circuits. In this case, brake control remains in the foot brake valve. For each air pressure system, there is a warning telltale in the telltale warning panel connected to a low pressure switch that comes on if air pressure goes below 70 psi +/- 6 psi (485 kPa) in either system. At the same time, the buzzer will sound and the main warning telltale will illuminate. This pressure drop warns the operator to make a manual emergency stop before an automatic emergency stop is made.

Brake System Controls

AC-382-0505-00884-B

Figure 99 Manitowoc cranes are designed to meet or exceed all applicable federal brake standards and regulations. They use a dual-circuit, compressed air system. It consists of two independent brake systems that use a single set of brake controls.

Each circuit is supplied by its own compressed air tank which is protected by a check valve. Both air tanks receive compressed air from the same supply tank (wet tank) and are charged with equal pressure. The two circuits are interconnected for the parking brake system by means of a double check valve.

The air compressor, governor, pressure regulator valve and reservoirs are control devices. Their function is to build up, maintain and control air pressure in the reservoirs. This is so that pressure is held constant between the minimum and maximum range established for air brake operation.

The brake valve, quick release valve, brake chambers, and slack adjusters are application devices. They distribute the air pressure and convert its energy into the mechanical force necessary to apply or release the brakes.

Air pressure in the two circuits is monitored by two gauges in the main instrument cluster. The two gauges should register equal or nearly equal pressure. By observing the gauges, the operator is forewarned in the event of a pressure drop in either or both of the circuits, and also may readily identify the specific circuit.

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TM500E-2 CARRIER OPERATOR’S MANUAL Foot Brake Valve The foot brake valve is directly connected to the brake pedal. The valve gives a progressive output against the pedal travel. This allows better control of the pressure in the first half of the pedal travel. In the last half of the pedal travel, the pressure output increase is faster.

The foot brake valve applies the service brakes, incorporating both the primary and secondary air systems. The primary system controls the rear brakes and the secondary system controls the front brakes. The foot brake valve receives air from the compressed air tanks. Air pressure is then delivered to the wheel brake chambers as required by the amount of pressure exerted on the foot brake pedal. The brake chamber force then applies the wheel brakes.

6. When descending a long grade, do not use the service brakes too long or too often. The brakes may overheat and lose their effectiveness.

7. Before descending a steep grade, the transmission should be shifted into a lower gear and the crane speed reduced. Other speed retardation devices should also be used if available (engine brakes or retarder).

Failure to observe these precautions can result in loss of crane control and serious personal injury or death can occur.

Parking Brake Valve Figure 100

From the operator’s viewpoint, operating the foot brake valve of a crane equipped with air brakes differs very little from the operation of a conventionally braked crane. Because the operation of the brake pedal requires scarcely more effort than depressing the average throttle pedal, air brakes are naturally much easier to control. If the driver gives full attention to the following suggestions, a little experience will make him/her thoroughly familiar with the air-controlled braking of this crane.

PULL TO APPLY

PARKING BRAKE PUSH TO RELEASE

Brake Application 1. The best possible stop will be made when the first brake application is as firm as the speed and road condition permit. Then, ease off as the speed is reduced. Never apply the brakes lightly at first and increase the pressure as the speed diminishes.

2. Do not fan the brake pedal. Fanning gives poor brake performance and wastes air.

3. The air brake is designed so that when the brake pedal is fully depressed, an emergency application results. This application should be made only in an emergency situation.

4. In making a stop or a slow-down, allow the transmission to remain in gear with the throttle closed, disengaging the clutch only when engine idling speed is reached.

5. When parking the crane, place the transmission in neutral and set the parking brake before shutting down engine.

AC-551-0508-G827

Figure 100 To release the parking brake, push in the knob (yellow) after sufficient air pressure is built up.

(Apply foot brake to prevent crane from rolling.)

The parking brake valve knob will automatically pop out if the system pressure (both front and rear circuits) drops to 25 - 35 psi (170 - 240 kPa). The spring brake chambers will then apply the wheel brakes.

