DOWNLOAD PDF Grove Crane TM500E-2 Carrier Operator's Manual 166-05

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

© 2009 Manitowoc Published 03-24-09, Control # 166-05

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

CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain 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.

TM500E-2 CARRIER OPERATOR’S MANUAL General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Information for the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Diesel Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Battery Posts, Terminals, and Related Accessories . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cab Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tilting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pre-Trip Inspection and Daily Maintenance . . . . . . . . . . . . . . . . . . . 14 Crane Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pre-Trip Inspection Quick List . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Safety Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Instruments and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Dashboard Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Main Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Telltale Warning Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Center Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Steering Column Switches/Controls . . . . . . . . . . . . . . . . . . . . . . 46 Miscellaneous Switches/Controls . . . . . . . . . . . . . . . . . . . . . . . . 46 Heating and Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Cab Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Fuel Economy Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Fuel Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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TM500E-2 CARRIER OPERATOR’S MANUAL Engine Start and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Transmission Warning Functions . . . . . . . . . . . . . . . . . . . . . . . . 62 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Brake System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Air Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 FMVSS 121 Brake Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Anti-Lock Brake System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Crane Speed Retardation Devices . . . . . . . . . . . . . . . . . . . . . . . 68 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 General Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Battery Jump-Starting and Charging . . . . . . . . . . . . . . . . . . . . . . 69 Electrical Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Breakers and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Power Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Battery Main Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . 71 Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Axles and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Emergency Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Caging Spring Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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Published 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL

GENERAL INFORMATION Figure 1

Superstructure Cab

Carrier Cab

6977

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 Crane Care 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.

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 03-24-09, Control # 166-05

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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.

The Manitowoc Company, Inc. 1565 Buchanan Trail Shady Grove, PA 17256 Phone: 717-597-8121 Fax: 717-593-5152

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Published 03-24-09, Control # 166-05

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.

Diesel Engine Exhaust

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.

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

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.

GROVE

CALIFORNIA PROPOSITION 65 WARNING

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 03-24-09, Control # 166-05

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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 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 Manitowoc distributor and/or Manitowoc Crane Care.

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.

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.

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Published 03-24-09, Control # 166-05

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.

Figure 2 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.

GROVE

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).

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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 Crane Care. The crane must 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 Manitowoc Crane Care 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.

• 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 a thunderstorm.

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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 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 Maintenance and Inspection Manual. Any questions regarding procedures and specifications should be directed to the your local, authorized Manitowoc distributor.

Lubrication The Manitowoc Company, Inc. 1565 Buchanan Trail Shady Grove, PA 17256 Phone: 717-597-8121 Fax: 717-593-5152 product.safety@manitowoc.com

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.

Provide a complete description of the accident, including the crane model and serial number.

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:

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.

GROVE

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:

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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 03-24-09, Control # 166-05

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

Noise Emissions Figure 2

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

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.

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

Figure 3 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.

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

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.

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

GROVE

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9

TM500E-2 CARRIER OPERATOR’S MANUAL

CRANE ACCESS

General Entry Guidelines

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

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.

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.

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.

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.

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.

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

Cab Steps

7172

Figure 5 • 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.

Figure -1

Figure 4 10

Published 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL • Do not jump from the cab or from the steps to the ground.

• Always face the cab when entering or exiting.

• 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.

Open the door. Place any hand-carried items on the cab floor or in the seat. Grasp the right grab handle (1, Figure 6) 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.

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

Passenger Side Entry/Exit Figure 4

2

1 1

Driver Side Entry/Exit Figure 3

2 3

7175

Figure 7

1

Open the door. Place any hand-carried items on the cab floor or in the seat. Grasp the cab grab handle (1, Figure 7) 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.

3

Step into the cab with the left foot first.

7174

Figure 6

GROVE

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

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TM500E-2 CARRIER OPERATOR’S MANUAL

Tilting the Cab

Raising the Cab Figure 7

Apply the parking brakes .

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.

General Apply the parking brakes.

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.

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 11 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 5

2

Figure 9

1 7173

Figure 8 Remove the pump handle (1) (Figure 8) from its storage location on the passenger side seat riser. It is held in place with two clips.

Figure 6

Read the label (2) (Figure 8) on cab tilting, located on the passengers side door jam.

12

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.

Published 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL 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.

Figure 10

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.

Figure 9

AC-910-0706-01255-A

Figure 11 Remove the pump handle when not in use. It may stick out and could cause injury to passersby.

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.

GROVE

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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 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.

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.

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TM500E-2 CARRIER OPERATOR’S MANUAL

Pre-Trip Inspection Quick List Figure 10

Figure 12 Inspect the crane in a circular manner as shown in Figure 12 and Figure 13.

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.

GROVE

• 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.

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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 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL

Figure 11

Figure 13

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.

GROVE

• 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.

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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 03-24-09, Control # 166-05

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.

Figure 12

AC-180-0705-01244-A

Figure 14 • 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 14.

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.

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.

GROVE

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.

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TM500E-2 CARRIER OPERATOR’S MANUAL See Oil Level Sensor for procedure to check the transmission oil. (Use Castrol Transynd transmission oil ONLY.)

Figure 13

• 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

AC-185-0506-G500

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

AC-180-0705-01232-B

Figure 16

Figure 15 • Check oil level in the engine with the dipstick (1) (Figure 15) 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.

To add oil to the engine, remove the oil cap Figure 15 (2) on the filler tube (below the oil dipstick) and fill through the tube.

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

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 15

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 15 (3) located on the right side behind the cab. The oil level should be between the minimum and maximum marks on the dipstick.

Figure 17 • Clean the side windows in the same way with a long-handled sponge and squeegee.

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Published 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 16

Figure 17

Figure 19 7179

Figure 18 • Check all lights for proper function: • Headlights •

Daytime running lights

•

Parking and marker lights

•

Stoplights

•

Turn signals

GROVE

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.

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TM500E-2 CARRIER OPERATOR’S MANUAL

SAFETY FEATURES

Figure 19

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 cn result inserious 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.

AC-884-0508-G008

Figure 21 Figure 18

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 20 Figure 20

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 22 22

Published 03-24-09, Control # 166-05

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 22

The tethers are not adjustable.

Operating the Safety Belt Figure 21

AC-884-0508-G010

Figure 24

AC-884-0508-G009

Figure 23 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.

GROVE

If a Komfort Latch is used on the safety belt, always adjust the belt so that there is a maximum of 1 in.

(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.

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.

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23

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 23

Figure 24

Figure 25 Note: After the crane has been started, a telltale indicator light (Figure 26) 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.

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

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.

Figure 25

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.

24

Figure 27 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.

Published 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 26

Figure 28

Figure 28 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 27

Figure 30 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 29

Figure 29 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.

Figure 31 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.

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25

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.

Komfort Latch Operation Figure 30

Important Facts About Safety Belts in Heavy Crane Driving 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.

26

AC-884-0508-G011

Figure 32 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 in. (25 mm) of slack (approximately two fingers’ width) when measured between the chest and the belt. See Figure 33.

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.

Published 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 31

AC-884-0508-G010

Figure 33 Always adjust the clip so that there is a maximum of 1 in. (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.

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27

TM500E-2 CARRIER OPERATOR’S MANUAL

INSTRUMENTS AND CONTROLS Dashboard Overview Figure 32

1 2

3

4

7176

1 – Main Instrument Cluster (Page 29) 2 – Telltale Warning Indicators (Page 35)

3 – Center Switch Panel (Page 41) 4 – Transmission Selector (Page 56)

Figure 34

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 lit 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.

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TM500E-2 CARRIER OPERATOR’S MANUAL

Main Instrument Cluster Figure 33

3

7176-1

4

5

8

6

7

1 2

1 – Tachometer & Hourmeter (Page 30) 2 – Speedometer & Odometer (Page 30) 3 – Engine Oil Pressure (Page 31) 4 – Engine Coolant Temperature (Page 32)

5 – Fuel Level (Page 33) 6 – Reserve Pressure A (Page 33) 7 – Reserve Pressure B (Page 33) 8 – Telltale Warning Indicators (Page 35)

Figure 35

GROVE

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29

TM500E-2 CARRIER OPERATOR’S MANUAL Tachometer

Speedometer

Figure 34

Figure 35

7002

7004

Figure 36

Figure 37

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.

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.

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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 36

Figure 38

7003

Figure 40 Figure 39

Figure 38 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 37

Figure 41

Figure 39

The low oil pressure warning limit is dependent on the engine manufacturer’s electronic program. With low oil pressure, the Check Engine telltale (Figure 40) 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.

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.

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31

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 42

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.

Figure 44

Engine Coolant Temperature

The high temperature warning limit is dependent on the engine manufacturer’s electronic program. With high temperature, the Check Engine telltale (Figure 43) 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.

Figure 40

Figure 42 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 a qualified service technician.

If the high temperature condition remains, and if your engine electronic control module has been programmed for engine shutdown, the Stop Engine telltale (Figure 44) 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.

Figure 41

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

Figure 43

32

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.

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TM500E-2 CARRIER OPERATOR’S MANUAL

Figure 44

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 46 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 Figure 43

E

ULTRA LOW SULFUR FUEL ONLY

Note: Ultra low sulfur diesel is not required with the Export Engine Option.

F

Reserve Pressure “A” & “B” Figure 45

FUEL LEVEL

D

AC-380-0701-01155-A

Figure 45 The gauge is connected to a sending unit in the fuel tank via the gateway module on the right-side frame rail.

AC-382-0505-00863-B

Figure 47

GROVE

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33

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 46

Figure 47

Figure 49

AC-382-0505-00884-B

Figure 48 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.

34

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 49) 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.

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TM500E-2 CARRIER OPERATOR’S MANUAL

Telltale Warning Indicators Figure 48

1

10

2

11

3

12

4

13

5

14

6

15

7

16

8

17

9

18

19 AC-380-0701-01153-A

1 – DPF (Diesel Particulate Filter) (Page 36) 2 – Check Engine (Page 36) 3 – Stop Engine (Page 36) 4 – Brake Pressure (Page 37) 5 – High Beams (Page 37) 6 – Transmission Temperature (Page 37) 7 – Transmission Warning (Page 38) 8 – ABS, Front (Page 38) 9 – ABS, Back (Page 38)

10 – Air Filter (Page 38) 11 – HEST (High Exhaust System Temperature) (Page 38) 12 – Parking Brake (Page 39) 13 – Neutral (Page 39) 14 – Wait to Start (Page 39) 15 – Communication Error (Page 39) 16 – Charging System (Page 39) 17 – Traction Control (not in use) 18 – Fuel (Page 39) 19 – Safety Belt (Page 40)

Figure 50 Note: The indicators are located above the tachometer and speedometer.

Note: A carrier with the Export Engine Option does not have a regeneration system. For such a crane, there is no operating diesel particulate filter indicator (1) or high exhaust system temperature indicator (11).

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35

TM500E-2 CARRIER OPERATOR’S MANUAL Diesel Particulate Filter

Check Engine

Figure 49

Figure 50

AC-384-0701-01156-A

Figure 51

Figure 52

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.

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.

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.

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

Note: A carrier with the Export Engine Option does not have a regeneration system. This indicator is inactive for such a crane.

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 51

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.

Figure 53

36

Published 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL 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.

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.

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.

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.

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 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 52

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 53

Figure 55 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.

Transmission Temperature Figure 54

Figure 54 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.

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Figure 56

37

TM500E-2 CARRIER OPERATOR’S MANUAL 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.

Figure 57

For more information, see Transmission Warning Functions.

Transmission Warning

Figure 59 If the ABS telltale illuminates during driving, the ABS self-test has detected a fault in the system.

Figure 55

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).

Figure 57 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.

Anti-Lock Brake System

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 58

Figure 56

Figure 60 The Air Filter Restriction telltale will illuminate when the air filter becomes clogged.

Figure 58 The Anti-Lock Brake System telltale will illuminate amber if the Anti-Lock Brake System (ABS) senses a problem under the following conditions:

High Exhaust System Temperature Figure 59

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 61 38

Published 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL 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.

Note: The Export Engine Option does not have a Regeneration System.

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.

Communication Error Figure 63

Parking Brake Figure 60

Figure 65

Figure 62 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.

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 64

Neutral Figure 61

Figure 63 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.

Figure 66 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 Guidelines.

information,

see

General

Safety

Wait to Start Figure 62

Fuel Figure 65

Figure 64

Figure 67 GROVE

Published 03-24-09, Control # 166-05

39

TM500E-2 CARRIER OPERATOR’S MANUAL 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.

Safety Belt Figure 66

Figure 68 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.

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TM500E-2 CARRIER OPERATOR’S MANUAL

Center Switch Panel Figure 67

7176-3

15

7098

1

14

12 10 11 3

13

2

4

9

5

6

7176-2

8

7

1 – Ignition/Start Key (Page 42) 2 – Engine Diag Active Reg (Page 43) 3 – Headlights (Page 42) 4 – Engine Brake (aka Exhaust Brake) (Page

8 – Transmission Gear Selector (Page 56) 9 – Cross (Differential) Axle Lock (Optional) (Page 44) 10 – Interaxle Lock (Optional) (Page 44) 11 – Deflate Air Ride Suspension (Page 45) 12 – Pusher Axle (Optional) (Page 45) 13 – Windshield Wiper/Washer (Page 42) 14 – Interior Lights (Page 47) 15 – Instrument Light Dimmer Switch (Page 44)

44) 5 – Cruise Control (Page 43) 6 – Parking Brake (Page 65) 7 – Heater and A/C Controls (Page 48)

Figure 69

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41

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

Figure 70

Figure 68

AC-334-0705-01240-A

Figure 70 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.

Headlights

7179

Figure 72 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

Figure 69

Figure 71

AC-364-0701-01165-A

Figure 71

Figure 73

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 headlights are of a halogen sealed beam type.

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

42

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.

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 03-24-09, Control # 166-05

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

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.

Figure 72

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 74

Engine Diagnostic Active Regeneration

Figure 73

Figure -2

7176-4

Figure 75

Figure 76

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

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

GROVE

This switch enables the operator to start manual exhaust regeneration. (Despite its label, this switch is not involved in engine diagnostics.)

Note: The Engine Diagnostic Active Regeneration Switch is not used with the Export Engine Option.

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TM500E-2 CARRIER OPERATOR’S MANUAL Instrument Light Dimmer Switch Figure 74

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

Interaxle Lock (optional) Figure -3

Figure 77 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 Lock (Optional) Figure 75

7176-5

Figure 79 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 78 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 Engine Brake (Exhaust Brake)

Deflate Air Ride Suspension

Figure 76

Figure -4

7176-6

Figure 81 Figure 80 The suspension system air bags are inflated by pressing UP on the switch, to deflate the air bags press the word LOWER.

Pusher Axle (Optional) 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.

Figure -5

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.

Figure 82

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

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.

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

GROVE

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45

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 77

Hazard Light Switch Figure 79

Figure 83 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.

The ashtray is located on top of the center panel.

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Steering Column Switches/Controls

Figure 85

Turn Signal/Headlight Beam Change Figure 78

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 80

7176-8

Figure 84 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.

46

Figure 86 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 Air Horn Figure 81

AC-362-0705-01241-A

Figure 87 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 -6

7176-9

Figure 88 The interior light switch turns the two cab interior overhead lights on and off.

GROVE

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TM500E-2 CARRIER OPERATOR’S MANUAL

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.

Cab Ventilation 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.

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.

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.

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TM500E-2 CARRIER OPERATOR’S MANUAL

SEATS

Seat Adjustments Figure 82

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.

AC-852-0312-G843-A. Figure 83

Figure 89 Figure 84

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.

GROVE

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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 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

air

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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charge

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TM500E-2 CARRIER OPERATOR’S MANUAL Gradients

Avoid High Engine Speeds

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.

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.

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.

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

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: • 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

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

Starting the Engine 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.)

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TM500E-2 CARRIER OPERATOR’S MANUAL

ENGINE START AND OPERATION Starting the Engine Start Procedure Note: For cold weather starting, see Cold Weather Operation.

4. Turn on the ignition by turning the key switch to IGN. (See Ignition/Start Key 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.

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.

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

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.

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.

Figure 85

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

2. Make sure the parking brakes are engaged.

3. Place the transmission in NEUTRAL.

Figure 91

AC-334-0705-01240-A

Figure 90

52

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.

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).

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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.

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

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.

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:

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.

Figure 86

Ignition Switch Figure 87

Figure 92 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.

GROVE

AC-334-0705-01240-A

Figure 93 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.

Cold Weather Operation 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.

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TM500E-2 CARRIER OPERATOR’S MANUAL 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.

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).

Figure 88

120 V, 20 A

AC-333-0509-G016

Figure 94 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 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.

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120 V, 30A

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TM500E-2 CARRIER OPERATOR’S MANUAL

Engine Operation

Engine Overspeed

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.

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.

GROVE

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.

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.

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.

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.

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TM500E-2 CARRIER OPERATOR’S MANUAL Low Idle Adjustment

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.

Figure 89

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.

Automatic Transmission Figure 95

Transmission Selector

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

Base PTO Mode Figure 90

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

Operation Mode Indicator

Mode ID Mode LED Mode Button

Range Buttons

Up and Down Arrows

Figure 96 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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6840

Figure 97 NOTE: If fault codes cannot be retrieved, contact your Manitowoc distributor or Manitowoc Crane Care for fault code diagnostics procedures.

NOTE: Visually check the display window whenever a bu tt on is p u sh e d to e n su re the ra nge is selected. A flashing display indicates the selection is inhibited

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

Drive (D) Push-button

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

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

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

NOTE: Fluid level information is displayed after pressing both the up ( ) or 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.

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

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

Press the drive (D) 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 v a 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 drive will not occur. When the drive (D) button is flashing, it indicates the shift to drive is inhibited. Check for active diagnostic codes if drive is not attained.

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 up () or down () arrow buttons or wait until the unit automatically exits the diagnostic mode.

Reverse (R) Push-button

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

Up and Down Arrow Buttons

When a lower range is desired after the drive (D) button has been pressed, press the 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 down () arrow button, press the up () arrow button to request the next higher range. Continuous pressing of either the up () arrow or down () arrow buttons will request the highest or lowest range available.

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

Do not idle in reverse for more than five minutes.

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

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

Push the reverse push-button for reverse travel.

(N) Neutral Push-button

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 GROVE

CAUTION

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

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TM500E-2 CARRIER OPERATOR’S MANUAL Oil Level Sensor

Display

T h e t ra n s m i s s i on s h i ft s e l e c t o r c a n d i s p l ay t h e transmission fluid level. By pressing both the up () or 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 up () and down () arrow buttons on the shift selector panel simultaneously. The following conditions must be met before a valid level check is displayed: -

Engine is at idle.

-

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

-

Transmission output shaft must be stopped.

-

Transmission must be in neutral (N).

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

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:

Lube Type - TranSynd Automatic Transmission Fluid

Table 1-1: Transmission Fluid Fill Codes

Application - Fill through dipstick fill tube.

Display

Description

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

Lube Interval - Check fluid level every 3000 hours.

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

Lube Amount - Capacity - 27.2 liters (29.0 quarts) 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.

• Temperature is below 60° C (140° F). oL, –n

• Temperature is above 104° C (220° C).

• Engine speed is too high (above idle).

• Transmission is not in neutral (N).

• Transmission output shaft is not stopped.

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

oL, oK 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.

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TM500E-2 CARRIER OPERATOR’S MANUAL

Cruise Control

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.

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 91

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.

Figure 98 Figure 92

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.

Figure 99 The cruise control switches are located on the center switch panel.

GROVE

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TM500E-2 CARRIER OPERATOR’S MANUAL Engage and Set Desired Crane Speed 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.

The aftertreatment assembly can clean its diesel particulate filter in processes called regeneration.

Passive regeneration occurs when temperature of the diesel oxidation catalyst is at the right level during operation to ensure burning of soot and particles without needing to add fuel.

Active regeneration occurs during operation when controls cause the injection of fuel into the exhaust to promote soot and particle burning. The operator can operate the crane normally until the filter is clean enough. If he shuts down the engine before this happens, the regeneration control circuitry will resume active regeneration when the crane is mobile.

Manual regeneration occurs when the operator parks the crane and runs the 20-minute manual regeneration cycle. The regeneration control circuitry causes the injection of fuel into the exhaust to promote soot and particle burning. Instructions for this are later in this section.

The HEST light comes on when regeneration is taking place. This light will stay on during regeneration and will continue to stay on after regeneration until the aftertreatment assembly has cooled enough.

Default settings for regeneration are as follows: Regeneration starts when the crane is traveling on highway above 40-45 mph (64-72 kph).

Regeneration Procedures NOTE: The Export Engine Option does not have the Regeneration System.

Regeneration is not permitted at crane speeds below 5 mph (8 kph). The regeneration cutout can be set at the factory to as high as 25 mph (40 kph).

Regeneration is not permitted when a crane (if so equipped) is operating PTO-driven equipment.

During passive regeneration and active regeneration, the operator must keep the crane away from overhanging foliage or other materials that could ignite by being near the exhaust. He must also keep the crane out of any area with gases or dust or any other flammable matter that could ignite due to the presence of the superheated aftertreatment assembly.

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.

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The HEST light comes on when exhaust temperature is at or above 1100 degrees F (593 degrees C). The HEST light goes out when exhaust temperature is below 1000 degrees F (538 degrees C).

Warning Indications There are several levels of filter cleanliness that the operator needs to know. The indications and operator actions for each follow: Level 0: Normal Operation. The diesel particulate filter is clean, recent regeneration has occurred, and passive regeneration can occur. No associated warning lights light. The operator doesn’t need to do anything.

Level 1:Normal Operation. The diesel particulate filter has a low soot load, and passive regeneration can occur. The DPF Regeneration Required light lights. The operator doesn’t need to do anything.

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TM500E-2 CARRIER OPERATOR’S MANUAL Level 2:Normal Operation. The diesel particulate filter has a moderate soot load, and passive regeneration can occur. The DPF Regeneration Required light blinks on and off. The operator needs to run the crane on a road, and run one gear down to allow active regeneration.

If the operator cannot start manual regeneration, the Stop Engine light comes on and the DPF Regeneration Required light goes out. If this happens, the operator needs to shut down the engine, and have the aftertreatment assembly and/or its controls serviced.

Level 3:Moderate Derated Engine Operation (15% loss). The diesel particulate filter has a full soot load, and passive regeneration can occur. The DPF Regeneration Required light blinks on and off, and the Engine Warning light lights. The operator needs to run the crane on a road, and run one gear down to allow active regeneration. The operator might need to have the aftertreatment assembly and/or its controls serviced.

Level 4:Severe Derated Engine Operation (50% down). The diesel particulate filter has a full soot load, and passive regeneration will likely not occur.

The Stop Engine light comes on. The DPF Regeneration Required light and the Engine Warning light go out. The operator needs to pull over, or stop on-site, shut down the engine, and have the aftertreatment assembly and/or its controls serviced.

Manual Regeneration Park the crane. Apply the parking brake and put the transmission at neutral.

Run the carrier engine at normal idle.

Press the carrier cab’s engine diagnostic active regeneration switch.

The engine will run at different speeds automatically as needed to burn off the soot.

The cycle will take 20 minutes.

When the cycle is done, the DPF Regeneration Required light will go out and the HEST light will go out.

Troubleshooting If the HEST light does not light and the DPF Regeneration Required light has lit and the Engine Warning light has lit, the operator should park the crane and try to run manual regeneration. If successful, the HEST light lights (indicating regeneration has begun).

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TRANSMISSION

Figure 95

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

Figure 101 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.

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

Figure 93

Transmission Warning Functions Figure 94

Figure 100 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.

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BRAKES

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.

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.

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 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.

General Figure 96

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.

AC-382-0505-00863-B

Figure 102

Do not use replacement parts anywhere in the brake system unless they conform exactly to original specifications. A GROVE

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TM500E-2 CARRIER OPERATOR’S MANUAL 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.

Figure 97

AC-382-0505-00884-B

Figure 103 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.

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.

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).

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.

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Brake System Controls 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.

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.

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TM500E-2 CARRIER OPERATOR’S MANUAL 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.

Parking Brake Valve Figure 98

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.

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

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).

AC-551-0508-G827

Figure 104 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.

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.

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

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TM500E-2 CARRIER OPERATOR’S MANUAL • 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.

Figure 99

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.

Figure 105 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.

Air Tanks

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.

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 100

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 106 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.

• 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).

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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.

Anti-Lock Brake System (ABS) 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.

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.

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 101

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.

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.

Figure 107

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.

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.

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Crane Speed Retardation Devices

ELECTRICAL SYSTEM

Safety Guidelines

General 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.

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.

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.

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

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.

Note: The Export Engine Option does not have an Engine Brake System.

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.

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TM500E-2 CARRIER OPERATOR’S MANUAL 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

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.

Battery Jump-Starting and Charging

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 102

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.

Figure 108 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.

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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.

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TM500E-2 CARRIER OPERATOR’S MANUAL Figure 103

Figure 105

Figure 109 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

AC-372-0705-01238-A

Figure 111 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.

Breakers and Relays

Figure 104

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.

AC-371-0705-01237-A

Figure 110 70

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Battery Main Disconnect Switch Figure 107

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.

Circuit breaker designation and location are listed on a label attached to the inside of each circuit breaker box cover.

Power Ports Figure 106

Figure 113 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.

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.

Figure 112 Use the power ports on the front of the dashboard to power cellular phone chargers and other 12 V DC low-current accessories.

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POWER STEERING

Figure 108

General 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.

Figure 114

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.

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.

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 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.

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.

3. Choose a suitable gear.

4. Slowly depress the accelerator pedal.

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.

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 109

Check-Tightening Wheel Lug Nuts Figure 110

7176-5

Figure 115 Engaging the cross axle locks must always be done in the following way: 1. Wait for the drive wheels to stop spinning.

2. Engage the cross axle lock.

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Figure 116

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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.

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.

Figure 111

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.

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.

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.

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

Figure 112

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.

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

1 – Steer Tire 2 – Drive Tire

Figure 117 Check tires for abnormal wear. Also check the tire tread depth.

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EMERGENCY INFORMATION

Wheel Bearing Adjustment 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.

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 113

Figure 118

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 119 Figure 114

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.

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Figure 120 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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TM500E-2 CARRIER OPERATOR’S MANUAL 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.

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

Towing Instructions

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.

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 115

Figure 121 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.

Caging Spring Brake

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.

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

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.

76

Published 03-24-09, Control # 166-05

TM500E-2 CARRIER OPERATOR’S MANUAL Figure 117

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.

Figure 123 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 116

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.

Figure 122 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.

GROVE

Published 03-24-09, Control # 166-05

77

TM500E-2 CARRIER OPERATOR’S MANUAL

THIS PAGE BLANK

78

Published 03-24-09, Control # 166-05

SUB MENU

SUB MENU

SUPERSTRUCTURE OPERATOR’S MANUAL

1

This manual has been prepared for and is considered part of -

TM500E-2 Crane Model Number

2 This Manual is divided into the following sections: SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6

INTRODUCTION SAFETY INFORMATION OPERATING CONTROLS SET-UP AND INSTALLATION LUBRICATION MAINTENANCE CHECKLIST NOTICE

3

The crane serial number is the only method your distributor or the factory has of providing you with correct parts and service information.

The crane serial number is identified on the builder’s decal attached to the operator’s cab. Always furnish crane serial number when ordering parts or communicating service problems with your distributor or the factory.

4 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 operate or work on this crane without first reading and understanding Operator’s Manual and Rating Plate supplied with crane.

• Store Operator’s Manual in holder provided on crane.

• Attach laminated Capacity Charts supplied with crane to chain in operator’s cab.

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

5

6 © 2008 Manitowoc Crane Group

Published 01-15-2008, Control # 150-01

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

Factory Service

Training

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

TABLE OF CONTENTS

SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Noise/vibration Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Noise Level Test Results Are As Follows: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Vibration Level Test Results Are As Follows: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information Diesel Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Battery Posts, Terminals, and Related Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Operator’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Operator’s Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Multiple Crane Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Load Moment Indicating (LMI) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Two-Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Special Operating Conditions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Crushing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Job Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Hand Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Transporting The Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Temperature Effects On Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

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SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Controls

TOC-1

TABLE OF CONTENTS

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Superstructure Cab Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tachometer with Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Stop/Module Off Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Warning/Electrical System Diagnostic Indicator . . . . . . . . . . . . . . . . . . . . . 3-2 Engine Wait To Start/Battery Discharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic Oil Cooler Temperature/Emergency Stop Indicator. . . . . . . . . . . . . . . . . 3-2 Swing Brake Engaged Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hoist 3rd Wrap Indicator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Boom Lights Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Defroster Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Dimmer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Right Front Outrigger Beam/Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Left Front Outrigger Beam/Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Left Rear Outrigger/Stabilizer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Right Rear Outrigger/Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Outrigger Extend/Retract Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Air Conditioner Switch (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Crane Function Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Engine Increment/Decrement Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Windshield Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Skylight Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Main Hoist Speed Selector Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Hoist Rotation Indicators (Main and Auxiliary Hoist) . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Boom Lift/Main Hoist Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Swing Horn Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Telescope/Auxiliary Hoist/Swing Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Swing Brake Selector Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Auxiliary Hoist Speed Selector Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Telescope Control Foot Pedal (Optional with Auxiliary Hoist) . . . . . . . . . . . . . . . . . 3-8 Cab Circulating Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Skylight Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Cab Dome Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 12 VDC Accessory Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Pin Swing Lock Control (Pin Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Electrical Diagnostic Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Cab Control Modules (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 360° Swing Lock Control (Positive Lock Type) (Optional) . . . . . . . . . . . . . . . . . . . . 3-9 Bubble Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Additional Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Outrigger Control Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Outrigger Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Outrigger Beam Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Extend/Retract Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Stabilizer Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

TABLE OF CONTENTS

Superstructure Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 New Crane Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Pre-Starting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Superstructure Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Crane Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Moving The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 General Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Using Your Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Crane Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Crane Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

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SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set-up And Installation General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Installing Cable On The Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Dead-end Rigging/wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Installing Wedge And Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Erecting And Stowing The Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Erecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Setting The Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Changing Boom Extension From Telescoping Type To Fixed Type. . . . . . . . . . . . 4-11 Setting The Telescoping Extension Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Traveling With 26ft/45ft Boom Extension Erected (95 ft and 102 ft Boom). . . . . . . 4-11 Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Arctic Conditions Below -18°C (0°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Arctic Conditions Down To -40°F.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Superstructure Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . . 5-9 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Checklist General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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TABLE OF CONTENTS

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

SECTION 1 INTRODUCTION

1

TABLE OF CONTENTS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Noise/vibration Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Noise Level Test Results Are As Follows: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Vibration Level Test Results Are As Follows: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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INTRODUCTION

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

INTRODUCTION

SECTION 1 INTRODUCTION GENERAL NOTE:

Throughout this handbook, reference is made to left, front, and rear when describing locations.

These reference locations are to be considered as those viewed from the operator’s seat with the superstructure facing forward over the front of the carrier frame.

This Operator Manual provides important information for the operator of the Model TM500E-2. In addition, to this Operator Manual, there are other manuals and documents in the Carrier cab. Be sure to read and understand all the manuals and documents thoroughly before operating from the Superstructure or Carrier cab.

The superstructure engine and its components are installed as part of a power plant tray mounted on the superstructure.

Hydraulic, double box, sliding beam outriggers are integral with the frame.

The superstructure is capable of 360° rotation in either direction. All crane functions are controlled from the fullyenclosed superstructure cab. The crane is equipped with a four-section cable synchronized full power boom. Additional

1

reach is obtained by utilizing a swingaway boom extension.

Lifting is provided by a main hoist and an optional auxiliary hoist.

NOISE/VIBRATION TEST RESULTS Noise Level Test Results Are As Follows: •

At the operator’s station with closed cab operation, the value is 78.5 dba maximum when measured according to the directives 98/37/EC and Kebomatief 27.

Vibration Level Test Results Are As Follows: •

At the operator’s station with closed cab operation, vibration levels are less than 0.5 m/s/s for Whole Body Vibration exposure and are less than 2.5 m/s/s for Hand Arm Vibration exposure when measured according to 89/392/EEC Community Legislation on Machinery per standard ISO 2631/1 - Evaluation of Human Exposure to Work Body Vibration, ISO 5349 - Guidelines for the Measurement and Assessment of Human Exposure to Hand Transmitted Vibrations, and ISO/DIS 8041 Human Response Vibration Measuring Instrumentation.

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8

7

20

14

18

22

6

1

16 15 5

17

9 6942-1

4 14 19

5

3 7

10

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21 2

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2 13

12

14 8

9

6942-2

4

2

4 3

21

3

FIGURE 1-1 Item

Description

Item

Description

1

Superstructure Cab

12

Boom Extension

2

Outrigger Float

13

Boom Extension Nose

3

Outrigger Stabilizer Cylinder

14

Boom & Lift Cylinder Pivot

4

Steps

15

Hydraulic Tank

5

Counterweight

16

Hydraulic Filter

6

Lift Cylinder

17

Main Hoist

7

Boom

18

Auxiliary Hoist

8

Boom Nose Sheaves

19

Air Cleaner

9

Auxiliary Boom Nose

20

Boom Rest

10

Superstructure Engine

21

Remote Outrigger Controls

11

Boom Extension Mast Sheave

22

Fuel Tank

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

INTRODUCTION

1 13 20 5

7

11

12

6

20

14

8 9

6942-3

2

21

View With 95 Foot Boom Option

FIGURE 1-1 continued

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INTRODUCTION

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THIS PAGE BLANK

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Published 01-15-2008, Control # 150-01

SECTION 2 SAFETY INFORMATION TABLE OF CONTENTS Diesel Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Battery Posts, Terminals, and Related Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Operator’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Operator’s Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Multiple Crane Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Load Moment Indicating (LMI) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Two-Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Special Operating Conditions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Crushing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Job Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Hand Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Transporting The Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Temperature Effects On Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2

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SAFETY INFORMATION

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

SAFETY INFORMATION

SECTION 2 SAFETY INFORMATION DIESEL ENGINE EXHAUST

Signal Words

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.

SAFETY MESSAGES

DANGER Identifies immediate hazards that will result in death or serious injury if the message is ignored.

2 WARNING Identifies potential hazards that could result in death or serious injury if the message is ignored.

CAUTION Identifies potential hazards that could result in minor or moderate injury if the message is ignored.

CAUTION Without the safety alert symbol, identifies potential hazards that could result in property damage if the message is ignored.

General

NOTE:

NOTE:

GENERAL

Refer to the Carrier Operator’s Manual for safety information pertaining to the carrier.

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.

NOTE:

Highlights operation or maintenance procedures.

Illustrations have been included in this section to emphasize certain proper and improper points; READ AND FOLLOW PRINTED INSTRUCTIONS.

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.

Safety Alert Symbol

With this thought in mind, this information has been provided to assist you, the operator, in promoting a safe working atmosphere for yourself and those around you. It is not meant to cover every conceivable circumstance which could arise. It is intended to present basic safety precautions that should be followed in daily operation.

This safety alert symbol means ATTENTION! Become alert — your safety is involved! Obey all safety messages that follow this symbol to avoid possible death or injury.

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

Published 01-15-2008, Control # 150-01

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SAFETY INFORMATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

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.

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. 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 Grove distributor.

Following any accident or damage to equipment the local Grove 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 Crane CARE.

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.

OPERATIONAL AIDS Grove remains committed to providing reliable products that enable users and operators to safely lift and position loads.

Grove has been an industry leader in the incorporation of operational aids into the design of its cranes. Federal law requires that cranes be properly maintained and kept in good working condition. The manuals that Grove provides that are specific for each crane and the manufacturer’s manuals for the operational aids shall be followed. If an operational aid should fail to work properly, the crane user or owner must assure that repair or recalibration is accomplished as soon as is reasonably possible.

An operational aid is an accessory that provides information to facilitate operation of a crane or that takes control of particular crane functions without action of the operator when a limiting condition is sensed.

Operational Aids include, but are not limited to the following: •

Hydraulic Capacity Alert System (HCAS)

•

Load Moment Indicator (LMI)

•

Anti-Two Block Prevention/Warning Device

You must READ and UNDERSTAND the Operator’s Manual and the Load Chart before operating the crane. You must also VIEW and UNDERSTAND the safety video titled “The Real Key to Crane Safety” supplied with your new Grove product. The Operator’s Manual and Load Chart must be readily available to the operator at all times and must remain in the cab while the crane is in use.

•

Load Indicator

•

Rated Capacity Limiter

•

Rated Capacity Indicator

•

Boom Angle Indicator

•

Crane Level Indicator

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.

•

Boom Length Indicator

•

Radius Indicator

OPERATOR’S INFORMATION

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 the Load Chart, this Operator’s Manual, 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.

2-2

If any operational aid is malfunctioning follow the guidance provided in ASME B30.5-2004 Section 5-3.2.1.2 (b), which is reprinted below: (b) When operational aids are inoperative or malfunctioning, the crane and/or device manufacturer's recommendations for continued operation or shutdown of the crane shall be followed until the problems are corrected. Without such recommendations and any prohibitions from the manufacturer against further operation, the following requirements shall apply: (1) Recalibration or repair of the operational aid shall be accomplished as soon as is reasonably possible, as determined by a qualified person.

(2) When a load indicator, rated capacity indicator, or rated capacity limiter is inoperative or malfunctioning, the designated person responsible for supervising the lifting operations shall establish procedures for determining load

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

SAFETY INFORMATION

weights and for conducting the lifts in accordance with paras.

5-3.2.1.1(a) through (c). (Note: Paras. 5-3.2.1.1(a)-(c) relate to using the crane within the limits of the load capacity chart.)

•

You are sure the machine is operating properly and has been inspected and maintained in accordance with the manufacturer’s manuals.

(3) When a boom angle or radius indicator is inoperative or malfunctioning, radii or boom angle shall be determined by measurement.

•

You are sure that all safety signs, guards, and other safety features are in place and in proper condition.

(4) When an anti-two-block device, two-block damage prevention device, or two-block warning device is inoperative or malfunctioning, the designated person responsible for supervising the lifting operations shall establish procedures, such as assigning an additional signal person, to furnish equivalent protection. This does not apply when lifting personnel. Personnel shall not be lifted when two-block devices are not functioning properly.

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.

(5) When a boom length indicator is inoperative or malfunctioning, the designated person responsible for supervising the lifting operations shall establish procedures for conducting the lifts in accordance with paras. 5-3.2.2.1(a) through (c).

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.

(6) When a level indicator is inoperative or malfunctioning, other means shall be used to level the crane within the level requirements specified by the manufacturer.

CRANE STABILITY/STRUCTURAL STRENGTH

OPERATOR’S QUALIFICATIONS

To avoid death or serious injury, ensure that the crane is on a firm surface with load and crane’s configuration within capacity as shown on the crane’s load rating chart and notes.

Do not lift loads unless the outriggers are properly extended and the crane leveled. On models equipped with outriggers that can be pinned at the mid-extend position, the outriggers must also be pinned when operating from the mid-extend position.

This crane should have a functional load moment indicator and control lock-out system. Test daily for proper operation.

Never interfere with the proper functioning of operational aids or warning devices.

Before swinging the superstructure over the side when the outriggers are retracted, check the load chart for backwards stability.

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 manufacturer’s manuals, your employer’s work rules, and applicable government regulations.

Long cantilever booms can create a tipping condition when in an extended and lowered position. Retract the boom proportionally with reference to the capacity of the applicable load chart.

Check crane stability before lifting loads. Ensure the outriggers are firmly positioned on solid surfaces. Ensure the crane is level, parking brakes are set, and the load is properly rigged and attached to the hook. Check the load chart against the weight of the load. Lift the load slightly off the ground and recheck the stability before proceeding with the lift. Determine the weight of the load before you attempt the lift.

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Ensure all pins and floats are properly installed and outrigger beams are properly extended before lifting on outriggers.

Unless lifting within On Rubber capacities, outrigger beams must be properly extended, jack cylinders extended and set, to provide maximum leveling of the crane. On models equipped with outriggers that can be pinned at the midextend position, the outriggers must also be pinned when operating from the mid-extend position. Tires must be clear of the ground before lifting on outriggers. Remove all weight from tires before lifting on outriggers.

The operator must select the proper Load Chart and Load Moment Indicating (LMI) System program for the outrigger position selected.

Use adequate cribbing under outrigger floats to distribute weight over a greater area. Check frequently for settling.

Carefully follow the procedures in this handbook when extending or retracting the outriggers. Death or serious injury could result from improper crane set-up on outriggers.