Note: Allow the engine to idle at low rpm for 5 minutes prior to shutdown.

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TM500E-2 CARRIER OPERATOR’S MANUAL Spring Brake for Parking

Never leave the crane without being certain the parking brakes are set or that other precautions are taken, such as chocking the wheels to prevent the crane from rolling. Failure to do so can result in serious personal injury or death.

Figure 101

The parking brake spring tension is sufficient to hold a fully loaded crane on maximum grades permitted on modern highways, provided the brake drums and linings are in good condition and are properly adjusted.

The crane must never be left unattended if the brakes are in poor condition or in need of servicing. Always have the brakes serviced at the correct intervals as prescribed by the manufacturer's specifications. The following procedure should be used to cool or dry the brakes if the crane has recently been driven during extreme operating conditions.

If the brakes are wet, drive the crane in low gear and lightly apply the brakes to heat and dry them.

Allow hot brakes to cool before using the parking spring brakes.

There are several ways to determine if the parking brakes have been set. By pulling out the yellow knob:

Figure 101 The parking brake mechanism uses spring pressure as a separate power medium to apply the service brakes on the driving axles. The parking brake is released by the same compressed air source used to apply the service brakes. Since this brake is released by air pressure, the system must be charged to at least 60 psi (420 kPa) before the parking brake may be released.

• An audible rush of air will be heard when the parking brake knob is pulled. The air exhausts from the park brake valve itself and from the spring brake chambers on the rear axle(s).

• A black ring around the base of the yellow control knob will be seen.

• The engine may stall if an attempt is made to set the crane in motion.

• There will be a fluctuation in the air pressure gauge needles.

• You cannot pull the knob out any further.

Never attempt to disassemble or tamper with the spring brake chamber. The force stored in the spring, if suddenly released, can cause serious personal injury or death.

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Air Tanks

Anti-Lock Brake System (ABS)

When draining the air tanks, do not look into the area of the draining air. Dirt or sludge particles may be in the air stream and could cause eye injury.

Figure 102

The crane has a standard brake system, equipped with an electronic speed monitoring and control system, Anti-Lock Brake System (ABS). ABS monitors wheel speed continuously but is not involved in controlling the wheel speed unless there is an emergency. In normal braking applications, the standard air brake system is in effect.

For proper ABS operation, do not change tire sizes. The size of the tires installed during production are programmed into the electronic control unit. Installing different size tires could result in a reduced brake force, leading to longer stopping distances.

Figure 102 Air tanks should be drained daily. Make sure the drain cocks close properly after draining. Empty moisture from air tanks by opening the drain valves.

The tanks should be checked for condensation fluid even if an automatic drain valve is installed.

FMVSS 121 Brake Standard Manuals may occasionally refer to “121” brakes.

Although some operators believe “121” only applies to vehicles equipped with anti-lock devices, the “121” standard applies to all cranes that are capable of on-highway operation.

The “121” requirement also covers alterations or changes to parts or systems related to the “121” standard once the crane has been placed in service. The owner and operator should be aware that it is a violation for any repair facility to make any part or component inoperative when it is required for “121” compliance.

There is a sensor installed in each wheel on a monitored axle. The sensors transmit information to the electronic control unit (ECU). The ECU interprets the signals and calculates wheel speed, wheel retardation and a crane reference speed. If the calculations indicate a wheel lock-up situation, a signal is sent from the ECU to the appropriate ABS modulator valve to reduce braking pressure.

During emergency braking, the modulator valve alternately reduces, increases or maintains air pressure in the brake chamber to prevent wheel lock-up.

During emergency or reduced-traction stops, fully depress the foot brake pedal until the crane comes to a safe stop. DO NOT PUMP the brake pedal.

With the brake pedal fully depressed, the ABS will control all wheels to provide steering control and a reduced braking distance.