Be sure the outriggers are properly extended and set and the crane is level for operation on outriggers.

All four outrigger beams must be equally extended to the appropriate vertical stripe before beginning operation.

All four outrigger beam lock pins must be engaged before operating from the mid-extend position.

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL KEEP THE BOOM SHORT. Swinging loads with a long line can create an unstable condition and possible structural failure of the boom.

Load Charts Load Charts represent the absolute maximum allowable loads, which are based on either tipping or structural limitations of the crane under specific conditions. Knowing the precise load radius, boom length, and boom angle should be a part of your routine planning and operation.

Actual loads, including necessary allowances, should be kept below the capacity shown on the applicable Load Chart.

SAFETY INFORMATION

programmed for the crane configuration. Refer to the LMI handbook supplied with the crane.

Before lifting, position the crane on a firm surface, properly extend and set the outriggers, and level the crane.

If the boom extension or auxiliary boom nose is to be used, you must ensure that the cable for the LMI system is properly connected at the junction box located on the boom nose.

Depending on the nature of the supporting surface, adequate cribbing may be required to obtain a larger bearing surface.

You must use the appropriate Load Chart when determining the capability of the crane in the configuration required to perform the lift.

DO NOT OVERLOAD THE CRANE by exceeding the capacities shown on the appropriate Load Chart. Death or serious injury could result from the crane tipping over or failing structurally from overload.

Maximum lifting capacity is available at the shortest radius, minimum boom length, and highest boom angle.

Do not rely on the crane’s tipping to determine your lifting capacity.

Do not remove the Load Charts from the crane.

If you should encounter a tipping condition, immediately lower the load with the hoist line and retract or elevate the boom to decrease the load radius. Never lower or extend the boom, this will aggravate the condition.

Work Site Prior to any operation, you must inspect the ENTIRE worksite, 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.

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.

Wind can have a significant affect on loads that may be lifted by a crane. Wind forces act differently on a crane depending upon the direction from which the wind is blowing (e.g., wind on the rear of the boom can result in decreased forward stability, wind on the underside of the boom can result in decreased backward stability, wind on the side of the boom can result in structural damages, etc.). To assist you in determining prevailing wind conditions, refer to Wind Velocity Chart (Table 2-1).

Lifting Operations If the boom extension or auxiliary boom nose is to be used, ensure the electrical cable and the weight for the anti-two b l o c k s w i t c h a r e p r o p e r l y i n s ta l l e d a n d t h e L M I i s

Be sure the load is properly rigged and attached. Always determine the weight of the load before you attempt to lift it and remember that all rigging (slings, etc.) and lifting devices (hook block, jib, etc.) must be considered part of the load.

Measure the load radius before making a lift and stay within approved lifting areas based on the range diagrams and working area diagrams on the crane’s Load Chart.

Verify the crane’s capacity by checking the Load Chart against the weight of the load then lift the load slightly at first to ensure stability before proceeding with the lift.

Always keep the load as near to the crane and as close to the ground as possible.

The crane can tip over or fail structurally if: •

The load and crane’s configuration is not within the capacity as shown on the applicable load rating chart and notes.

•

The ground is soft and/or the surface conditions are poor.

•

Outriggers are not properly extended and set. On models equipped with outriggers that can be pinned at the mid-extend position, the outriggers must also be pinned when operating from the mid-extend position.

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Table 2-1 Wind Velocity Chart Wind Force Beauford Scale

Designation

Wind Velocity km/h (mph)

Visible Indicator Effects of wind as observed on land

Zero (0)

Calm

<2 (<1)

No wind: smoke rises vertically

1

Light Air

2-5 (1-3)

Wind direction seen by smoke but not by wind vanes

2

Light Breeze

6-11 (4-7)

Wind felt on face: leaves rustle: wind vane moves slightly

3

Gentle Breeze

13-19 (8-12)

Leaves/small twigs in constant motion: wind extends flag

4

Moderate Breeze

21-29 (13-18)

Raises dust & loose paper: moves small branches

Reduce crane load ratings and operating parameters at 32 km/h (20 mph) 5

Fresh Breeze

31-39 (19-24)

Small trees in leaf begin to sway: on ponds, crested wavelets form

6

Strong Breeze

40-50 (25-31)

Large branches in motion: telegraph wires whistle: umbrellas used with difficulty

Cease all craning operations at 48 km/h (30 mph); lower & retract boom 7

Moderate Gale

52-61 (32-38)

•

Cribbing under the outrigger pads is inadequate.

•

The crane is improperly operated.

Whole trees in motion: walking against wind is inconvenient

Wind forces can exert extreme dynamic loads. Grove recommends that a lift not be made if the wind can cause a loss of control in handling the load. Grove recommends if the wind speed (velocity) is between 32 km/h (20 mph) to 48 km/h (30 mph), that the load capacities shall be reduced to account for the size and shape of the load and the wind direction in relation to the machine for all boom, boom extension, and jib lengths. Further, operation of the crane in wind velocities over 48 km/h (30 mph) is not recommended.

To assist you in determining prevailing wind conditions, refer to (Table 2-1).

The crane cab is equipped with a sight level bubble that should be used to determine whether the crane is level. The load line can also be used to estimate the levelness of the crane by checking to be sure it is in-line with the center of the boom at all points on the swing circle.

Use tag lines whenever possible to help control the movement of the load.

When lifting loads, the crane will lean toward the boom and the load will swing out, increasing the load radius. Ensure the load capacity chart is not exceeded when this occurs.

Be sure the hoist line is vertical before lifting. Do not subject the crane to side loading. A side load can tip the crane or cause it to fail structurally.

Do not strike any obstruction with the boom. If the boom should accidentally contact an object; stop immediately.

2-6

Inspect the boom. Remove the crane from service if the boom is damaged.

Never push or pull with the crane boom.

Avoid sudden starts and stops when moving the load. The inertia and an increased load radius could tip the crane over or cause it to fail structurally.

Load Chart capacities are based on freely suspended loads.

Do not pull posts, pilings, or submerged articles. Be sure the load is not frozen or otherwise attached to the ground before lifting.

Use only one hoist at a time when lifting loads.

Always use enough parts-of-line to accommodate the load to be lifted. Lifting with too few parts-of-line can result in failure of the wire rope.

Never operate the crane with less than two wraps of wire rope on the hoist drum.

Counterweight On cranes equipped with removable counterweights, ensure the appropriate counterweight sections are properly installed for the lift being considered.

To reduce the crushing hazard and to prevent death or seriou s injury, always clear all personne l from the counterweight area before moving the counterweight or rotating the superstructure.

Federal law prohibits modification or additions which affect the capacity or safe operation of the equipment without the manufacturer’s written approval. [29CFR 1926.550]

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL Do not add material to the counterweight to increase capacity.

Multiple Crane Lifts Multiple crane lifts are not recommended.

SAFETY INFORMATION

For detailed information concerning the operation and maintenance of the load moment indicating system installed on the crane see the manufacturer’s manual supplied with the crane.

Two-Blocking

Any lift that requires more that one crane must be precisely planned and coordinated by a qualified engineer.

If it is necessary to perform a multi-crane lift, the operator shall be responsible for assuring that the following minimum safety precautions are taken.

1.

Secure the services of a qualified engineer to direct the operation.

2.

Use one qualified signal person.

3.

Coordinate lifting plans with the operator, engineer and signal person prior to beginning the lift.

4.

Communication between all parties must be maintained throughout the entire operation. If possible, provide approved radio equipment for voice communication between all parties engaged in the lift.

5.

Use cranes and rigging of equal capabilities and use the same boom length.

6.

Use outriggers on cranes so equipped.

7.

Be certain cranes are of adequate lifting capacity.

8.

Calculate the amount of weight to be lifted by each crane and attach slings at the correct points for proper weight distribution.

9.

Ensure the load lines are directly over the attach points to avoid side loading and transfer of loading from one crane to the other.

Two-blocking occurs whenever the load block (hook block, headache ball, rigging, etc.) comes into physical contact with the boom (boom nose, sheaves, jib, etc.). Two-blocking can cause hoist lines (wire rope) rigging, reeving, and other components to become highly stressed and overloaded in which case the wire rope may fail allowing the load, block, etc. to free fall.

Two-blocking is more likely to occur when both the main and auxiliary hoist lines are reeved over the main boom nose and boom extension/jib nose respectively. An operator, concentrating on the specific line being used, may telescope or lower the boom allowing the other hoist line attachment to contact the boom or boom extension/jib nose, thus causing damage to the sheaves, or causing the wire rope to fail, dropping the lifting device to the ground and possibly injuring personnel working below.

Caution must be used when lowering or extending the boom.

Let out load line(s) simultaneously to prevent two-blocking the boom tip(s) and the hook block, etc. The closer the load is carried to the boom nose the more important it becomes to simultaneously let out wire rope as the boom is lowered.

Keep load handling devices a minimum of 107 cm (42 in.) below the boom nose at all times.

10. DO NO TRAVEL. Lift only from a stationary position

Two-blocking can be prevented. Operator awareness of the hazards of two-blocking is the most important factor in preventing this condition. An anti two-block system is intended to assist the operator in preventing dangerous twoblock conditions. It is not a replacement for operator awareness and competence.

LOAD MOMENT INDICATING (LMI) SYSTEMS

To avoid death or serious injury, keep load handling devices away from boom/jib tip when extending or lowering the boom and when hoisting up.

Electronic equipment on this crane is intended as an aid to the operator.

This crane should have a functional ANTI-TWO BLOCK and CONTROL LOCK- OUT system. Test daily for proper operation.

Under NO CONDITION should it be relied upon to replace the use of capacity charts and operating instructions. Sole reliance upon these electronic aids in place of good operating practices can cause an accident.

Know the weight of all loads and always check the capacity of the crane as shown on the Load Chart before making any lifts.

NEVER exceed the rated capacity shown on the Load Chart.

Always check the Load Chart to ensure the load to be lifted at the desired radius is within the rated capacity of the crane.

Never interfere with the proper functioning of operational aids or warning devices.

Do not pass loads or boom over ground personnel.

Barricade the area where the crane is working and keep all unnecessary personnel out of that area. DO NOT allow personnel to be under the load or boom.

Never pass loads, load handling devices, or the crane boom over people on the ground.

Never operate the crane with less than two wraps of wire rope on the hoist drum.

Never interfere with the proper functioning of operational aids or warning devices.

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ELECTROCUTION HAZARD

Even if the crane operator is not affected by an electrical contact, others in the area may become seriously injured or killed.

It is not always necessary to contact a power line or power source to become electrocuted. Electricity, depending on magnitude, can arc or jump to any part of the load, load line or crane boom if it comes too close to an electrical power source. Low voltages can also be dangerous.

Thoroughly read, understand, and abide by all applicable federal, state and local regulations.

To avoid death or serious injury, keep all parts of this machine, the rigging, and materials being lifted at least 6 m (20 ft.) away from all electrical power lines and equipment.

Federal law prohibits the use of cranes closer than 3 m (10 ft.) to power sources up to 50,000 volts and greater distances for higher voltages. [29CFR1910.180 and 29CFR1926.550] Grove recommends keeping cranes twice the minimum distance (e.g., 6 m (20 ft.)) as specified by US Department of Labor - Occupational Safety and Health Administration (OSHA) standards.

Keep all personnel away from this machine if it is being operated near electrical power lines or equipment.

Set-Up and Operation

Before operating this crane in the vicinity of electrical power lines or equipment, notify the power utility company. Obtain positive and absolute assurance that the power has been turned off.

This machine is NOT INSULATED. Always consider all parts of the load and the crane, including the wire rope, hoist cable, pendant cables and tag lines, as conductors.

Most overhead power lines ARE NOT insulated. Treat all overhead power lines as being energized unless you have reliable information to the contrary from the utility company or owner.

The rules in this handbook must be followed at all times, even if the electrical power lines or equipment have been deenergized.

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.

Crane operation is dangerous when close to an energized electrical power source. Exercise extreme caution and prudent judgement. Operate slowly and cautiously when in the vicinity of power lines.

If the load, wire rope, crane boom or any portion of the crane contacts or comes too close to an electrical power source, everyone in, on, and around the crane can be seriously injured or killed.

The safest way to avoid electrocution is to stay away from electrical power lines and electrical power sources.

You, the operator, are responsible for alerting all personnel of dangers associated with electrical power lines and equipment. The crane is not insulated. Do not allow unnecessary personnel in the vicinity of the crane while operating. Permit no one to lean against or touch the crane.

Permit no one including riggers and load handlers to hold the load, load lines, tag lines or rigging gear.

2-8

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.

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL 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.

Tag lines should always be made of non-conductive materials. Any tag line that is wet or dirty can conduct electricity.

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

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.

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).

•

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 o r no prote ction f rom e lec tric al haz ards. 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.

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.

Electrical Contact

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.

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.

SAFETY INFORMATION

If the crane should come in contact with an energized power source, you must: 1.

Stay in the crane cab. DON’T PANIC.

2.

Immediately warn personnel in the vicinity to stay away.

3.

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

4.

Stay in the crane until the power company has been contacted and the power source has been de-energized.

NO ONE must attempt to come close to the crane or load until the power has been turned-off.

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 Grove 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 Crane CARE. The crane must 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 Gro ve Manito woc C rane CAR E or y our loc al Gro ve distributor.

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Special Operating Conditions and Equipment

Always be aware of your working environment during operation of the crane. Avoid contacting any part of the crane with external objects.

Never operate the crane during an electrical thunderstorm.

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.

CRUSHING HAZARDS

You must always be aware of everything around the crane while lifting or traveling. If you are unable to clearly see in the direction of motion, you must post a look-out or signal person before moving the crane or making a lift. Sound the horn to warn personnel.

Clear all personnel from the outrigger area before extending or retracting the outriggers.

Carefully follow the procedures in this Operator’s Manual when extending or retracting the outriggers. Death or serious injury could result from improper crane set up on outriggers.

Be sure the outriggers are properly extended, set and the crane is level for operation on outriggers.

All four outrigger beams must be equally extended to the appropriate vertical stripe before beginning operation.

Death or serious injury could result from being crushed by moving machinery.

Clear all personnel from the counterweight and superstructure area before removing the counterweight or rotating the superstructure.

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

Never allow anyone to stand or work on or near the superstructure while the crane is in operation.

Always barricade the tail-swing of the rotating superstructure.

Before actuating swing or any other crane function, sound the horn and verify that all personnel are clear of rotating and moving parts.

Watch the path of the boom and load when swinging. Avoid lowering or swinging the boom and load into ground personnel, equipment or other objects.

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All four outrigger beam lock pins must be engaged before operating from the mid-extend position.

The operator must select the proper Load Chart and LMI System program for the outrigger position selected.

Only the crane operator shall occupy the crane when traveling or in operation.

PERSONNEL HANDLING The American Society of Mechanical Engineers issued a new American National Standard entitled, Personnel Lifting Systems, ASME B30.23-1998. This standard provides, "lifting and lowering of personnel using ASME B30 Standard hoisting equipment shall be undertaken only in circumstances when it is not possible to accomplish the task by less hazardous means. Unless all of the applicable requirements of this volume are met, the lifting or lowering of personnel using ASME B30 Standard equipment is prohibited." This new standard is consistent with the U.S. Department of Labor, Occupational Safety and Health Administration (OSHA) regulations for Construction that state, in 29CFRI926.550(g)(2): "General requirements. The

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL use of a crane or derrick to hoist employees on a personnel platform is prohibited, except when the erection, use, and dismantling of conventional means of reaching the work site, such as a personnel hoist, ladder, stairway, aerial lift, elevating work platform or scaffold, would be more hazardous or is not possible because of structural design or work site conditions." Additional requirements for crane op e ra tio ns ar e s ta te d in AS ME B3 0. 5, Mo bile An d Locomotive Cranes, and in OSHA regulations 29CFRI910.180 for General Industry and 29CFRI926.550 for Construction.

Use of a Grove crane to handle personnel is acceptable provided: • •

The requirements of the applicable national, state and local regulations and safety codes are met.

A determination has been made that use of a crane to handle personnel is the least hazardous means to perform the work.

•

The crane operator shall be qualified to operate the specific type of hoisting equipment used in the personnel lift.

•

The crane operator and occupants have been instructed in the recognized hazards of personnel platform lifts.

•

The crane is in proper working order.

•

The crane is equipped with a functional anti-two block device.

•

The crane's load capacity chart is affixed inside the crane's cab, readily accessible to the Operator. The total weight of the loaded personnel platform and related rigging shall not exceed 50 percent of the rated capacity for the radius and configuration of the crane.

•

•

• •

•

SAFETY INFORMATION

NEVER permit anyone to ride loads, hooks, slings or other rigging for any reason.

NEVER get on or off a moving crane.

NEVER allow anyone other than the operator to be on this crane while the machine is operating or traveling.

Grove Manitowoc Crane CARE continues to recommend that cranes be properly maintained, regularly inspected and repaired as necessary. Grove Manitowoc Crane CARE reminds crane owners to ensure that all safety decals are in place and legible. Grove Manitowoc Crane CARE continues to urge Grove Manitowoc crane owners to upgrade their cranes with load moment indicator (LMI) and control lever lockout systems for all lifting operations.

The following standards and regulations are available by mail at the following addresses: •

ASME (formerly ANSI) B30 Series American National Safety Standards For Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, And Slings; ASME B30.5, Mobile And Locomotive Cranes, and ASME B30.23, Personnel Lifting Systems, are available by mail from the ASME, 22 Law Drive, Fairfield, New Jersey, 0700-2900.

•

US DOL/OSHA Rules and Regulations are available by mail from the Superintendent of Documents, PO Box 371954, Pittsburgh, PA, 15250-7954.

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.

•

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

•

The crane's Operator Manual and other operating manuals are inside the crane's cab, readily accessible to the Operator.

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.

•

The platform meets the requirements as prescribed by applicable standards and regulations.

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

•

For wire rope suspended platforms, the crane is equipped with a hook that can be closed and locked, eliminating the throat opening.

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.

The crane is uniformly level within one percent of level grade and located on a firm footing. Cranes with outriggers shall have them all fully deployed following manufacturer's specifications.

The platform is properly attached and secure.

To avoid death or serious injury: NEVER use this crane for bungee jumping or any form of amusement or sport.

Published 01-15-2008, Control # 150-01

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SAFETY INFORMATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

•

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.

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: Grove Manitowoc Crane Group 1565 East Buchanan Trail Shady Grove, PA 17256-0021 Phone: Fax: E-mail:

888-777-3378 (888-PSR-DEPT) 717-593-5074 psafety@groveworldwide.com

solutions used should be appropriate for the job and nonflammable/toxic.

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.

Service and Repair Service and repairs to the crane must only be performed by a qualified person. All service and repairs must be performed in accordance with manufacturer’s recommendations, this Operator’s Manual and the Service Manual for this machine.

All replacement parts must be approved by Manitowoc Crane CARE.

Provide a complete description of the accident, including the crane model and serial number.

Any modification, alteration, or change to a crane which affects its original design and is not authorized and approved

by Grove Worldwide is STRICTLY PROHIBITED. Such action invalidates all warranties and makes the owner/user liable for any resultant accidents.

MAINTENANCE

Before performing any maintenance, service or repairs on the crane:

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 (e.g. LMI).

•

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

2-12

•

The boom should be fully retracted and lowered and the load placed on the ground.

•

Stop the engine and disconnect the battery.

•

Controls should be properly tagged. Never operate the crane if it is TAGGED-OUT nor attempt to do so until it is restored to proper operating condition and all tags have been removed by the person(s) who installed them.

Recognize and avoid pinch-points while performing maintenance. Stay clear of sheave wheels, holes, and lattice work in crane booms.

After maintenance or repairs: •

Replace all guards and covers that had been removed.

•

Remove all tags, connect the battery, and perform a function check of all operating controls.

•

Load tests must be performed when a structural or lifting member is involved in a repair.

Lubrication 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:

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

SAFETY INFORMATION

1.

Follow the manufacturer’s recommendations when adding oil to the system. Mixing the wrong fluids could destroy seals, causing machine failure.

7.

In standing ropes, more than three (3) breaks in one rope lay in sections beyond the end connection or more than two (2) broken wires at an end connection.

2.

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

8.

3.

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

Core deterioration is usually observed as a rapid reduction in rope diameter and is cause for immediate removal of the rope.

4.

Never exceed the manufacturers recommended relief valve settings.

Refuse to work with worn or damaged wire rope.

When installing and inspecting wire ropes and attachments keep all parts of your body and clothing away from rotating hoist drums and all rotating sheaves.

Never handle the wire rope with bare hands.

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

Periodic rope inspection records are required by law. Make sure these records have been reviewed and are up to date.

When installing a new rope :

Ensure all lug nuts are properly torqued.

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

•

Follow proper instructions for removing rope from a reel.

•

Apply back tension to the storage/payoff reel of the new rope to insure tight, even spooling onto the hoist drum.

•

Operate the new rope, first through several cycles at light load and then through several cycles at intermediate load to allow the rope to adjust to operating conditions.

Wire Rope Use ONLY the wire rope specified by Grove Manitowoc Crane CARE as indicated on the crane’s load capacity chart.

Substitution of an alternate wire rope may require the use of a different permissible line pull and, therefore, require different reeving.

Always make daily inspections of the wire rope, keeping in mind that all wire rope will eventually deteriorate to a point where it is no longer usable. Wire rope shall be taken out of service when any of the following conditions exist: 1.

For rotation resistant running ropes - more than two (2) broken wires in a length of rope equal to six(6) times the rope diameter, or more than four (4) broken wires in a length of rope equal to thirty (30) times the rope diameter.

2.

For running ropes other than rotation resistant - six (6) broken wires in one rope lay or three (3) broken wires in one strand.

3.

One valley break where the wire fractures between strands in a running rope is cause for removal.

4.

Abrasion of the rope resulting in wear of the individual outside wires of 1/3 of the original wire diameter.

5.

Any kinking, bird caging, crushing, corrosion, or other damage resulting in distortion of the rope structure.

6.

Rope that has been in contact with a live power line or been used as a ground in an electric circuit (e.g. welding) may have wires that are fused or annealed and must be removed from service.

When using a wedge socket : •

Always inspect socket, wedge, and pin for correct size and condition.

•

Do not use parts that are damaged, cracked, or modified.

•

Assemble the wedge socket with live end of rope aligned with the centerline of pin and assure proper length of tail (dead end) protrudes beyond the socket.

Never overload or shock load a wire rope.

Lubricate the wire rope periodically as the lubricant becomes depleted.

Inspect the boom nose and hook block sheaves for wear.

Damaged sheaves cause rapid deterioration of wire rope.

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SAFETY INFORMATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

To attain maximum wire rope life and minimize hook block rotation, it is recommended that even numbers of parts-ofline be used in multiple-part reevings whenever possible.

allow the radiator time to cool before removing the remote surge tank cap.

If applicable to your crane, the use of nylon (nylatron) sheaves, as compared with metallic sheaves, may change the replacement criteria of rotation resistant wire rope.

NOTE:

If applicable to your crane, the use of cast nylon (nylatron) sheaves, as compared with steel sheaves, will substantially increase the service life o f w i r e r o p e . H o w e v e r, c o n v e n t i o n a l r o p e retirement criteria based only upon visible wire breaks may prove inadequate in predicting rope failure. The user of cast nylon sheaves is therefore cautioned that a retirement criteria should be established based upon the user’s experience and the demands of his application.

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

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:

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

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

WORK PRACTICES Crane Access

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

•

Disconnect the batteries.

•

Wear safety glasses when servicing batteries.

•

Do not short across the battery posts to check charge.

Short circuit, spark, or flame could cause battery explosion.

•

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.

ENGINE Be careful when checking the engine coolant level. The fluid may be hot and under pressure. Shut down the engine and

2-14

You must take every precaution to ensure you do not slip and/or fall off the crane. Falling from any elevation could result in serious injury or death.

Never exit or enter the crane superstructure cab or deck by any other means than the access system(s) provided (i.e., steps and grab handles).

If necessary, use a ladder or aerial work platform to access the boom nose.

Do not step on surfaces on the crane that are not approved or suitable for walking and working. All walking and working surfaces on the crane should be clean, dry, slip-resistant, and have adequate supporting capacity. Do not walk on a surface if slip-resistant material is missing or excessively worn.

Do not use the top of the boom as a walkway.

Do not step on the outrigger beams or outrigger pads (floats) to enter or exit the crane.

Wear shoes with a highly slip-resistant sole material. Clean any mud or debris from shoes before entering the crane cab or climbing onto the crane superstructure. Excessive dirt and debris on the hand-holds, access steps or walking/working surfaces could cause a slipping accident. A shoe that is not clean might slip off a control pedal during operation.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

SAFETY INFORMATION

Do not make modifications or additions to the crane’s access system that have not been evaluated and approved by Grove Manitowoc Crane CARE.

A good practice is to make a “dry run” without a load before making the first lift. Become familiar with all factors peculiar to the job site

Job Preparation

Ensure the wire rope is properly routed on the hook block and boom nose and that all rope guards are in place.

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

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

2

You must ensure that the outriggers are properly extended and set and crane level before performing any lifting operations. On models equipped with outriggers that can be pinned at the mid-extend position, the outriggers must also be pinned when operating from the mid-extend position.

Wear appropriate clothing and personal protective e qu i p m e nt w h e t h er o r n o t re q u i re d b y l o c a l o r j o b 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.

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

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.

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.

USE ENOUGH PARTS OF LINE FOR HEAVY LIFTS AND CHECK ALL LINES, SLINGS, AND CHAINS FOR CORRECT ATTACHMENT. To obtain maximum lifting capacities the hook block must be set up with enough parts of line. NO LESS THAN TWO WRAPS of wire rope should remain on the hoist drum. When slings, ties, hooks, etc., are used, make certain they are correctly positioned and secured before raising or lowering the loads.

Working

Be sure the rigging is adequate before lifting and use tag lines when possible to position and restrain loads. Personnel using tag lines should be on the ground.

Never operate the crane when darkness, fog or other visibility restrictions make operation unsafe. Never operate a crane in thunderstorms or high winds.

Be sure good rigging practices are being used. Refuse to use any poorly maintained or damaged equipment. Never wrap the hoist cable around a load

Keep unauthorized personnel clear of the working area during operation.

Lifting

Operate the crane only from the operator’s seat. Do not reach in a window or door to operate any controls.

Operate the crane slowly and cautiously, looking carefully in the direction of movement.

“Stunt” driving and “horse-play” is strictly prohibited. Never allow anyone to hitch a ride or get on or off a moving crane.

Operate the crane at or near governed RPM during all lifting operations.

Check the hoist brake by raising the load a few inches, stopping the hoist and holding the load. Be sure the hoist brake is working correctly before continuing the lift.

When lowering a load always slow down the load’s descent before stopping the hoist. Do not attempt to change speeds on multiple speed hoists while the hoist is in motion.

Published 01-15-2008, Control # 150-01

2-15

SAFETY INFORMATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

LIFT ONE LOAD AT A TIME. Do not lift two or more separately rigged loads at one time, even if the loads are within the crane’s rated capacity.

If communication with the signal person is lost, crane movement must be stopped until communications are restored.

Never leave the crane with a load suspended. Should it become necessary to leave the crane, lower the load to the ground and stop the engine before leaving the cab.

Keep your attention focused on the crane’s operation. If for some reason you must look in another direction, stop all crane movement first.

Remember - all rigging equipment must be considered as part of the load. Lifting capacities vary with working areas.

Permissible working areas are posted in the crane cab.

When swinging from one working area to another, ensure load chart capacities are not exceeded. Know your crane!

When vision is obscured, use and follow the directions of a single qualified signal person.

Never swing or lower the boom into the carrier cab.

Stop the hook block from swinging when unhooking a load.

Swinging rapidly can cause the load to swing out and increase the load radius. Swing the load slowly. Swing with caution and keep the load lines vertical.

Look before swinging your crane. Even though the original set-up may have been checked, situations do change.

Keep everyone away from suspended loads. Allow no one to walk under a load. Ensure that all slings, ties, and hooks are correctly placed and secured before raising or lowering the load.

Use tag lines, as appropriate, for positioning and restraining loads. Check the load slings before lifting.

Be sure everyone is clear of the crane and work area before making any lifts.

Never swing over personnel, regardless of whether load is suspended from or attached to the boom.

Be sure the load is well secured and attached to the hook with rigging of proper size and in good condition.

Use only slings or other rigging devices rated for the job and use them properly. Never wrap the hoist cable around a load.

Check all tackle, hardware, and slings before use. Refuse to use faulty equipment.

Never work the crane when darkness, fog, or other visibility restrictions make such operations unsafe.

Hand Signals A qualified signal person shall be used at all times when: •

Working in the vicinity of power lines.

•

The crane operator cannot clearly see the load at all times.

•

Moving the crane in an area or direction in which the operator cannot clearly see the path of travel.

At all times use standardized hand signals previously agreed upon and completely understood by the operator and signal person.

2-16

Obey a signal to stop from anyone.

TRANSPORTING THE CRANE When loading or unloading the crane on a trailer or railroad car, use a ramp capable of supporting the weight of the crane.

Ensure the crane is adequately secured to the transporting vehicle.

Check load limits of bridges on the travel route and ensure they are greater than the combined weight of the crane and transporting vehicle.

Always drive the crane carefully, obeying speed limits and highway regulations. Keep lights on and use traffic warning flags and signs and front and rear flag vehicles as applicable.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL SHUT-DOWN Never leave the crane with a load suspended. Lower the load to the ground before shutting down the crane.

Use the following steps when shutting down the crane:

SAFETY INFORMATION

Do not remove all the pins from both front and rear stowage brackets unless the boom extension is pinned to the right side of the boom nose.

See the appropriate section of this handbook for the proper boom extension erection and stowage procedure.

•

Engage the parking brake.

•

Fully retract and lower the boom.

Properly inspect, maintain, and adjust boom extension and mounting.

•

Engage the pin swing lock or 360 degree swing lock.

Sling jib sections from the main chords or the end fittings.

•

Place controls in neutral position.

NOTE:

•

Shut down the engine and remove the ignition key.

•

Chock the wheels.

•

Lock the operator’s cab and install vandal guards, if used.

In cold weather, never park the crane where the tires can become frozen to the ground.

The following are applicable only if crane is equipped with Jib Sections.

When assembling and disassembling jib sections, use blocking to adequately support each section and to provide proper alignment.

Stay outside of jib sections and lattice work.

Watch for falling or flying pins when they are being removed.

COLD WEATHER OPERATION

BOOM EXTENSION To avoid death or serious injury, follow proper procedures during erection, stowage, and use of the boom extension.

Install and secure all pins properly.

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.

Control movement of boom extension at all times.

Allow ample time for hydraulic oil to warm up.

Do not remove right side boom nose pins unless boom extension is properly pinned and secured on front and rear stowage brackets.

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.

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

If applicable to your crane, always handle propane tanks according to the supplier’s instructions.

Never store flammable materials on the crane.

If cold weather starting aids are provided on your crane, use them. 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.

TEMPERATURE EFFECTS ON HYDRAULIC CYLINDERS

6582

Hydraulic oil expands when heated and contracts when cooled. This is a natural phenomena that happens to all liquids. The coefficient of expansion for API Group 1 hydraulic oil is approximately 0.00043 cubic inches per cubic inch of volume for 1°F of temperature change. Thermal contraction will allow a cylinder to retract as the hydraulic fluid which is trapped in the cylinder cools.

The change in the length of a cylinder is proportional to the extended length of the cylinder and to the change in temperature of the oil in the cylinder. For example, a cylinder

Published 01-15-2008, Control # 150-01

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2

SAFETY INFORMATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

extended 25 feet in which the oil cools 60°F would retract approximately 7 3/4 inches (see chart below). A cylinder extended 5 feet in which the oil cools 60°F would only retract approximately 1 1/2 inches. The rate at which the oil cools depends on many factors and will be more noticeable with a larger difference in oil temperature verses the ambient temperature.

Thermal contraction coupled with improper lubrication or improper wear pad adjustments may, under certain conditions, cause a “stick-slip” condition in the boom. This “stick-slip” condition could result in the load not moving smoothly. Proper boom lubrication and wear pad adjustment is important to permit the boom sections to slide freely. Slow movement, of the boom may be undetected by the operator unless a load is suspended for a long period of time.

decrease as the lift cylinder(s) retracts causing an increase in radius and a decrease in load height.

This situation will also occur in reverse. If a crane is set up in the morning with cool oil and the daytime ambient temperature heats the oil, the cylinders will extend in similar proportions.

Table 2 has been prepared to assist you in determining the approximate amount of retraction/extension that may be expected from a hydraulic cylinder as a result of change in the temperature of the hydraulic oil inside the cylinder. The chart is for dry rod cylinders. If the cylinder rod is filled with hydraulic oil, the contraction rate is somewhat greater.

NOTE:

If a load and the boom is allowed to remain stationary for a period of time and the ambient temperature is cooler than the trapped oil temperature, the trapped oil in the cylinders will cool. The load will lower as the telescope cylinder(s) retracts allowing the boom to come in. Also, the boom angle will

Operators and service personnel must be aware that load movement, as a result of this phenomena, can be easily mistaken as leaking cylinder seals or faulty holding valves. If leaking seals or faulty holding valves are suspected to be the problem, refer to Service Bulletin 98-036 dealing with testing telescope cylinders.

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

3

3

Coeff. = 0.00043 (in /in / °F) STROKE (FT.) 10 20 5 0.26 0.52 10 0.52 1.03 15 0.77 1.55 20 1.03 2.06 25 1.29 2.58 30 1.55 3.10 35 1.81 3.61 40 2.06 4.13 45 2.32 4.64 50 2.58 5.16 55 2.84 5.68 60 3.10 6.19

30 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74 8.51 9.29

Temperature Change (°F) 40 50 60 1.03 1.29 1.55 2.06 2.58 3.10 3.10 3.87 4.64 4.13 5.16 6.19 5.16 6.45 7.74 6.19 7.74 9.29 7.22 9.03 10.84 8.26 10.32 12.38 9.29 11.61 13.93 10.32 12.90 15.48 11.35 14.19 17.03 12.38 15.48 18.58

70 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06 19.87 21.67 3

3

80 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64 22.70 24.77

Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in /in / °F) X 12 in/ft

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Published 01-15-2008, Control # 150-01

90 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22 25.54 27.86

100 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80 28.38 30.96

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

OPERATING CONTROLS

SECTION 3 OPERATING CONTROLS TABLE OF CONTENTS Superstructure Cab Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tachometer with Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Gauge Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Voltmeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Fuel Quantity Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Ignition Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Stop/Module Off Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine Warning/Electrical System Diagnostic Indicator . . . . . . . . . . . . . . . . . . . . . . 3-2 Engine Wait To Start/Battery Discharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic Oil Cooler Temperature/Emergency Stop Indicator . . . . . . . . . . . . . . . . . 3-2 Swing Brake Engaged Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hoist 3rd Wrap Indicator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Boom Lights Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hi/Med/Low Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Right Front Outrigger Beam/Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Right Front Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Left Front Outrigger Beam/Stabilizer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Left Front Outrigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Left Rear Outrigger/Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Right Rear Outrigger/Stabilizer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Outrigger Extend/Retract Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Air Conditioner Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Crane Function Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Engine Increment/Decrement Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Windshield Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Skylight Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Main Hoist Speed Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Hoist Rotation Indicators (Main and Auxiliary Hoist). . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Boom Lift/Main Hoist Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Swing Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Telescope/Auxiliary Hoist/Swing Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Swing Brake Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Auxiliary Hoist Speed Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Telescope Control Foot Pedal (Optional with Auxiliary Hoist) . . . . . . . . . . . . . . . . . 3-8 Cab Circulating Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Skylight Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Cab Dome Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 12 VDC Accessory Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Pin Swing Lock Control (Pin Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Electrical Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Cab Control Modules (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Canister Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

360° Swing Lock Control (Positive Lock Type) (Optional) . . . . . . . . . . . . . . . . . . . . 3-9 Bubble Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Additional Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Outrigger Control Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Outrigger Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Outrigger Beam Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Extend/Retract Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Stabilizer Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Superstructure Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 New Crane Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Pre-Starting Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Superstructure Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Superstructure Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Hydraulic Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Hook Block and Headache Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Signal and Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Operation Below -40°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Superstructure Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Warm Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Cold Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Idling The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Racing The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Battery Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Crane Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Traveling - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Traveling With Boom Extension Erected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Moving The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 General Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Control Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Preload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Using Your Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Crane Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Setting the Outriggers Using Superstructure Cab Controls . . . . . . . . . . . . . . 3-15 Engaging the Mid Extend Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Stowing The Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Stowing the Mid-Extend Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Elevating and Lowering the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Telescoping the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Lowering And Raising The Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Hoist Speed Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Load Moment Indicator (LMI) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Control Lever Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Crane Shutdown Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

OPERATING CONTROLS

SECTION 3 OPERATING CONTROLS The following paragraphs describe all the available (standard and optional) controls and indicators located in the superstructure cab. Some machines may not be equipped w i th th e op t i on a l c o nt r ol s sh o w n. T h e c a b u t i li z e s international symbols to label the various controls.

The numbers in ( ) represent the index number from (Figure 3-1) and (Figure 3-2).

Water Temperature Gauge The engine coolant temperature (TEMP) gauge is located on the lower left of the gauge cluster. The gauge indicates the engine coolant temperature on a scale calibrated from 100° to 240° F. The gauge receives a signal from the crane’s electronic operating system which receives the signal from the engine ECM via J1939.

NOTE:

All rocker switches contain one or two LED’s in the switch for illumination.

Fuel Quantity Gauge

NOTE:

All indicators on the top row of the console will illuminate solid, all at the same time for approximately two seconds as a diagnostic test when the ignition switch is positioned to on. If any indicator fails to illuminate, replace it immediately.

The fuel quantity (FUEL) gauge is located on the upper left of the gauge cluster. The gauge indicates the quantity of fuel in the tank and has a scale calibrated from empty (E) to full (F).

The fuel quantity gauge receives a signal from the crane’s electronic operating system which monitors a sending unit in the fuel tank.

SUPERSTRUCTURE CAB CONTROLS AND INDICATORS

Emergency Stop Switch

Tachometer with Hourmeter

The emergency stop switch (3) is located on the right side of the front console. Push in on the switch to remove power and stop the engine.

The tachometer/hourmeter (1) is located on the right side of the front console and registers engine RPM and speed of rotation. The tachometer is calibrated in rpm x 100 with a range of zero (0) to 35. It receives a signal from the crane’s electronic operating system which receives the signal from the engine ECM via J1939.

The hourmeter at the bottom of the tachometer is used to register hours of engine operation.

Gauge Cluster The gauge cluster (2) is located on the left side of the front console assembly and contains a voltmeter, oil pressure gauge, water temperature gauge and a fuel quantity gauge.

Voltmeter The voltmeter (VOLTS) is located on the lower right of the gauge cluster. With the ignition switch in the run (between vertical and far right) position and before starting the engine, the voltmeter indicates the condition of the batteries. With the engine running, the voltmeter indicates output voltage of the alternator. The voltmeter scale is from 10 to 16 volts.

Engine Oil Pressure Gauge The engine oil pressure (OIL) gauge is located on the upper right of the gauge cluster. The gauge indicates the engine oil pressure on a scale calibrated from zero (0) to 80 psi. It receives a signal from the crane’s electronic operating system which receives the signal from the engine ECM via J1939.

Ignition Switch The ignition switch (4) is located on the right side of the front console. The switch is key operated with four positions: accessory (left position), off (vertical position), run (position between vertical and right), and start (right position).

With the ignition switch in the off position, all electrical power is off except for the headlights, marker lights, gauge lights, turn and stop light, cab dome light, cab 12V accessory outlet, cab work lights, and horn.

The accessory position energizes all electrical components except the engine ECM. The run position is the same as accessory except the engine ECM is energized. The start position energizes the starter relay which in turn energizes the cranking motor solenoid and cranks the engine for starting. The switch will return to run when the switch is released after the engine is started. Turn the switch to off to shut down the engine.

Engine Stop/Module Off Line Indicator The engine stop/module off line indicator (5) is located on the top left side of the front console. The top portion of the switch is the stop indicator. It illuminates red when energized by a signal from the engine ECM that signifies a serious engine problem that requires the vehicle and the engine to be stopped as soon as safely possible. In addition, a warning buzzer will also sound.