Although the ABS improves crane control during emergency braking situations, the operator still has the responsibility to change driving styles depending on the existing traffic, road and/or weather conditions. For example, the ABS cannot prevent an accident if the driver is speeding or following too closely on slippery surfaces.

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TM500E-2 CARRIER OPERATOR’S MANUAL The ABS control unit contains a self-testing program that is engaged each time the ignition is turned on. The operator can verify the testing by listening for the ABS modulator valves actuating twice in series. To increase the sound, hold down the foot brake pedal when the ignition is turned on.

The self-test is not finished and the telltale will stay on until the crane has started to move. The wheel speed sensors are tested when the crane starts to move. If they are testing OK, then the telltale will go out at approximately 5 mph (8 km/h).

Figure 103

Note: It is normal to experience a slight delay in the application of a crane speed retardation device. When using devices of this type, be sure to think ahead and analyze conditions in order to use the device properly.

Failure to observe these precautions can result in loss of crane control and serious personal injury or death can occur.

Engine Brake System The engine brake is a device that uses engine compression to help slow the engine to assist in braking.

Figure 103

If any of the ABS telltales come on during driving or do not go out after a short time after turning on the ignition, take the crane to a Manitowoc dealer to repair the ABS or brake system.

Crane Speed Retardation Devices Safety Guidelines

The service brakes must be used in an emergency. The engine brake alone may not stop you fast enough to prevent an accident. Failure to follow this instruction can result in loss of crane control and serious personal injury or death.

A crane speed retardation device, “Exhaust Brake,” is not intended to bring the crane to a stop. A crane speed retardation device is only intended to retard the crane speed under certain conditions.

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ELECTRICAL SYSTEM General Safety Guidelines Failure to repair a malfunction in the electrical system can result in serious damage due to crane fire. Always let an experienced electrical technician perform repairs. Always determine the source of the fault; do not just treat the symptoms.

Always wear eye protection when working around batteries to prevent the risk of injury due to an explosion or contact with sulfuric acid.

Electronic circuits and components are designed to sense voltage differences smaller than 1 volt. While static electricity is not normally dangerous to humans, it can seriously damage electronic circuits and components.

Circuit boards mounted in the instrument cluster, for example, may not fail immediately after being hit with a static discharge. Rather, they may work for a while and then fail for no apparent reason. (Always work with proper grounding straps and antistatic mats around electric components.)

Today’s cranes contain many electronic devices. It is very important to exercise caution when working on a modern electrical system, charging batteries or jump-starting the engine. To minimize the risk for any damage to the electronic components, follow the procedures below when work is being done to the electrical system.

Attempting to work on electronic components without proper equipment can damage internal parts with static electricity.

Do not work on the electric system without proper tools and training. Repair work on the electrical system must be done by trained professionals. Your authorized Manitowoc dealer has the right tools and trained technicians.

Charging System An alternator with an integrated voltage regulator is used to supply power to the crane electrical system. The charging system voltage should be checked periodically to prevent overcharging or undercharging the batteries and to detect any voltage drop in the wiring.

Battery Box When inspecting or cleaning batteries, never smoke or expose batteries (or the area around them) to sparks or flames.

The battery area may contain an explosive gas mixture that can ignite, causing an explosion, leading to serious personal injury.

Figure 104

Figure 104 There is three batteries installed. Always make sure the batteries are fastened properly in the box.

When disconnecting battery terminals, always disconnect the main ground terminal (negative) first. When reconnecting, always connect the main ground terminal (negative) last.

If there are other ground cables connected to the battery (such as engine ECU), disconnect those ground cables first, then remove the main battery ground cable (negative). Electronic modules may be damaged when additional grounds are connected/disconnected without the main battery ground connected.

Disconnect the main battery ground (negative) last.

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Battery Jump-Starting and Charging It is very important to exercise caution when charging batteries or jump-starting an engine in a crane with a modern electrical system. Electrical control units can be damaged by voltage spikes or current surges created by jump-starting.

To minimize any risk for damage to the electronic components, see the following guidelines for charging/jump-starting.