The bottom portion is the module off line indicator. This indicator will illuminate solid red and a buzzer will sound

Published 01-15-2008, Control # 150-01

3-1

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OPERATING CONTROLS

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

whenever communication with one of the crane’s electronics modules is lost. The vehicle should be stopped as soon as safely possible. The crane must be restored to proper condition before operating again.

Engine Warning/Electrical System Diagnostic Indicator The engine warning/electrical system diagnostic indicator (6) is located at the top left side of the front console. The top portion is the warning indicator. It illuminates amber when energized by a signal from the engine ECM that signals the operator of an engine problem which must be corrected.

In addition to alerting the operator of system faults, the warning light, in conjunction with the stop light, is used in the diagnostic operation of the engine control system. The diagnostic mode begins when the ignition and engine diagnostic switch is on and the engine is not running. The amber light flashes at the beginning of a fault code sequence, the red light flashes the three-digit or four-digit code for the active fault and the amber light flashes again to separate the previous red light sequence from the next one.

Each code will be flashed twice before moving to the next code. When all codes have been flashed, the sequence will begin again. If no codes are present, both the warning and stop lights will remain on.

The bottom portion of the switch is the electrical system diagnostic indicator. There are three conditions for this indicator as follows: a.

On solid with buzzer sounding - There is an interruption of communication over the main canbus control line between the crane’s electronic control modules. Proper crane operating condition shall be restored as quickly as possible.

b.

Flashing with buzzer sounding - An undesirable condition with the crane’s joysticks has been detected. Proper crane operating condition shall be restored before performing any hydraulic function.

c.

Flashing without buzzer - An undesirable component or electrical system condition has occurred.

Engine Wait To Start/Battery Discharge Indicator The engine wait to start indicator (7) is located on the top left side of the front console. The top of the switch illuminates amber for a period of time when the ignition switch is turned to the on position. The engine should not be cranked until the wait to start indicator turns off. The bottom of the switch illuminates red for a battery discharge condition.

3-2

Hydraulic Oil Cooler Temperature/ Emergency Stop Indicator The hydrauic oil cooler temperature/emergency stop indicator (8) is located at the top left side of the front console.

The emergency stop portion of the switch illuminates red if the emergency stop (3) is pushed in. Rotate and pull siwtch out to reset

Swing Brake Engaged Indicator The swing brake engaged indicator (9) is located on the top left side of the front console. The top of the indicator illuminates red to warn the operator that the swing brake is engaged.

Hoist 3rd Wrap Indicator (Optional) The hoist 3rd wrap indicator (10) is located on the top left side of the front console. The indicator is a red light that will illuminate when three wraps or less of cable remains on either hoist. This light is controlled by the LMI System.

Boom Lights Switch (Optional) The boom lights switch (11) is a two position on/off switch located on the left side of the front console. The switch controls the flood lights located on the boom base section.

Press the top of the switch to the on position to illuminate the flood lights. The amber indicator in the switch will illuminate.

Press the bottom of the switch to turn the flood lights off.

Work Lights Switch The work lights switch (12) is a two position on/off switch located on the left side of the console that controls the crane’s work lights mounted on the bottom front of the cab.

Press the top of the switch to the on position to illuminate the work lights. The amber indicator in the switch will illuminate.

Press the bottom of the switch to turn the work lights off.

Defroster Fan Switch The fan switch (13) controls the windshield defroster fan and is located at the bottom left side of the front console. It is a two-position switch that regulates the volume of air to the windshield.

•

High Speed - press top of switch

•

Low Speed - switch centered

•

Off - press bottom of switch

NOTE:

The heater switch (20) must be positioned to on before fan will become operational. Rotate the heater switch clockwise to increaase fan speed.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL Dimmer Switch The dimmer switch (14) is located on the left side of the front console. The switch controls the brightness of the gauge lights.

Right Front Outrigger Beam/Stabilizer Switch Right Front Outrigger Switch The right front outrigger switch (15) is located on the left side of the front console. It is a three-position switch used to extend or retract the right front stabilizer and extension cylinders. It must be used in conjunction with the outrigger extend/retract switch (19) located on the lower right side of the front console.

To extend the right front outrigger beam, push the top of the outrigger extend/retract switch (19) and the top of the right front outrigger switch (15).

To retract the right front outrigger beam, push the bottom of the outrigger extend/retract switch (19) and the top of the right front outrigger switch (15).

To extend the right front stabilizer, push the top of the outrigger extend/retract switch (19) and the bottom of the right front outrigger switch (15).

To retract the right front stabilizer, push the bottom of the outrigger extend/retract switch (19) and the bottom of the right front outrigger switch (15).

Left Front Outrigger Beam/Stabilizer Switch Left Front Outrigger Switch The left front outrigger switch (16) is located on the left side of the front console. It is a three-position switch used to extend or retract the left front stabilizer and extension cylinders. It must be used in conjunction with the twoposition outrigger extend/retract switch (19) located on the lower right side of the front console.

To extend the left front outrigger beam, push the top of the outrigger extend/retract switch (19) and the top of the left front outrigger switch (16).

To retract the left front outrigger beam, push the bottom of the outrigger extend/retract switch (19) and the top of the left front outrigger switch (16).

OPERATING CONTROLS

To extend the left front stabilizer, push the top of the outrigger extend/retract switch (19) and the bottom of the right front outrigger switch (16).

To retract the left front stabilizer, push the bottom of the outrigger extend/retract switch (19) and the bottom of the right front outrigger switch (16).

Left Rear Outrigger/Stabilizer Switch The left rear outrigger switch (17) is located on the left side of the console. It is a three-position switch used to extend or retract the left rear stabilizer and extension cylinders. It must be used in conjunction with the outrigger extend/retract switch (19) located on the lower right side of the front console.

To extend the left rear outrigger beam, push the top of the outrigger extend/retract switch (19) and the top of the left rear outrigger switch (17).

To retract the left rear outrigger beam, push the bottom of the outrigger extend/retract switch (19) and the top of the left rear outrigger switch (17).

To extend the left rear stabilizer, push the top of the outrigger extend/retract switch (19) and the bottom of the left rear outrigger switch (17).

To retract the left front stabilizer, push the bottom of the outrigger extend/retract switch (19) and the bottom of the right front outrigger switch (17).

Right Rear Outrigger/Stabilizer Switch The right rear outrigger switch (18) is located on the left side of the console. It is a three-position switch used to extend or retract the right rear stabilizer and extension cylinders. It must be used in conjunction with the outrigger extend/retract switch (19) located on the lower right side of the front console.

To extend the right rear outrigger beam, push the top of the outrigger extend/retract switch (19) and the top of the right rear outrigger switch (18).

To retract the right rear outrigger beam, push the bottom of the outrigger extend/retract switch (19) and the top of the right rear outrigger switch (18).

To extend the right rear stabilizer, push the top of the outrigger extend/retract switch (19) and the bottom of the right rear outrigger switch (18).

Published 01-15-2008, Control # 150-01

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OPERATING CONTROLS

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

42 38

41 6969-2

43

40

37

34

39 See View A 45

47 36

6969-1

35 See View B

46

FIGURE 3-1

3-4

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

5

6

8

7

10

1

2

9

OPERATING CONTROLS

16

3 14 13

15

12

11

4

17

20

21

22

18

19

23

6968-1

25

24

26

3

View A

27 28

29

28

33 30 32 31 6566-1

Published 01-15-2008, Control # 150-01

FIGURE 3-1 continued

3-5

OPERATING CONTROLS

Item

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Item

Description

Description

35

Telescope Control Foot Pedal (Optional with Auxiliary Hoist)

36

Swing Brake Pedal

37

Cab Circulating Fan

38

Skylight Wiper

39

Fire Extinguisher

40

Cab Dome Lights

41

12 VDC Accessory outlet

42

Pin Swing Lock Control (Pin Type)

43

Electrical Diagnostic Connector

44

Cab Control Modules (Not Shown)

Boom Lights Switch (Optional)

46

360° Swing Lock Control (Positive Lock Type) (Optional)

12

Work Lights Switch

47

Bubble Level Indicator

13

Hi/Low Fan Switch

14

Dimmer Switch

15

Right Front Outrigger Beam/Stabilizer Switch

16

Left Front Outrigger Beam/Stabilizer Switch

Outrigger Extend/Retract Switch

17

Left Rear Outrigger/Stabilizer Switch

NOTE:

18

Right Rear Outrigger/Stabilizer Switch

The park brake in the cab must be set before the outrigger controls will operate.

19

Outrigger Extend/Retract Switch

NOTE:

20

Fan Switch Off/Low /Med/High

Be sure the outriggers are properly extended and set, and the crane is level for operation on outriggers.

21

Heater Switch

22

Air Conditioner Switch (Optional)

23

Crane Function Power Switch

24

Engine Increment/Decrement Switch

25

Windshield Wiper/Washer Switch

26

Skylight Wiper Switch

27

Main Hoist Speed Selector Switch

28

Hoist Rotation Indicators (Main and Auxiliary Hoist)

29

Boom Lift/Main Hoist Controller

30

Swing Horn Button

31

Telescope/Auxiliary Hoist/Swing Controller

In addition, when the switch is positioned to either extend or retract position, a signal is sent to the engine ECM to increase engine speed above idle for operation of the outriggers.

32

Swing Brake Selector Switch

Fan Switch

33

Auxiliary Hoist Speed Selector Switch

34

Throttle Pedal

1

Tachometer with Hourmeter

2

Gauge Cluster

3

Emergency Stop Switch

4

Ignition Switch

5

Engine Stop/Module Off Line Indicator

6

Engine Warning/Electrical System Diagnostic Indicator

7

Engine Wait To Start/Battery Discharge Indicator

8

Hydraulic Oil Cooler Temperature/Emergency Stop Indicator

9

Swing Brake Engaged Indicator

10

Hoist 3rd Wrap Indicator

11

3-6

To retract the right rear stabilizer, push the bottom of the outrigger extend/retract switch (19) and the bottom of the right rear outrigger switch (18).

All four outrigger beams must be equally extended to the mid position vertical stripe or fully extended position before beginning operation.

The outrigger extend/retract momentary switch (19) is located on the right side of the front console. It must be used in conjunction with the outrigger selector switches to control the operation of the stabilizer and extension cylinders.

Push the top of the switch to select the extend function or push the bottom of the switch to select the retract function, then select desired outrigger selector switch.

The FAN control switch (20) is located on the lower left side of the front console. The switch is a four-position rotary switch (OFF, LOW, MED, HI) that controls operation of the heater or air conditioning blower to circulate heated or cool air throughout the cab.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL Heater Switch

OPERATING CONTROLS

The HEAT control switch (21) is located on the lower left side of the front console. The rotary switch turns the heater on and off.

high and off. Pushing the switch up from the off position energizes the wiper motor. Continue to push switch up for each intermittent position and the high position. Push the switch down to off to stop the motor and return the wiper blade to the parked position.

Air Conditioner Switch (Optional)

Skylight Wiper Switch

The air conditioning switch (22) is located on the lower left side of the front console. The switch controls the operation of the optional air conditioning system in conjunction with the fan switch. Rotate the switch to turn the air conditioner on or off.

The skylight wiper switch (26) is installed on the lower right side of the front console. The wiper is used to remove moisture from the skylight. The switch has an off and high position with six intermittent positions between high and off.

Pushing the switch up from the off position energizes the wiper motor. Continue to push switch up for each intermittent position and the high position. Push the switch down to off to stop the motor and return the wiper blade to the parked position.

Crane Function Power Switch The crane function power switch (23) is located on the right side of the front console. This two-position on/off switch permits the operator to disconnect power from the crane functions controlled by the hydraulic remote controllers on the armrests.

Push the bottom of the switch to disconnect power from the crane functions controlled by the controllers on the armrests.

Push the top of the switch to energize the pilot supply solenoid to allow functions controlled by the controllers on the armrests to be performed.

Positioning the switch to OFF prevents inadvertent operation of functions due to bumping the controllers while roading or any other operation.

NOTE:

The seat switch must be activated and the left hand armrest must be in the down position before the crane function solenoid may be energized.

NOTE:

When crane function power switch is in the on position, the engine is limited to 2200 RPM’s.

Engine Increment/Decrement Switch The engine increment/decrement switch (24) located on the right side of the front console is used when increasing and decreasing engine rpm’s.

It is a two-position (+/-) momentary switch that is a secondary throttle control.

Pushing and holding the top of the switch will increases (+) engine RPM. Release the switch and the engine RPM will stay at that level with transmission in neutral. Push the switch once, the engine will go to max engine RPM. Push the bottom of the switch and the engine RPM will go to idle mode.

Main Hoist Speed Selector Switch The three-position main hoist speed selector switch (27) is located on the right armrest. Select the top of the switch for high speed or the bottom of the switch for low speed.

Position the switch in the center position to off to disable main hoist functions.

Hoist Rotation Indicators (Main and Auxiliary Hoist) The hoist rotation indicators (28) are located on the top of the main and auxiliary hoist controllers. The indicator is electronically driven by a sensor attached to the main hoist.

A pulsating signal is sensed by the operator’s thumb during hoist operation at slow rotation only.

Boom Lift/Main Hoist Controller The boom lift/main hoist controller (29) is located on the right armrest. The controller, when pushed to the right (lowers the boom) or left (raises the boom), actuates the control valve to raise or lower the boom.

When used for main hoist, the controller, when pushed forward (lowers the cable) or back (raises the cable), actuates the control valve to raise or lower the main hoist cable.

Swing Horn Button The swing horn button (30) is located on the right side of the swing controller and is used by the operator to provide a warning that the superstructure is rotating. Press in on the button to sound the swing horn.

Windshield Wiper/Washer Switch

Telescope/Auxiliary Hoist/Swing Controller

The windshield wiper/washer toggle switch (25) is located on the lower right side of the front console. The switch is used for removing moisture from the windshield.The switch has an off and high position with six intermittent positions between

The telescope or auxiliary hoist/swing controller (31) is located on the left hand armrest. The controller controls the telescope functions when the crane is not equipped with an auxiliary hoist. Pushing the controller forward actuates the

Published 01-15-2008, Control # 150-01

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OPERATING CONTROLS

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

control valve to telescope the boom out and pulling the controller back telescopes the boom in.

When equipped with an auxiliary hoist, the controller controls auxiliary hoist functions and telescope functions through a foot pedal (3). Pushing the controller forward actuates the control valve to let out the hoist cable and pulling the controller back reels the cable in.

When used for swing, the controller, when pushed to the right (rotates the turntable clockwise) or left (rotates the turntable counterclockwise), actuates a control valve to provide 360 degree continuous rotation in the desired direction.

Swing Brake Selector Switch The swing brake selector switch (32) is located on the left hand armrest. This two-position switch on/off is used to control a hydraulic valve that directs a regulated flow of pressure to and from the swing brake. Push the top of the switch to apply the swing brake or push the bottom of the switch to release the swing brake.

Swing Brake Pedal The swing brake pedal (36) is located on the left side of the cab floor. The swing brake pedal is used to actuate the swing brake to slow or stop swing motion. Braking is proportional to pedal depression.

With the pedal not depressed and the swing brake control valve disengaged, hydraulic pressure is applied to the brake, overcoming spring pressure and releasing the brake.

Depressing the pedal actuates a swing power brake valve to apply pressure to the brake assembly. This pressure aids the spring pressure to overcome the hydraulic pressure being applied to the brake release circuit and applies the spring brake according to the pressure from the swing power brake valve.

Cab Circulating Fan The cab circulating fan (37) is mounted on the left front of the cab. A swivel allows the fan to be rotated and it is controlled by a two speed switch on the base of the fan.

Auxiliary Hoist Speed Selector Switch

Skylight Wiper

The three-position auxiliary hoist speed selector switch (33) is located on the left armrest. Select the top of the switch for high speed and the bottom of the switch for low speed.

Position the switch in the center to “off” to disable auxiliary hoist functions.

The electrically-operated skylight wiper (38) removes moisture from the skylight. The skylight wiper is controlled by the skylight wiper switch (26) located on the right side of the front console.

Throttle Pedal The foot throttle pedal (34) is located on the right side of the cab floor. The pedal is used to control engine RPM. The foot pedal modulates engine speed proportionately to the foot pressure applied. The foot pedal is monitored by the crane’s electronic operating system which sends the information to the engine ECM via J1939.

Telescope Control Foot Pedal (Optional with Auxiliary Hoist) The telescope control foot pedal (35) is located to the left of the throttle pedal on the cab floor. Pushing forward on the top of the pedal will extend the boom and pushing down on the bottom of the pedal will retract the boom.

Fire Extinguisher The fire extinguisher (39) is mounted behind the operator’s seat in the cab.

Cab Dome Lights The cab dome lights (40) are located at the rear of the cab.

They are controlled by a switch on the light to provide illumination in the cab.

12 VDC Accessory Outlet The 12 vdc accessory outlet (41) is located at the front of the cab beneath the front console. It provides an outlet for the operator to plug in a 12 vdc accessory. This outlet should be used only for components requiring 8 amps or less.

Pin Swing Lock Control (Pin Type) The pin swing lock control handle (42) is located on the right side of the cab. The purpose of the pin swing lock is to lock the superstructure in position directly over the front or over the rear. When the control handle is depressed and the superstructure is directly over the front or rear, the swing lock pin drops into a socket on the carrier frame, locking the superstructure in place. When the control handle is pulled out, the pin is pulled out of the socket, unlocking the superstructure.

3-8

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL Electrical Diagnostic Connector The electrical diagnostic connector (43) is located beneath the front console. It is used for servicing the engine ECM, or the crane’s electrical system.

NOTE:

A laptop computer with appropriate cable and engine or electrical system software are required.

Cab Control Modules (Not Shown) The cab control modules (44) are installed on a panel at the rear of the cab.

360° Swing Lock Control (Positive Lock Type) (Optional) The 360 degree swing lock control lever (46) is located on the right side of the operator’s seat next to the control armrest. The purpose of the swing lock is to secure the superstructure in position at any point in its 360 degree of rotation. The lock is engaged when the control lever is pushed down and disengaged when the control lever is pulled up.

Bubble Level Indicator The bubble level indicator (47) is located on a bracket on the left side of the cab. The indicator provides the operator with a visual indication for determining the levelness of the machine.

ADDITIONAL CONTROLS AND INDICATORS The following paragraphs describe the outrigger control panels located on each side of the crane carrier. The numbers in parentheses ( ) represent the index number from (Figure 3-2).

Outrigger Control Summary There is an outrigger control panel located on each side of the crane carrier. Each control panel contains switches for extending and retracting the outrigger beams and for raising and lowering the outrigger stabilizer (jack) cylinders on all sides of the crane.

A push button emergency stop switch (5) is installed on the panel.

OPERATING CONTROLS

A level (6) is installed on a bracket to the right of the panel on the outrigger box.

Outrigger Control Panel There is one outrigger control panel (1) on each side of the unit’s frame. The panel on the right side operates the outrigger beams for that side only. The panel on the left side operates the outrigger beams for that side only. The stabilizers may be operated from the left or right side of the unit.

Outrigger Beam Selector Switch The outrigger beam selector switch (2) is used to indicate desired operation of the front or rear outrigger beam for the side of the unit the control panel is on.

Extend/Retract Switch The extend/retract switch (3) will operate both the outrigger beams or the stabilizers. After positioning the desired selector switch (beam or stabilizer), position the extend/ retract switch to move the selected component in the desired direction.

In addition, when the switch is positioned to either position, a signal is sent to the engine ECM to increase engine speed above idle for operation of the outriggers.

Stabilizer Selector Switch The stabilizer selector switch (4) selects which stabilizer is to be operated.

Emergency Stop Switch The emergency stop switch (5) is located on the center of the outrigger panel. Push the switch to remove all electrical power from the controls and stop the engine.

Pull switch out to resume operation.

If the emergency stop switch on either outrigger control panel or in the superstructure cab is not pulled out for normal operation, the emergency stop indicator in the superstructure cab will illuminate red if operation of any function is attempted.

Published 01-15-2008, Control # 150-01

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OPERATING CONTROLS

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

6943-2

4

1

6

3

2

6943-1

5

Item

Description

FIGURE 3-2

4

Item

Description

1

Outrigger Control Panel

4

Stabilizer Selector Switch

2

Outrigger Beam Selector Switch

5

Emergency Stop Switch

3

Extend/Retract Switch

6

Level

3-10

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

OPERATING CONTROLS

SUPERSTRUCTURE OPERATING PROCEDURES NOTE:

Refer to the Carrier Operator Manual for carrier cab operating procedures.