If the batteries are discharged to the point where they do not have enough voltage to start the engine they should be recharged with a low voltage (less than 16 volt) charge.

Do not use battery chargers with “boosting” capability. These produce high voltage that will cause damage to the crane electrical and electronic components.

Connect the jumper cables to the positive, or “hot,” terminal first and ground terminal (negative) last.

When disconnecting the cables, disconnect the ground terminal first. Connect the jumper cable clamps to the discharged battery first and to the booster battery last. Avoid creating sparks by making all connections quickly and firmly. Do not permit vehicles to touch each other when jump-starting.

Always wear eye protection when working around batteries to prevent the risk of injury due to an explosion or contact with sulfuric acid.

Electrical Center Figure 106

If the engine needs to be started immediately, use starting batteries. Connect the cables as follows: When jumping batteries to start an engine, it is important that the jumper cables are connected directly from one set of batteries in the crane, to the other set of batteries in the other vehicle (unless crane is equipped with optional Emergency Start System). This way the cranking current is carried through the proper starter wiring.

Figure 105

AC-371-0705-01237-A

Figure 106

Figure 105

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TM500E-2 CARRIER OPERATOR’S MANUAL Circuit breaker designation and location are listed on a label attached to the inside of each circuit breaker box cover.

Figure 107

Power Ports Figure 108

AC-372-0705-01238-A

Figure 107 On the Crane the Crane Electrical Center (CEC) is located on the left side of the cab to the left of the steering wheel on the driver kick panel. Most of the circuit breakers and relays are found at this location. Since the function of some breakers or relays may change based on crane application, refer to the list of functions attached to the underside of the CEC cover.

Figure 108 Use the power ports on the front of the dashboard to power cellular phone chargers and other 12 V DC low-current accessories.

Battery Main Disconnect Switch Figure 109

Breakers and Relays Auto-reset breakers are standard equipment in some circuits on the crane. Auto-reset breakers can be reset by cycling the ignition switch on and off.

Manual-reset circuit breakers can be reset by pressing the button located on the top of the breaker. Manual reset circuit breakers are used on battery circuits.

Failure to repair a malfunction in the electrical system can result in serious damage, possibly leading to a crane fire.

Always let an experienced electrical technician determine the source of the fault and perform needed repairs.

Figure 109 A Battery Main Disconnect switch is standard. Note that is does not disconnect electrical power form the engine and transmission control units. Use of this switch does not replace the need for proper disconnect procedures when welding on the vehicle.

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POWER STEERING General Failure to observe safe handling procedures when servicing the electrical system can result in damage to the crane or personal injury. Do not make metal-to-metal contact between the positive terminals of the batteries and the negatively charged chassis or any chassis component.

The power steering consists of an integrated gear and hydraulic power cylinder, and a power steering pump with fluid container. Depending on the front axle rated load, there may be a hydraulic assist cylinder on the other side from the main gear, to help with the steering load.

The pump, driven by the engine, provides hydraulic pressure to the power steering. If the engine is not working, the steering is only manual. With the power steering not working, the effort required to turn the steering wheel is much greater than with power assist. If the power steering assist fails, bring the crane to a safe stop. Do not drive the crane until correcting the cause of the problem.

Never drive the crane without power assisted steering. When the power assist has failed, the effort to turn the steering wheel is much greater, especially in sharp turns or at low speeds. This can cause an accident and lead to serious personal injury or death.

While operating the crane, avoid ruts and obstructions which cause a binding condition on the sides of the front wheels. Drive the crane out of the rut, then turn the steering wheel. If possible, avoid turning the wheels while the crane is at a standstill as this places a considerable load on the power steering system and front axle.

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AXLES AND WHEELS

Figure 110

Axles Cross Axle Locks The drive axle(s) may be equipped with an optional cross axle locks. With tandem drive axles, there could be both wheel cross axle locks (optional) and an interaxle differential lock (standard).