New Crane Conditioning Your new crane has been thoroughly tested, adjusted, lubricated, and inspected prior to delivery. However, during the initial hours of operation, an occasional oil, air, or coolant leak may develop. Immediate corrective action should be taken concerning each of these leaks to avoid major repairs later. For detailed superstructure engine conditioning, refer to the applicable engine manual.

FIGURE 3-3

The guidelines below will aid in getting a long service life out of the crane.

1.

Avoid long periods of operation with the engine at idle or continuous maximum horsepower levels.

2.

Observe instruments often and shut down at the first indication of an abnormal reading.

3.

Check all components frequently for proper operation, unusual noises, and excessive heating.

4.

Check the superstructure engine oil and coolant levels frequently.

These guidelines should not be considered limitations but rather as a guide for familiarization of the machine and development of good operating habits.

Pre-Starting Checks

Batteries For standard or low maintenance batteries, check each cell for the correct fluid level. Add only clean distilled water and do not overfill. For maintenance free batteries, check the state-of-charge indicator if applicable. On all batteries ensure the cables and clamps are tight and not corroded.

Hydraulic Reservoir and Filter Check the hydraulic level sight gauge and filter condition indicator on the hydraulic tank. Hydraulic fluid should be at normal operating temperature and the boom and outriggers in a retracted position.

Check breather for cleanliness and security.

Wire Rope

A complete walk-around visual inspection of the crane should always be made with special attention to structural damage, loose equipment, leaks, or other conditions that would require immediate correction for safe operation. Refer to Section 6 - Maintenance Checklist. The following checklist items are suggested to ensure the crane is prepared for starting the day’s work.

Inspect the wire rope in accordance with applicable Federal Regulations. Sheaves, guards, guides, drums, flanges, and any other surfaces that come in contact with the rope should be inspected for any condition that could cause possible damage to the rope.

Superstructure Engine Oil Check the oil level in the crankcase and fill to the FULL mark on the dipstick. Do not overfill.

Inspect for nicks, gouges, cracks, and evidence of any other damage. Replace a hook that has cracks or shows evidence of excessive deformation of the hook opening (including twist). Be sure the safety latch is free and aligned.

Superstructure Engine Coolant

Signal and Running Lights

Check the coolant level in the radiator and fill to the proper level. Do not overfill and ensure the radiator cap is secure.

Check all signal and running lights for proper operation.

Replace burned out lamps with those of the same number, or equivalent.

Hook Block and Headache Ball

Safety Equipment

DANGER Do not loosen radiator cap on a hot engine. Steam or hot coolant will cause severe burns.

Check all lights, windshield wipers, washers, washer liquid supply, horn, instruments, signaling devices, etc.

Published 01-15-2008, Control # 150-01

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OPERATING CONTROLS

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Daily Lubrication Ensure all components requiring daily lubrication have been serviced. Refer to Section 5 - LUBRICATION.

Cold Weather Operation The following recommendations are for operating Grove cranes in very low (i.e. freezing) temperatures.

Use particular care to ensure that cranes being operated in very cold temperatures are operated and maintained in accordance with the procedures as provided by Manitowoc Crane Group. Cranes should have appropriate hydraulic oil, lubricants, and other auxiliary items required for operation in sub-zero temperatures. Individual crane functions should be operated to ensure they are sufficiently warmed prior to performing a lift.

Operation of cranes at full rated capacities in temperatures between 0°C and -40°C (+32°F and -40°F) or lower shall be accomplished only by competent operators who possess the skill, experience, and dexterity to ensure smooth operation.

Shock loading shall be avoided. See Section 5 of this manual for more detailed information on operation of cranes down to -40°F.

Operation Below -40°C For crane operation below -40°C, capacities shall be derated 3.67% of the capacities shown on the load chart for each degree (1°C) below -40°C. NOTE:

Refer to SECTION 5 - Lubrication for all Weather package & lubricants.

CAUTION Never crank engine for more than 30 seconds during an attempted start. If engine does not start after 30 seconds, allow starter motor to cool for about two minutes before attempting another start.

CAUTION If engine does not start after four attempts, correct malfunction before attempting another start.

Use the correct grade of oil for the prevailing temperature in the crankcase to prevent hard cranking. Diesel fuel should have a pour point of 5°C (10°F) less than the lowest expected temperature. In case of an emergency, white kerosene can be added to the fuel to bring the pour point down to the required temperature. This will prevent clogging of filters and small passages by wax crystals. The addition of kerosene is NOT recommended for general use.

Warm Engine The engine warning and engine stop indicators will illuminate and go off in sequence after about two seconds (as a check) when the key is first turned on. If an indicator comes on and continues to blink after initial start-up, there is a problem that needs to be corrected. Position the engine diagnostic idle switch to ON for code retrieval and check the engine manufacture’s service manual for code identification.

1.

Ensure the parking brake is set and emergency stop is not off.

Start-up and shutdown procedures for most diesel engines are generally the same. Therefore, the following procedures can be applied, except where specific differences are noted.

(Refer to the applicable engine manufacturer’s manual for detailed procedures).

2.

Turn the ignition switch to start (far right position) and release immediately when the engine starts. Do not push or hold the throttle down. The ECM will automatically provide the proper amount of fuel to start the engine.

Start-Up Procedure

3.

Immediately check the engine instruments for proper indication after starting. Shut down the engine if the oil pressure gauge does not reach the proper reading within 15 seconds.

4.

Function the boom retract control to warm up the hydraulic oil by running oil over the relief.

Superstructure Engine Operation

Make an under-the-hood inspection for fuel, oil, and coolant leaks, worn drive belts, and trash build-up.

DANGER Diesel engine exhaust can be harmful to your health. Only operate the engine in a well ventilated area or vent exhaust outside.

CAUTION If oil pressure and/or temperature indicator(s) do not display the proper readings, shut down engine and correct malfunction.

5.

3-12

Allow the engine to warm up for about five minutes before applying a load. Do not race the engine for a faster warm up.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

OPERATING CONTROLS

Cold Engine

Shutdown Procedure

The engine warning and engine stop indicators will illuminate and go off in sequence after about two seconds (as a check) when the key is first turned on. If an indicator comes on and continues to blink after initial start-up, there is a problem that needs to be corrected. Position the engine diagnostic idle switch to on for code retrieval and check the engine manufacture’s service manual for code identification.

1.

Allow the engine to run at fast idle speed for about five minutes to avoid high internal heat rise and allow for heat dissipation.

2.

Position the ignition switch to off (vertical position).

3.

Drain the fuel filter-water separator.

An engine block heater and grid heater are provided to aid in cold-starting.

1.

Ensure the parking brake is set and emergency stop is not off.

NOTE:

2.

3.

Battery Disconnect

The top of the engine wait to start indicator located on the top left side of the front console illuminates amber for a period of time when the ignition is turned to the on position. The engine should not be cranked until the indicator turns off.

Turn the ignition switch to start (far right position) and release immediately when the engine starts. Do not push or hold the throttle down. The ECM will automatically provide the proper amount of fuel to start the engine.

3

Immediately check the engine instruments for proper indication after starting. Shut down the engine if the oil pressure gauge does not reach the proper reading within 15 seconds.

FIGURE 3-4

CAUTION If oil pressure and/or temperature indicator(s) do not display the proper readings, shut down engine and correct malfunction.

4.

Allow the engine to warm up for about five minutes before applying a load. Do not race the engine for a faster warm up.

The battery disconnect switch is located in the power plant tray assembly on the superstructure. To disconnect the batteries, turn the battery disconnect switch to OFF. Turn the switch to ON to connect the batteries.

Crane Travel Operation Traveling - General

Idling The Engine

CAUTION

Idling the engine unnecessarily for long periods of time wastes fuel and fouls injector nozzles. Unburned fuel causes carbon formation; oil dilution; formation of lacquer or gummy deposits on the valves, pistons and rings; and rapid accumulation of sludge in the engine.

NOTE:

Ensure the crane function switch is turned to off for extended traveling, cold weather starting, or engine checks.

When prolonged engine idling is necessary, maintain at least 800 rpm.

CAUTION Do not drive the crane with the lift cylinder bottomed.

Position the boom slightly above horizontal.

Racing The Engine DO NOT race the engine during the warm-up period or operate the engine beyond governed speed (as might occur in downhill operation or downshifting). Engine bearings, pistons, and valves may be damaged if these precautions are not taken.

1.

Ensure the boom is fully lowered into the boom rest.

2.

Engage the swing brake.

3.

Engage the swing lock.

Published 01-15-2008, Control # 150-01

3-13

OPERATING CONTROLS

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

4.

Ensure the swingaway, if so equipped, is properly stowed and secured with mast in stowed position.

5.

Ensure the hook block and/or headache ball are stowed securely in the stowage trays provided.

6.

Ensure the outrigger stabilizers and outrigger beams are fully retracted and the floats are removed.

7.

Ensure the stabilizer floats are properly stowed in their holding racks (Figure 3-5). If stowing the optional aluminum floats, they must be positioned in the rack with the handle positioned as shown in the figure titled Outrigger Float Stowage.

8.

Ensure the cover doors on the battery box and sling box are closed.

9.

Close and/or install all superstructure cab windows and door.

5.

Remove the hook block and/or headache ball from the hoist cable(s) and stow securely before traveling or make sure the hook block or headache ball is properly secured to the tie down provided for that purpose.

6.

Fully retract the outrigger stabilizers and remove the floats.

7.

Properly store the floats.

General Crane Operation Pump Drive The hydraulic pumps are driven by the superstructure engine.

Control Lever Operation

Travel with boom extension erected is permissible under the following conditions.

The control lever operation for crane functions is proportional, i.e., the closer the lever is to neutral (center), the slower the system responds. Return the control lever to neutral to hold the load. Do not feather the hoist control to hold the load.

1.

Boom extension shall be erected at minimum offset with stinger section (if applicable) pinned in fully retracted position.

NOTE:

2.

Jobsite travel only on firm, level surface.

3.

Main boom shall be fully retracted.

4.

Maximum travel speed: 4 km/h (2.5 mph).

5.

Swing lock pin shall be engaged.

6.

Suspension air bags shall be inflated.

7.

Traveling With Boom Extension Erected

Always operate the control levers with slow, even pressure.

Preload Check After the crane has been readied for service, an operational check of all crane functions (with no load applied) should be performed. Preload check is as follows: •

Extend and set the outriggers and level the crane.

•

Raise, lower, and swing the boom right and left at least 45 degrees.

Tires shall be properly inflated.

•

8.

Hookblock may be reeved over main boom nose, hanging 0.9 m (3 feet) below nose sheaves.

Telescope the boom out and back in, ensuring all sections extend and retract properly.

•

9.

Headache ball may be reeved over boom extension, hanging 0.9 m (3 feet) below sheave.

Raise and lower the cable a few times at various boom lengths. Make sure there are no kinks and that the cable is spooling on the hoist properly.

Moving The Crane The following superstructure conditions should be strictly adhered to before moving the crane. Procedures for accomplishing the following can be found in the various sections of this manual.

1.

Fully retract the boom.

2.

Ensure the swingaway jib is properly stowed and secured.

3.

Swing the boom to over-the-front and lower it to slightly above horizontal.

4.

Press the top of the swing brake selector switch on the left hand armrest to apply the swing brake.

3-14

CAUTION Run the engine at or near the governed RPM during operation of all crane functions.

NOTE:

Carefully read and become familiar with all crane operating instructions before and operating the crane.

Using Your Load Chart NOTE:

One of the most important tools of every Grove crane is the load chart found in the crane operator's cab.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL The load chart contains the lifting capacities of the crane in all allowable lifting configurations, and must be thoroughly understood by the operator.

The load chart is divided into capabilities limited by crane structural strength and stability which is shown by a bold line across the chart. Structural strength limits are above the line and stability limits are below the line.

The left column is the load radius, which is the distance from the axis of the crane rotation to the load center of gravity. The top row lists various boom lengths from fully retracted to fully extended (with swingaway extension). The number at the intersection of the left column and top row is the total load limit for that load radius and boom length. The number in parentheses below the total load limit is the required boom angle (in degrees) for that load. Boom lengths between increments should always be treated as if it were the next longer length. For example, if the actual boom length is 15.2 m (50 ft) and the chart shows boom lengths of 14.6 to 16.4 m (48 to 54 ft), use the load capacity shown in the 16.4 m (54 ft) column.

Another important section is the range diagram. The range diagram shows the operating radius and tip height that can be achieved at a given boom length and angle. If the operator knows the radius and tip height required for a specific lift, the angle and boom length can quickly be determined from the range diagram. Or if he knows the boom length and angle, he can quickly determine the tip height and operating radius.

A lifting diagram is included for over-side, over-rear, and over-front lifting areas. The lifting area diagram shows that the locations of the outrigger stabilizer cylinders in the full extended position are used to mark the boundaries of the lifting areas.

Another section contains notes for lifting capacities. Be sure to read and understand all notes concerning lifting capacities.

The load chart also gives weight reductions for Manitowoc/ Grove load handling devices such as hookblocks, overhaul balls, boom extension sections, etc., which must be considered as part of the load. The weight of any other load handling devices such as chains, slings, or spreader bars must also be added to the weight of the load.

NOTE:

The information in the following paragraph is an example of how to compute a lift. The numbers

OPERATING CONTROLS

used in the example may not coincide with the load chart in the crane cab.

Problem: A concrete beam weighing 2268 kg (5000 pounds) needs to be lifted to a height of 9.1 m (30 ft) at a radius of 15.2 m (50 ft) (maximum). The range diagram indicates the boom must be extended to 18.9 m (62 ft) in order to reach a height of 9.1 m (30 ft) at a radius of 15.2 m (50 ft).

First we need to check the crane for load handling devices.

In our example, the crane is equipped with a auxiliary boom nose (rooster sheave) and a five ton overhaul ball. The rooster sheave is 50 kg (110 pounds), and the overhaul ball is 78 kg (172 pounds) for a total of 128 kg (282 pounds). The lift requires slings and spreader bars weighing 159 kg (350 pounds) which makes the total weight for the load handling devices 286 kg (632 pounds).

A check of the load chart for a 15.2 m (50 ft) radius and 19.5 m (64 ft) of boom length shows a capacity of 3601 kg (7940 pounds) on outriggers over-front and 4970 pounds on outriggers 360 degrees. We subtract the load handling weight of 632 pounds from the load capacity of 3601 kg (7940 pounds) and 2254 kg (4970 pounds). The result is a weight capacity of 3315 kg (7308 pounds) over-the-front and 1968 kg (4338 pounds) for 360 degrees. We are constricted in making the lift over-front only and the boom angle will be about 29 degrees.

Crane Functions Setting the Outriggers Using Superstructure Cab Controls

DANGER Crushing Hazard •

Death or serious injury could result from being crushed by moving machinery or by improper set-up on outriggers.

•

Ensure all pins and floats are properly installed and the outrigger beams are properly extended before lifting on outriggers.

•

Stand clear while outriggers are being extended or retracted.

Published 01-15-2008, Control # 150-01

3-15

3

OPERATING CONTROLS

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

DANGER

DANGER

Death or serious injury could result from improper crane set-up on outriggers.

Failure to follow these instructions can result in the crane overturning.

•

Be sure outriggers are properly extended and set and crane is level for operation on outriggers.

•

All four outrigger beams must be equally extended to the appropriate vertical stripe before beginning operation.

•

All four outrigger beam lock pins must be engaged before operating from the mid-extend position.

•

Operator must select proper load chart and LMI program for the outrigger position selected.

The outrigger switches are located on the lower left side of the front console in the superstructure cab.

The remote mounted outrigger control panels located on each side of the frame can be used to control the outrigger beams for that side only. All stabilizer cylinders can be operated from either remote outrigger panel.

NOTE:

Frame mounted controls should only be used for preliminary set-up. Use the superstructure cab controls for final set-up and leveling.

NOTE:

The park brake must be set before the outriggers will operate.

NOTE:

The engine speed is increased to 1000 RPM when the extend/retract switch is placed in either position.

1.

All four outrigger beams must be equally extended to the mid position vertical stripe or fully extended position before beginning operation.

NOTE:

More than one outrigger may be extended at one time. However, to ensure that each outrigger is fully extended, each outrigger selector switch should be depressed individually and the outrigger/retraction switch momentarily positioned to extend (press top of switch) after multi-outrigger extension.

3.

To extend the stabilizers, press the bottom of the desired outrigger switch and the top of the outrigger extend/ retract switch.

4.

Extend each stabilizer, positioning the float as necessary, until the locking levers of the float engage the stabilizer cylinder rod.

NOTE:

More than one stabilizer may be extended at one time.

5.

With each stabilizer float firmly touching the ground, press the bottom of the left or right front outrigger selector switch and press the top of the extend/retract switch. Extend the front stabilizers approximately 76 to 102 mm (3 to 4 in).

6.

Press the bottom of the left or right rear outrigger selector switch and press the top of the extend/retract switch. Extend the rear stabilizers approximately 76 to 102 mm (3 to 4 in).

7.

After all floats are on the ground, extend the front stabilizers about 8 to 10 cm (3 to 4 inches) and then extend the rear stabilizers the same distance. Repeat until all tires are off the ground.

Position the outrigger floats directly out from each outrigger to where the outriggers will be properly extended.

DANGER

CAUTION Always press an outrigger selector switch before pressing the outrigger extend/retract switch to extend or retract.

2.

Push the top of the desired outrigger selector switch then press the top of the outrigger extend/retract switch to extend the outrigger beam. The appropriate outrigger should begin to extend. Refer to Engaging the MidExtend Lock Pin if the crane is to be operated at the midextend position.

All four outrigger beam lock pins must be engaged before operating from the mid-extend position.

DANGER Operator must select proper load chart and LMI program for the outrigger position selected.

8.

3-16

Repeat step 3 until all wheels are clear of the ground and the crane is level as indicated by the sight level bubble located on the right side of the cab. If it is

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL suspected that the bubble level indicator is out of adjustment, verify and adjust the bubble level as follows:

e.

OPERATING CONTROLS

Adjust the bubble level indicator with the mounting screws to show level.

a.

Locate the crane on a firm level surface.

Engaging the Mid Extend Lock Pin

b.

Extend and set the outriggers. Level the crane, as indicated by the level indicator, with the outriggers.

NOTE:

c.

Place a miracle pointer, carpenter level, or similar type device on a machined surface such as the turntable bearing or bearing mounting surfaces.

1.

d.

Level the crane with the outriggers as indicated on the device used in step (c).

It may be necessary to jog the outrigger extension/ retraction switch slightly to ensure proper pin engagement.

With the outriggers fully retracted, turn the locking pin 90° from its stowed position and allow the pin to slip into the lug on the jack beam. If the pin will not slip into the lug, slowly extend or retract the outrigger beam, allowing the locking pin to drop into the lug.

3

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3-17

OPERATING CONTROLS 2.

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Slowly extend or retract the outrigger beam, allowing the locking pin to drop into the hole in the top of the outrigger beam, engaging the outrigger beam at the desired length.

3.

Repeat steps 1 and 2 until the crane is resting on all wheels and the stabilizer floats are several inches off the ground.

4.

Release the locking levers and allow the floats to drop to the ground.

5.

Continue to retract the stabilizers until they are fully retracted.

6.

Push the top of the desired outrigger selector switch then press the bottom of the outrigger extend/retract switch to retract each outrigger beam. Refer to Stowing the Mid-Extend Lock Pin if the crane was operated at the mid-extend position.

Stowing The Outriggers 1.

Press the bottom of the left or right rear outrigger selector switch and press the bottom of the extend/ retract switch. Retract until the rear stabilizers have retracted several inches .

2.

Press the bottom of the left or right front outrigger selector switch and press the bottom of the extend/ retract switch. Retract until the front stabilizers have retracted several inches.

NOTE: 7.

More than one outrigger beam may be retracted at one time.

After all outriggers have been fully retracted, stow the outrigger floats(Figure 3-5) .

DANGER Keep feet and hands clear of floats when unlocking the floats from the stabilizers.

4

2, 3 1

Item

Description

1

Outrigger Float Assembly

2

Quick Pin With Lanyard

3

Cotter Pin

4

Frame

2, 3 1

1

FIGURE 3-5

Stowing the Mid-Extend Lock Pin NOTE:

3-18

If the lock pin is wedged in the hole in the outrigger beam, it may be necessary to jog the outrigger

extend/retract switch slightly while pulling upward on the pin.

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL 1.

Swinging the Boom

OPERATING CONTROLS

To elevate the boom, push the controller on the right hand armrest to the left (raises the boom), and hold until the boom reaches the desired elevation.

Lowering the Boom

DANGER Death or serious injury could result from being crushed by moving machinery. Before activating swing, sound the steering wheel horn and verify that all personnel are clear of rotating and moving parts.

WARNING Keep the area beneath the boom clear of all obstructions and personnel when lowering the boom.

WARNING Keep the area beneath the boom clear of all obstructions and personnel when lowering the boom.

CAUTION

WARNING Long cantilever booms can create a tipping condition, even when unloaded and in an extended, lowered position.

The operator must select the proper load chart and LMI program for the outrigger position selected.

WARNING CAUTION Never push or pull the swing control lever through neutral to the opposite direction to stop swing motion. Use the swing brake foot pedal to stop swing rotation.

1.

To swing the boom, push the controller on the left hand armrest to the right for right swing (rotates turntable clockwise), or to the left for left swing (rotates turntable counterclockwise. Always operate the control lever with a slow, even pressure.

Use the swing brake foot pedal to stop rotation, then position the swing brake switch to ON to prevent further rotation.

When lowering the boom, simultaneously let out the hoist cable to prevent two-blocking the boom nose and hook block.

CAUTION The closer the load is carried to the boom nose, the more important it becomes to simultaneously let out the hoist cable as the boom is lowered.

1.

To lower the boom, push the controller on the right hand armrest to the right (lowers the boom) and hold until the boom is lowered to the desired position.

Telescoping the Boom

Elevating and Lowering the Boom

NOTE:

Elevating the Boom

The telescope function is controlled by a foot pedal if the crane is equipped with an auxiliary hoist.

Extending the Boom

WARNING Keep the area above and below the boom clear of all obstructions and personnel when elevating the boom.

WARNING When extending the boom, simultaneously let out the hoist cable to prevent two-blocking the boom nose and hookblock.

DANGER Check the load chart for the maximum load at a given radius, boom angle, and length before extending the boom with a load.

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3-19

3

OPERATING CONTROLS

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL Raising the Cable

CAUTION Before extending the boom, ensure the large access cover on top of the boom base section is installed.

Pull the main hoist (right hand armrest) or auxiliary hoist (left hand armrest) controller, toward the operator, and hold until the hook or load is raised to the desired height.

1.

Hoist Speed Range Selection

To extend the boom push the controller on the left hand armrest forward and hold until the boom reaches the desired length.

CAUTION

Retracting the Boom

Do not change the hoist speed range with the hoist rotating.

WARNING When retracting the boom, the load will lower unless the hoist cable is taken in at the same time 1.

To retract the boom, pull the controller on the left armrest back and hold until the boom retracts to the desired position.

To change the speed range of the hoist(s), press the top (high speed) or bottom (low speed) of the main hoist speed switch located on the right hand armrest or auxiliary hoist speed switch located on the left hand armrest.

Operational Aids

Telescope Control Pedal The telescope control pedal located to the left side of the superstructure cab is used on cranes equipped with an auxiliary hoist. Push on the top of the pedal to extend the boom or push on the bottom of the pedal to retract the boom.

Lowering And Raising The Hoist Cable

DANGER Electronic equipment on this crane is intended as an aid to the operator. Under no condition should it be relied upon to replace the use of capacity charts and operating instructions. Sole reliance upon these electronic aids in place of good operating practices can cause an accident.

Load Moment Indicator (LMI) System

WARNING Keep the area beneath the load clear of all obstructions and personnel when lowering or raising the cable (load).

CAUTION Do not jerk controller when starting or stopping hoist.

Jerking causes load to bounce, which could result in possible damage to the crane.

NOTE:

When the load is stopped at the desired height, the automatic brake will engage and hold the load as long as the controller remains in neutral.

Lowering The Cable Push the main hoist (right hand armrest) or auxiliary hoist (left hand armrest) controller forward, away from the operator, and hold until the hook or load is lowered to the desired height.

3-20

The Load Moment Indicator (LMI) is an electro-mechanical sensing system designed to alert the crane operator of impending capacity when the system has been properly preset by the operator. The control panel is mounted in the front console of the operator’s cab. When an overload condition is sensed, the system provides the operator with a visual and audible warning, and locks out the control levers to prevent lowering the boom, extending the boom, or raising the main or auxiliary hoist cables.

Three additional features are included within the LMI system: •

Swing Angle Set Limitation

•

Work Area Definition

•

Anti-two Block Device

Swing Angle Set Limitation allows left and right swing angle to be preset. When the preset angle is reached, the system will provide an audible warning.

Work Area Definition allows the crane operator to describe the crane’s working area by setting up “virtual walls”. They are referred to as virtual walls because they exist in the system and are not real walls. The virtual walls represent obstacles (i.e. buildings, towers, poles, etc.) in the crane’s working range. They are set by defining points along the outer limits of the working area with the tip of the boom. Once

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL the working area has been defined, the system will provide a visual and an audible warning if the boom approaches a virtual wall.

5.

Engage the swing brake, swing lock pin, and 360 degree house lock.

6.

Retract all stabilizer cylinders and outrigger beams.

7.

Turn the crane function power switch to the off position (press bottom of switch).

8.

Park the crane on a stable surface.

9.

Apply the parking brakes and if necessary, chock wheels.

CAUTION When defining virtual walls (s). always allow a safe working distance to any obstacles. Never work outside a safe working area as defined by common practice, standards, and manuals.

OPERATING CONTROLS

10. Ensure all operating controls are in neutral position.

11. Shut down engine following proper procedures specified in this Operator’s Manual and the applicable engine manual.

WARNING There are no cut-outs associated with the swing angle set limitation or the work are definition features.

An Anti-two Block Device is also incorporated into the system to prevent the hook block or headache ball from coming into contact with the boom nose or boom extension.

This condition will also cause a lockout of hoist up, boom down, and telescope out, and also provide a visual and an audible alarm.

Refer to the LMI Operator’s Handbook for more detailed information on the function of the LMI system.

Control Lever Lockout System

12. Remove the keys.

13. Close and lock, if applicable, all windows, covers, and doors.

14. Turn battery disconnect to OFF position if machine will be inactive for over 24 hours.

Crane Shutdown Procedures The following procedures will extend serviceable life of various crane components, reduce vandalism, and accidents during crane shutdown periods or anytime the crane is left unattended.

1.

The control lever lockout system consists of hydraulic solenoid valves located in the directional control valves. The valves are activated in such a manner as to prevent worsening the condition, i.e. boom down, telescope out, or hoist up. The control lever lockout system is used with the anti-two-block system or the load moment indicator (LMI) system. The LMI sends a signal to the canbus system which turns off the solenoids on the directional valves.

Stowing and Parking

Perform the procedures found Procedure in this handbook.

under

Shutdown

DANGER Never park crane near holes, on rocky surfaces, or on soft spots. This may cause crane to overturn, resulting in injury or death to personnel.

2.

Park the crane on a proper surface with the outrigger stabilizers and beams fully retracted. Do not park in a location where it may become frozen to the ground or settle unevenly and overturn.

Never park crane near holes, on rocky surfaces, or on soft spots. This may cause crane to overturn, resulting in injury or death to personnel.

3.

Apply parking brakes and if necessary, chock the wheels.

4.

Position all controls to neutral or off.

When parking the crane, do the following.

5.

Shut down the engine using the proper procedures as specified by this Handbook and the engine manual.

6.

Perform any other specified procedures required at the end of the workday, i.e., drain water from the fuel filter water separator, refueling, etc.

7.

Close all windows.

8.

Remove the keys from the crane.

DANGER

1.

Remove the load from the hook.

2.

Remove or stow boom extensions if so equipped.

3.

Fully retract all boom sections.

4.

Lower the boom to normal travel position.

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3-21

3

OPERATING CONTROLS 9.

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Lock the crane. Install vandal guards, if used.

DANGER

10. Make a thorough walk around inspection to ensure that all cylinders that can be retracted are retracted. The only exceptions are those cylinders which cannot be fully retracted, i.e., steer cylinders. Also, look for anything that could hinder or prevent starting the next day’s work.

Step 10 does not take the place of the prestarting checks which must be performed just prior to using the crane at the next working day.

3-22

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

SET-UP AND INSTALLATION

SECTION 4 SET-UP AND INSTALLATION TABLE OF CONTENTS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Installing Cable On The Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Dead-end Rigging/wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Installing Wedge And Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Erecting And Stowing The Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Erecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Setting The Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Changing Boom Extension From Telescoping Type To Fixed Type. . . . . . . . . . . . 4-11 Setting The Telescoping Extension Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4

4-i

SET-UP AND INSTALLATION

4-ii

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

SET-UP AND INSTALLATION

SECTION 4 SET-UP AND INSTALLATION GENERAL This section provides procedures for installing the hoist cable on the hoist drum, cable reeving, and erecting and stowing the boom extension.

INSTALLING CABLE ON THE HOIST Anchor Wedge

CAUTION If cable is wound from the storage drum, the reel should be rotated in the same direction as the hoist.

NOTE:

The cable should preferably be straightened before installation on the hoist drum.

Install cable on the hoist drum in accordance with the following procedure.

1.

2.

Position the hoist drum with the cable anchor slot on top.

3.

Insert the cable through the slot and position around the anchor wedge (Figure 4-1).

NOTE: 4.

3155a

Position the cable over the boom nose sheave and route to the hoist drum.

The end of the cable should be even with the bottom of the anchor wedge.

FIGURE 4-1 Within the limits of the load and range charts and permissible line pull, multi-part lines allow the operator to raise a greater load than can be raised with a single part line. Various cable reeving (part line) is possible with the boom nose and hook block. This reeving should be accomplished by a qualified rigger using standard rigging procedures (Figure 4-3).

Position the anchor wedge in the drum slot; pull firmly on the free end of the cable to secure the wedge.

NOTE:

4

If the wedge does not seat securely in the slot, carefully tap the top of the wedge with a mallet.

5.

Slowly rotate the drum, ensuring the first layer of cable is evenly wound onto the drum.

6.

Install the remainder of the cable, as applicable.

CABLE REEVING NOTE:

Do not weld any wire rope assembly or component unless welding is recommended by the wire rope m a n u f a c t u r e r. R e f e r t o S e c t i o n 1 INTRODUCTION for other wire rope information.

NOTE:

There are two types of cable (wire rope) available on this crane; 6 x 37 WS (not welded) and 35 x 7 (non-rotating)(welded).

FIGURE 4-2 In order to quick reeve the hook block without removing the wedge socket on the end of the cable refer to (Figure 4-2)

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4-1

SET-UP AND INSTALLATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Upper Boom Nose Sheaves

Upper Boom Nose Sheaves

To Main Hoist

To Hoist To Aux Hoist Bottom Boom Nose Sheaves

Aux. Nose Boom Nose Dead End

Bottom Boom Nose Sheaves

Ball Ball Hookblock Sheaves

Single Part Line 4-Sheave Hookblock Upper Boom Nose Sheaves

Four Parts Line 3-Sheave Hookblock To Main Hoist

To Aux Hoist To Main Hoist Bottom Boom Nose Sheaves Upper Boom Nose Sheaves

Bottom Boom Nose Sheaves

Aux. Nose Boom Nose Dead End

Hookblock Sheaves

Hookblock Dead End

Ball Hookblock Sheaves Six Parts Line 3-Sheave Hookblock

Seven Parts Line 3-Sheave Hookblock

6710-4

FIGURE 4-3

4-2

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

SET-UP AND INSTALLATION

Mast On Boom Extension

To Hoist

6710-2

One Part Line Using Fixed Boom Extension Ball

To Hoist

To Hoist

4

6710-9

One Part Line Using Fixed Boom Extension Shown at 15°Offset

One Part Line Using Fixed Boom Extension Shown at 30°Offset

6710-8

FIGURE 4-3 continued

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4-3

SET-UP AND INSTALLATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Upper Boom Nose Sheaves

Upper Boom Nose Sheaves

To Main Hoist

To Main Hoist

Bottom Boom Nose Sheaves Bottom Boom Nose Sheaves Hookblock Sheaves Hookblock Sheaves

Hookblock Dead End Hookblock Dead End Five Parts Line 3-Sheave Hookblock

Four Parts Line 4-Sheave Hookblock 6710-3

6710-5

Upper Boom Nose Sheaves

Upper Boom Nose Sheaves

To Main Hoist

To Main Hoist

To Aux Hoist Bottom Boom Nose Sheaves Bottom Boom Nose Sheaves

Aux Nose Boom Nose Dead End

Boom Nose Dead End

Hookblock Sheaves Hookblock Sheaves Six Parts Line 4-Sheave Hookblock

4-4

6710-6

6710-7

Eight Parts Line 4-Sheave Hookblock

FIGURE 4-3 continued

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL DEAD-END RIGGING/WEDGE SOCKETS Wedge socket assemblies are popular rigging accessories and have been successfully used for decades to terminate wire ropes on mobile cranes. A wedge socket assembly is easily installed and dismantled but it must be installed and used correctly. It is essential to use only a wedge and socket of the correct size for the rope fitted. Failure to do so may result in the rope pulling through the fitting.

When anchoring the socket to the boom, ensure the flat face of the socket is in position, as shown, toward the boom sections (Figure 4-4).

Installing Wedge And Socket 1.

Inspect the wedge and socket. Remove any rough edges and burrs.

2.

The end of the wire rope should be seized using soft, or annealed wire or strand. If the end of the rope is welded, the welded end should be cut off. This will allow the distortion of the rope strands, caused by the bend around the wedge, to adjust themselves at the end of the line.

Since state and local laws may vary, alternate attachment methods may be necessary depending upon work conditions. If alternate methods are selected, the user is responsible and should proceed in compliance with the regulations in force. If there are any questions, contact your local Grove Distributor or Manitowoc CraneCARE. Do not mix components from different manufacturers. The selection, installation and use of a wedge socket assembly must be in accordance with the requirements of the wedge socket manufacturer and the wire rope manufacturer upon whose wire rope the wedge socket assembly will be used.

Grove Crane specifies the size, type, class and line pulls for wire rope, predominately rotation resistant wire rope, and rigging accessories such as overhaul balls and hook blocks for use with each new crane that it manufactures. Other wire ropes and rigging accessories are available from various vendors. Different wire rope manufacturers have differing requirements for the construction, handling, cutting, seizing, installation, termination, inspection and replacement of the wire ropes they produce. Their advice should be sought for each specific type of wire rope a crane user intends to install on a mobile crane.

Live End Dead End

5337

3.

When assembly is complete, raise the boom to a working position with a load suspended to firmly seat the wedge and rope into the socket before the crane is used operationally.

Wrong FIGURE 4-5

Make sure the live-loaded side (Figure 4-5) of the rope is directly in line with the ears of the socket and the direction of pull to which the rope will be subjected. If the rope is loaded into the socket incorrectly, under a load the rope will bend as it leaves the socket, and the edge of the socket will wear into the rope causing damage to the rope and eventual failure.

Insert the end of a wire rope into the socket, form a loop in the rope, and route the rope back through the socket allowing the “dead” end to protrude from the socket.

Ensure the dead end of the rope is of sufficient length to apply end treatment to the dead end after the wedge has been seated.

5.

Insert the wedge into the loop and pull the live end of the rope until the wedge and rope are snug inside the socket. It is recommended that the wedge be seated inside the socket to properly secure the wire rope by using the crane’s hoist to first apply a light load to the live line.

6.

After final pin connections are made, increase the loads gradually until the wedge is properly seated.

7.

The wire rope and wedge must be properly secured inside the socket before placing the crane into lifting service. It is the wedge that secures the wire rope inside the socket whereas the dead-end treatment is used to

If the socket is not positioned with the flat face toward the boom sections, structural damage will occur.

FIGURE 4-4

Right

4.

CAUTION

6755

SET-UP AND INSTALLATION

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4-5

4

SET-UP AND INSTALLATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

restrain the wedge from becoming dislodged from the socket should the rope suddenly become unloaded from the headache ball or hook block striking the ground, etc.

Sketches A through F (Figure 4-6) illustrate various methods for treating the dead-ends of wire ropes which exit a wedge socket assembly. While use of the loop-back method is acceptable, care must be exercised to avoid the loop b ec o m i n g e n ta n g l e d w i t h t re e br a nc h e s a nd o t he r components during crane transport and with the anti-two block system and other components during use of the crane.

compressed, or wedge socket fittings shall be applied as recommended by the rope, crane or fitting manufacture.”

Wire ropes are addressed in ASME B30.5, section 5-1.7.2, ROPES, It states, in pertinent part, “(a) The ropes shall be of a c onst ruction rec ommende d by the ro pe or crane manufacturer, or person qualified for that service.” Additional information is published by the Wire Rope Technical Board in the Wire Rope Users Manual, latest revised.

Table 4-1 WIRE ROPE CLIP TORQUE VALUES Clip Sizes *Torque mm Inches Nm Ft-Lbs 3.18 1/8 6 4.5 4.76 3/16 10 7.5 6.35 1/4 20 15 7.94 5/16 40 30 13.28 3/8 60 45 11.11 7/16 90 65 12.70 1/2 90 65 14.29 9/16 130 95 15.88 5/8 130 95 19.05 3/4 175 130 22.23 7/8 300 225 25.40 1 300 225 28.58 1-1/8 300 225 31.75 1-1/4 490 360 38.68 1-3/8 490 360 38.10 1-1/2 490 360 *The tightening torque values shown are based upon the threads being clean, dry, and free of lubrication.

Of the methods shown below, Grove prefers that method A or B or F be used on Grove cranes, i.e., clipping a short piece of wire rope to the dead-end or using a commercially a v a i l a b l e s p e c i a l t y c l i p o r w e d g e . Ty p i c a l l y, i t i s recommended that the tail length of the dead-end should be a minimum of 6 rope diameters but not less that 15.2 cm (6 in) for standard 6 to 8 strand ropes and 20 rope diameters but not less than 15.2 cm (6 in) for rotation resistant wire ropes.

When using method A, place a wire rope clip around the dead end by clamping a short extra piece of rope to the rope dead end. DO NOT CLAMP THE LIVE END. The U-bolt should bear against the dead end. The saddle of the clip should bear against the short extra piece. Torque the U-bolts according to the figures listed in (Table 4-1).

Other sources for information with which crane users should be familiar and follow is provided by the American Society of Mechanical Engineers, American National Standard, ASME B30.5, latest revised. ASME (formerly ANSI) B30.5 applies to cableways, cranes, derricks, hoists, hooks, jacks, and sling s. I t sta te s , in s ec tion 5 -1. 7. 3, “( c) Sw ag ge d,

Specialty Clip

Specialty Wedge

A

B

C

D

E

F FIGURE 4-6

4-6

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

SET-UP AND INSTALLATION

ERECTING AND STOWING THE BOOM EXTENSION

NOTE:

General Warnings

3.

Rig either the main hoist or optional auxiliary hoist cable for single part line with nothing but the wedge socket on the end of the cable. Refer to Cable Reeving and Dead End Rigging in this section.

4.

Remove the retainer clips from the right side attachment pins (1) stowed in the base of the boom extension (2) and remove the attachment pins from the boom extension. Insert the right side attachment pins (1) through the boom attachment and boom extension anchor fittings. Install the retainer clips in the attachment pins (Figure 4-7).

DANGER To prevent serious injury or death, always wear personal protective equipment; i.e., a hard hat, eye protection, gloves and metatarsal boots.

The auxiliary boom nose (rooster sheave) does not have to be removed. However, if reeved, the hoist cable must be removed from the sheave.

DANGER Boom angles are used to control speed at which extensions swing during erecting and stowage. Improper boom angles will cause uncontrollable swing speeds of extension.

NOTE:

Tag line used in these procedures is to control the movement of the boom extension.

1

2

DANGER Before attempting to erect or stow the boom extension; read and strictly adhere to all danger decals installed on the boom/boom nose, boom extension, and stowage brackets.

6814-4

5.