Never operate the crane with the differentials locked any longer than is necessary as this places a great strain on the axles and may cause rapid tire wear.

Figure 110 Periodically check the power steering fluid reservoir and keep it filled to the proper level with the recommended fluid. On cranes with two steering axles, the hydraulic reservoir is much larger than standard to accommodate the increased fluid volume in the system.

The cross axle lock should be used only on icy or slippery surfaces, and at low speed. As soon as the slippery surface has been passed, the cross axle lock should be disengaged.

Cross axle locks must, under no circumstances, be engaged when in a wheel-spin situation. Engage the locks ahead of the slippery area. If already slipping, stop the wheels, engage the locks and then continue. If the cross axle locks are engaged when the wheels are spinning, the differential will be damaged and the rear axle drive unit could possibly fail.

Figure 111

7176-5

Figure 111 Engaging the cross axle locks must always be done in the following way: 1.

2.

3.

4.

Wait for the drive wheels to stop spinning.

Engage the cross axle lock.

Choose a suitable gear.

Slowly depress the accelerator pedal.

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TM500E-2 CARRIER OPERATOR’S MANUAL Under normal traction conditions, do not engage the cross axle locks. If at all possible, do not use the cross axle locks while taking a curve. With good traction and the cross axle locks engaged, the crane will be understeered and therefore will tend to drive straight in a curve. If the locks must be used on good traction surface, drive cautiously and do not exceed 25 mph (40 km/h). Disengage the locks as soon as possible.

Check-Tightening Wheel Lug Nuts Figure 112

When the cross axle locks are disengaged, the couplings may be under tension. Disengage the locks by returning the switch to the OFF position.

Help the disengagement by briefly letting up on the accelerator to relieve the torque on the couplings.

The telltales for the cross axle locks and interaxle locks are located on the switches controlling the cross axle locks and axle locks.

Wheels General Wheel changes should be done by an authorized Manitowoc dealer because of wheel size, equipment needed and procedures used. By having an expert technician perform this procedure, personal injury and property damage may be avoided.

Note: When replacing the wheel equipment or tires, use the same size wheels or tires as originally manufactured. Changing the tire or wheel size will affect brake performance. If changing tire size, ABS and speedometer must be recalibrated.

Figure 112

Check-tighten all wheel lug nuts after the first 50 - 100 miles (80 - 160 km) after taking delivery of the crane, and the first 50 - 100 miles (80 - 160 km) after the wheels have been removed and reinstalled on the crane. This applies to both single and dual wheels in connection with normal service but should be performed at least every six months.

All disc wheels have fasteners that require a torque of 450-500 ft-lb (610-678 N•m). For spoke wheels, check the wheel manufacturer’s specifications.

This check-tightening is particularly important when rims or brake drums are newly painted. Paint can flake off from these surfaces, causing the nuts to lose their grip and the wheel to loosen.

Failure to properly check-tighten the wheel nuts can result in the breakage of wheel studs and the subsequent loss of wheels. Loss of crane control and serious personal injury or death can occur.

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TM500E-2 CARRIER OPERATOR’S MANUAL Inflating Tires

Wheel Bearing Adjustment

Always check inflation pressure when tires are cool, using an accurate tire pressure gauge. Check the pressures at regular intervals.

For reliable operation and adequate service life, the wheel bearings must be properly adjusted and checked during the service period. Loose wheel bearings could cause premature tire wear and possibly affect crane handling. See your authorized Manitowoc dealer for proper servicing.

Tires and wheels must be serviced only by a qualified technician. Do not attempt to perform this work yourself. Inflated tires on wheels contain compressed air, and if suddenly released, do so with an explosive force. Serious personal injury or death can occur.

Never bleed the air from hot tires.

Increased tire pressure measured in a hot tire is normal. Lower than recommended pressures may cause side wall fluxing resulting in an increased tire heat. This may cause premature failure.

For specific information and warranty on rims and tires, contact the tire manufacturer’s distributor.

Figure 114

Figure 114 Watch carefully for oil leaks and listen for unusual noises. These are indications of worn bearings, bad seals or maladjusted bearings. These are developing problems which must be corrected as soon as possible.

Figure 113

Failure to keep wheel bearings properly adjusted may result in accelerated tire wear, poor handling and, in extreme cases, wheel separation from the hub. It is important that wheel bearings are checked and adjusted regularly. Failure to properly maintain these bearings can ultimately result in loss of crane control and cause serious personal injury or death.

1 – Steer Tire 2 – Drive Tire

Figure 113 Check tires for abnormal wear. Also check the tire tread depth.

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EMERGENCY INFORMATION Towing Procedure General

The driveshaft must be removed before towing the crane. Failure to remove the driveshaft may result in damage to the transmission.

Figure 115

Axle shafts must be removed if the crane is to be towed at speeds over 25 mph (40 km/h) or for a long distance. Openings should be covered to prevent loss of oil and entry of dirt and grit. Where oil-lubricated bearings are used, openings should be thoroughly sealed with metal discs and new gaskets before towing.

If a crane with air suspension is lifted by the rear frame or crossmember, there is a risk that the air springs will separate from the spring plates. When towing has been completed, do not under any circumstances use your hands to reposition the air springs again. There is a great risk that your hand will be caught between spring and plate, causing personal injury.

The crane may now be towed. It is recommended that a recovery vehicle with a lift bar is used since the service brakes will not function. The system must be filled with air to release the parking brake or follow the mechanical spring brake caging procedures. See Spring Brake for Parking Page 64.

Figure 115 Figure 116

Note: The power steering does not function when towing a crane with a disabled engine.

Towing Instructions

If the crane becomes disabled, it is very important to tow it properly. Failure to do so can cause damage to the frame and body parts. Follow the instructions below to avoid damage.

Figure 116 Remove the driveshaft from the rear axle before moving the crane, unless it only needs to be moved a small distance for safety reasons. The reason for removing the driveshaft is that when the transmission is driven from the rear wheels without the engine running, there is no lubrication in the transmission.

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In the event that the crane cannot be reached for placing the wrecker lift bar under the front axle, use the tow eyes if supplied with the crane. The front tow eyes are used as a point at the front of the crane where the crane can be pulled.

Do not use the tow eyes for raising the front of the crane; the tow eyes can break. Do not crawl under a crane suspended by tow eyes. Failure to follow these instructions can result in serious personal injury or death.

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TM500E-2 CARRIER OPERATOR’S MANUAL Note: When the driveshaft or axle shafts are reinstalled, make sure the axle flange cap screws are tightened to the correct torque.

Also, make sure the axle shafts are installed in the proper sides, with the left shaft in the left side and the right shaft in the right side.

Figure 118

Figure 117

Figure 118 Figure 117 When the crane is positioned properly, lift the front and locate the lift bar under the front axle and secure. Using the front axle for towing minimizes the possibility for damage to the crane body, frame and suspension.

Remove the plastic plug in the front end of the chamber. Remove the screw from the holder in the side of the brake chamber. Insert the screw into the front hole and push in until it bottoms. Screw into the cylinder so at least four to six threads have entered.

Figure 119

Caging Spring Brake The parking spring brake chambers may be released mechanically if there is no compressed air available.

Always start by chocking the wheels to prevent the crane from rolling. Chocking the wheels is important since you have to work under the crane. Failure to do so can result in unexpected crane movement and serious personal injury or death can occur.

In the event of brake system failure, where the spring chambers are caged, the crane cannot be driven. There would be no means for stopping the crane and this could result in serious personal injury or death. Before caging the spring chambers, make the connection to a towing crane or chock the wheels.

Figure 119 Install the washer and nut. Tighten the nut. This compresses the brake chamber spring and releases the parking brake.

Never attempt to disassemble or tamper with the spring brake chamber. If the force stored in the spring is suddenly released, it can cause serious personal injury or death.

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NOTES

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