Erecting

FIGURE 4-7

Remove the retaining pin from the hitch pin (3) that secures the boom extension to the rear hangar. Remove the hitch pin, unlocking the boom extension (4) from the boom (Figure 4-8).

3

DANGER To prevent serious injury or death, do not stand on decking until extensions are secure.

NOTE:

Some illustrations show the 31 m (102 foot) standard boom for this model. The same Erecting and Stowing procedure applies for the optional 29 m (95 foot) boom.

1.

Visually check to ensure all pins are installed.

2.

Crane should be set up on outriggers using normal setup procedures. Refer to Section 3 - OPERATING CONTROLS and PROCEDURES. a.

Fully retract boom.

b.

Lower boom to horizontal for erecting over the front of the crane.

4 6821-1

6.

FIGURE 4-8

Attach a length of rope to the boom extension tip to aid in swinging the boom extension into place ahead of the boom nose.

Published 01-15-2008, Control # 150-01

4-7

4

SET-UP AND INSTALLATION 7.

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Raise the boom to horizontal and extend the boom approximately 51 to 64 cm (20 to 25”). Make certain that the boom extension stowage lugs clear the guide pins (5) (Figure 4-9) and ramp (4) (Figure 4-8) on the front and rear stowage brackets.

9

6

55 7

6814-3a

5 6821-3

FIGURE 4-9

FIGURE 4-10

10. Extend the boom extension alignment jack (7) until the lower left side boom nose and boom extension adapter lugs are aligned.

11. Install the bottom left side attachment pin (8) and retainer clip into the lower anchor and attachment fittings of the boom nose.

DANGER When erecting the boom extension, ensure that all personnel and equipment are kept clear of the swing path.

8.

8

Slightly raise and/or lower the boom to help control the boom extension. Using the rope attached to the top of the boom extension, manually swing the extension into place ahead of the boom nose, engaging the attachment fittings (5) with the anchor fittings on the left side of the boom nose. (Figure 4-10)

12. Connect LMI cables: a.

Remove cable from boom extension.

b.

Remove dummy plug from junction box on the boom nose.

c.

Install cable end connector from the boom extension where dummy plug was removed

13. Release pressure on the boom extension alignment jack (7) (Figure 4-10).

14. Install the mast assembly (9) in the upright position using the locking pin.

DANGER Do not modify the attachment points to permit the installation of the attachment pins.

15. Reeve the hoist cable. Refer to Cable Reeving in this section.

Stowing 1.

With crane set up on outriggers, fully retract the boom and swing to over-the-front.

2.

Lower the boom to minimum elevation.

3.

Remove the cable retainer pin from the boom extension tip and the mast assembly. Remove the hoist cable from the sheaves. Install the cable retainer pins.

4.

Remove the mast assembly retainer pin and the pin securing the mast assembly in the upright position (9) (Figure 4-10). Lay the mast assembly over to the stowed position. Insert the pins securing the mast to the base section.

CAUTION Do not place blocking under the boom extension sheave wheel. Damage to the sheave wheel may occur.

9.

4-8

Install the top left side attachment pin (6) and retainer clip into the upper anchor and attachment fittings of the boom nose. (Figure 4-10)

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL 5.

Attach a length of rope to the boom extension tip.

6.

Disconnect LMI cable:

SET-UP AND INSTALLATION

3

a.

Remove connector from junction box on boom nose.

b.

Install dummy plug in junction box.

c.

Route cable to and attach to boom extension

7.

Raise the boom to horizontal.

8.

Extend the boom approximately 51 to 64 cm (20 to 25”).

Make certain that the boom extension stowage lugs will line up in front of the guide pins (5) (Figure 4-11) and ramp (4) (Figure 4-12) on the stowage brackets when the boom extension is positioned to the side of the boom.

4

FIGURE 4-13

6821-1

10. Extend the boom extension alignment jack (7) (Figure 4-14) until the bottom left side attachment pin (8) is free. Remove the bottom left side boom extension clip pin and attachment pin.

9 5

6821-3

FIGURE 4-11 6

3

4

55 6814-3a

7

8

FIGURE 4-14

11. Release pressure on the boom extension alignment jack. Completely retract the jack.

12. Remove the top left side attachment pin (6) (Figure 4-14) and clip pin from the upper anchor and attachment fittings of the boom nose.

4

6821-1

9.

FIGURE 4-12

Ensure the hitch pin (3) and clip pin are removed from the rear stowage hangar (4) (Figure 4-13).

DANGER When stowing the boom extension, ensure that all personnel and equipment are kept clear of the swing path.

CAUTION Do not allow the boom extension to slam into the stowage bracket when swinging into the stowed position.

Published 01-15-2008, Control # 150-01

4-9

SET-UP AND INSTALLATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

13. Using the rope attached to the tip of the boom extension, manually swing the extension to the side of the boom.

18. Rig the boom nose and hoist cable as desired and operate the crane using normal operating procedures.

14. Align the stowage lugs on the boom extension with the guide pins and ramp on the stowage hangar (Figure 4-11) and (Figure 4-12) and fully retract the boom.

Setting The Offset

15. Install the hitch pin (3) and clip pin securing the boom extension to the rear stowage hangar (4) (Figure 4-12).

The mast assembly must be positioned on top of the base section before attempting to offset the swingaway to 30 degrees. Failure to do so can cause damage to the mast and/or swingaway adapter.

CAUTION

1.

Extend and set the outriggers. Swing the boom over to the front of the crane.

2.

To set the offset from zero degrees (0°) to thirty degrees (30°), perform the following:

1

CAUTION Do not overload the swingaway or the attachment points when lowering the boom.

2

6814-4

a.

Slowly lower the boom until the tip of the swingaway is on the ground and the pressure on the offset pin is relieved.

b.

Remove the lock pin, washers, and offset pin (12).

(Figure 4-17)

FIGURE 4-15

16. Remove the attachment pins (1) and clip pins from the anchor and attachment fittings on the right side of the boom nose and stow them in the base of the boom extension (Figure 4-15). Stow left side attachment pins and clips in outside attachment fitting on swingaway.

17. On the rear stowage bracket, remove the pin securing the sliding support in the “OUT” position. Push in on the handle (10) (Figure 4-16) to push the swingaway against the rear of the boom and disengage the swingaway anchor fittings from the boom nose attachment lugs (2) (Figure 4-15). Install the retainer pin (11) (Figure 4-16) securing the sliding support in the “IN” position.

12

6814-3b

c.

11

3.

10

6821-2

4-10

FIGURE 4-16

FIGURE 4-17

Slowly elevate and telescope the boom at the same time until the offset shaft takes the full load of the swingaway.

To set the offset from thirty degrees (30°) to zero degrees (0°), perform the following: a.

Slowly lower the boom until the tip of the swingaway is on the ground and the offset pin can be installed.

b.

Install the offset pin, washers, and lock pin (12).

(Figure 4-17)

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL c.

Raise the boom and operate as desired.

6.

Changing Boom Extension From Telescoping Type To Fixed Type Erect the boom extension.

2.

Position the boom to horizontal.

3.

Disconnect the anti-two block cable connector from the junction box.

Remove the telescoping section hitch pin and retaining pin.

NOTE: 5.

6.

7.

The telescoping section weighs approximately 702 kg (1548 pounds).

Extend the telescoping section and attach an adequate lifting device to support the telescoping section. Remove the stop bolts from the base section and remove the telescoping section from the base.

NOTE:

The pin-on boom extension approximately 60 kg (132 lb).

If not already reeved, reeve the hoist cable over the mast and boom extension nose sheave. Install all cable retainer pins.

Stowing

1.

4.

SET-UP AND INSTALLATION

nose

weighs

Using a adequate lifting device, position the pin-on boom extension nose in the base section and secure with the two pins and hitch pins.

1.

Unreeve the boom extension nose.

2.

Position the boom to horizontal.

3.

Remove the hitch pin and retainer pin securing the telescoping section in the base.

4.

Push the telescoping section into the base and secure with the retainer pin and hitch pin.

5.

Loop the anti-two block cable over the spool on the side of the base section.

Traveling With 26ft/45ft Boom Extension Erected (95 ft and 102 ft Boom) Travel with either the 26ft or 45ft boom extension erected is permissible under the following conditions.

1.

Main boom shall be fully retracted.

2.

The boom extension shall be erected at minimum (0 deg) offset. The stinger section shall be pinned in the fully retracted position when traveling with the 26 ft extension.

3.

Jobsite travel shall be only on firm and level surface.

4.

Maximum travel speed - 2.5 mph.

5.

Main boom angle shall be between 2 degrees and 40 degrees.

6.

Main counterweight shall be installed.

7.

Aux hoist or IPO counterweight must be installed.

8.

Boom shall be over front or rear and swing lock shall be engaged.

9.

Suspension air bags shall be inflated.

Connect the anti-two block cable connector to the junction box.

Setting The Telescoping Extension Length Extending 1.

Position the boom to over the front.

2.

Lower the boom to horizontal.

3.

Remove the loop of anti-two block cable from the spool on the side of the base section and let the cable hang free.

4.

Remove the hitch pin and retainer pin securing the telescoping section in the base.

5.

Carefully pull the telescoping section from the base until the holes in the base and telescoping section lineup.

Install the retainer pin and hitch pin.

4

10. Tires shall be properly inflated.

11. hook block must be removed from main boom nose.

12. Headache ball may be reeved over boom extension, hanging 3 ft below sheave.

Published 01-15-2008, Control # 150-01

4-11

SET-UP AND INSTALLATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

COUNTERWEIGHTS

Removal

Description A 1360 kg (3000 pound) or 2495 kg (5500 pound) cast counterweight (Figure 4-18) is installed at the rear of the turntable.

If an auxiliary hoist is not installed, a 350.63 kg (773 pound) plate counterweight is installed in place of the hoist.

DANGER Death or serious injury could result from being crushed by a falling counterweight.

NOTE:

Use of a forklift to remove/install the fixed counterweight is not recommended.

2, 3, 4, 5

1

7 6984

6

2, 3, 4, 5

FIGURE 4-18 NOTE: Item

Description

1

Cast Counterweight

2

Capscrew

3

Flatwasher

4

Lockwasher

5

Nut

6

Power Plant Tray

7

Turntable

3.

Lower and fully retract the boom

4.

Shut down crane.

5.

Attach an adequate lifting device to the counterweight.

6.

Remove the capscrews, washers and nuts securing the counterweight.

7.

Use the lifting device to remove the counterweight.

Installation

1.

Fully extend and set the outriggers.

2.

Rotate the superstructure so the counterweight is over the front of the carrier to gain additional clearance.

Engaging the pin type turntable lock will aid alignment.

4-12

The counterweight weighs either 1360 kg (3000 pound) or 2495 kg (5500 pound) depending on option installed.

1.

Fully extend and set the outriggers.

2.

Shut down crane.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL NOTE:

CAUTION When lifting/handling the counterweight, keep the chains/ straps vertical to minimize side pull on the lifting lugs.

NOTE:

The counterweight weighs either 1360 kg (3000 pound) or 2495 kg (5500 pound) depending on option installed.

SET-UP AND INSTALLATION

Use of a forklift to remove/install the fixed counterweight is not recommended.

3.

Attach an adequate lifting device to the counterweight.

Lift and install the counterweight onto the superstructure.

4.

Install the capscrews, washers and nuts and secure the counterweight. Torque the capscrews 581 to 629 kg (304 to 329 pounds-foot).

5.

Remove the lifting device from the counterweight.

4

Published 01-15-2008, Control # 150-01

4-13

SET-UP AND INSTALLATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

THIS PAGE BLANK

4-14

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TM500E-2 OPERATOR’S MANUAL

LUBRICATION

SECTION 5 LUBRICATION TABLE OF CONTENTS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Arctic Conditions Below -18°C (0°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Arctic Conditions Down To -40°F.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ALL Weather Package & Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Standard Lubricants Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Superstructure Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . . 5-9 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5

5-i

LUBRICATION

5-ii

TM500E-2 OPERATOR’S MANUAL

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

LUBRICATION

SECTION 5 LUBRICATION GENERAL Following the designated lubrication procedures is important in ensuring maximum crane lifetime and utilization. The procedures and lubrication charts in this section include information on the types of lubricants used, the location of the lubrication points, the frequency of lubrication, and other information.

The service intervals specified are for normal operation where moderate temperature, humidity, and atmospheric conditions prevail. In areas of extreme conditions, the service periods and lubrication specifications should be altered to meet existing conditions. For information on extreme condition lubrication, contact your local Grove Distributor or Manitowoc CraneCARE.

CAUTION Chassis grease lubricants must not be applied with air pressure devices as this lubricant is used on sealed fittings.

CAUTION

lubricants alone are not sufficient to operate at extreme low temperatures. We also recommend the use of appropriately sized heaters for the hydraulic tank, engine oil pan, engine jacket water and batteries. The operator needs to follow the guide lines as stated in the operator’s manual. We assume that the customer has take steps for use of an appropriate engine antifreeze coolant, have taken care of the fuel, fuel system and starting system. And has done whatever they feel necessary to add insulation for under hood temperatures and meet the engine manufacture's intake air temperature.

Other lubricants may be used if they meet the specification of the lubricant that is requested. Please consult factory.

Axles and Swing Box -- Petro- Canada Traxon E Synthetic 75W-90; CITGO, Syntetic Gear Lube 75W-90; Eaton, Roadranger EP75W-90; Mobil, Mobilube SCH 75W-90; Shell, Spirax S 75W-90; Sunoco Duragear EP75W-90; -Spec 6829014058 Engine -- Petro-Canada Duron Synthetic CI-4- 5W-40; Mobil Delvac 1, 5W-40; -- Spec 6829101560 Hydraulic tank and Transmission -- Petro-Canada Duratran Synthetic THF; Chevron All Weather THF; Texaco TDH Oil SS; -- Spec 6829101559 Hoist -- Petro-Canada ENDURATEX Synthetic EP 150; Mobil SHC629; -- Spec 6829103636

The multipurpose grease installed during manufacture is of a lithium base. Use of a noncompatible grease could result in damage to equipment.

Grease -- Petro-Canada Precision Synthetic EP1; Mobil: Mobilith SHC 220; -- Spec 6829104275

Arctic Conditions Below -18°C (0°F).

Open Gear Lube -- (bearing/swingdrive teeth) ---Vultrex....

OGL Synthetic All Season -- No Spec

In general, petroleum based fluids developed especially for low temperature service may be used with satisfactory results. However, certain fluids, such as halogenated hydrocarbons, nitro hydrocarbons, and phosphate ester hydraulic fluids, might not be compatible with hydraulic system seals and wear bands. If you are in doubt about the suitability of a specific fluid, check with your authorized Grove distributor or Manitowoc CraneCARE. NOTE:

All fluids and lubricants may be purchased by contacting the Manitowoc CraneCARE Parts Department.

Regardless of temperature and oil viscosity, always use suitable start-up procedures to ensure adequate lubrication during system warm-up.

Arctic Conditions Down To -40°F. ALL Weather Package & Lubricants Engineering recommends the following lubricants for components for ambient temperatures to -40F. Special

Antifreeze Coolant -- Petro-Canada AFC 60/40; Old World Industries, Inc Fleet Charge SCA Pre-charged Antifreeze/ Coolant-60/40; Fleetguard Compleat EG Antifreeze/Coolant Premix 60/40; -- Spec 6829104212

Standard Lubricants Package Axle and Swing Box -- Century Unigear Semi-synthetic SAE 80W-90; Texaco Multigear SS 80W-90; Chevron DELO 80W-90; -- Spec 6829012964 Engine -- CI-4 Rated 15W-40 Engine Oil Exxon XD-3; Conoco Fleet Supreme; -- Spec 6829003483 Hydraulic Tank and Transmission -- To meet John Deere Standard JDM J20C – Hyden 052-10W-20; Exxon Torque Fluid 56- 10W-20; Esso Torque Fluid 56- 10W-20; BPEldoran UTH & Trak-Tran 9 – 10W20; BP- Blend- 7367 10W20; Exxon Mobil 424- 10W-30 -- Spec 6829006444 Hoist -- AGMA No. 4 EP Extreme Pressure Gear LubeMobil: Mobilfluid 629 ; Texaco: Meropa 150; -- Spec 6829100213

Published 01-15-2008, Control # 150-01

5-1

5

LUBRICATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Grease -- EP-MPG- Multipurpose Grease – Citgo Lithoplex MP # 2; Texaco Starplex Moly # 2; Phillips 66 Philube M Grease; Mobil Mobilgrese XHP 222 Special, # 53055-0; Chemtool Inc, Lube-A-Boom-Grease; -- Spec 6829003477 Open Gear Lube -- (bearing / swingdrive teeth -- FUCHS: CEPLATTYN 300 SPRAY -- Spec 6829102971 Antifreeze Coolant -- AFC – 50/50 Old World Industries, Inc. Fleet Charge SCA Pre-charged Antifreeze/Coolant; Caterpillar DEAC Antifreeze/Coolant; Fleetguard Complete EG Antifreeze/Coolant; -- Spec 6829101130

LUBRICATION POINTS A regular frequency of lubrication must be established for all lubrication points. Normally, this is based on component operating time. The most efficient method of keeping track of lube requirements is to maintain a job log indicating crane usage. The log must use the engine hourmeter to ensure coverage of lube points that will receive attention based on their readings. Other lubrication requirements must be made on a time basis, i.e. weekly, monthly, etc.

All oil levels are to be checked with the crane parked on a level surface in transport position, and while the oil is cold, unless otherwise specified.

On plug type check points, the oil levels are to be at the bottom edge of the check port.

On all hoists with a check plug in the drum, the fill plug shall be directly on top of the hoist, and the check plug level.

All grease fittings are SAE STANDARD unless otherwise indicated. Grease non-sealed fittings until grease is seen extruding from the fitting. One ounce(28 grams) of EP-MPG equals one pump on a standard one pound (0.45 kg) grease gun.

Over lubrication on non-sealed fittings will not harm the fittings or components, but under lubrication will definitely lead to a shorter lifetime.

On sealed U-joints, care must be exercised to prevent rupturing seals. Fill only until expansion of the seals first becomes visible.

Unless otherwise indicated, items not equipped with grease fittings, such as linkages, pins, levers, etc., should be lubricated with oil once a week. Motor oil, applied sparingly, will provide the necessary lubrication and help prevent the formation of rust. An Anti-Seize compound may be used if rust has not formed, otherwise the component must be cleaned first.

Grease fittings that are worn and will not hold the grease gun, or those that have a stuck check ball, must be replaced.

5-2

Where wear pads are used, cycle the components and relubricate to ensure complete lubrication of the entire wear area.

Surface Protection for Cylinder Rods Steel cylinder rods include a thin layer of chrome plating on their surfaces to protect them from corroding. However, chrome plating inherently has cracks in its structure which can allow moisture to corrode the underlying steel. At typical ambient temperatures, hydraulic oil is too thick to penetrate these cracks. Normal machine operating temperatures will allow hydraulic oil to warm sufficiently to penetrate these cracks and if machines are operated daily, protect the rods.

Machines that are stored, transported, or used in a corrosive environment (high moisture, rain, snow, or coastline conditions) need to have the exposed rods protected more frequently by applying a protectant. Unless the machine is operated daily, exposed rod surfaces will corrode. Some cylinders will have rods exposed even when completely retracted. Assume all cylinders have exposed rods, as corrosion on the end of the rod can ruin the cylinder.

It is recommended that all exposed cylinder rods be protected using Boeshield® T-9 Premium Metal Protectant.

Manitowoc CraneCARE has Boeshield® T-9 Premium Metal Protectant available in 12 oz. cans that can be ordered through the Parts Department.

Cylinder operation and inclement weather will remove the Boeshield® protectant; therefore, inspect machines once a week and reapply Boeshield® to unprotected rod The following describe the lubrication points and gives the lube type, lube interval, lube amount, and application of each. Each lubrication point is numbered, and this number corresponds to the index number shown on the Lubrication (Figure 5-1) thru (Figure 5-4) Lube description and symbols are found in (Table 5-1) and (Table 5-2).

SAFETY To lubricate many of the locations the engine will need to be started. After positioning areas of the unit for lubrication the engine must be turned off and the moved areas stable before approaching.

WARNING Movement of the superstructure and the boom may create a crushing and/or pinching hazard. Failure to observe this warning could result in death or serious injury if the message is ignored.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

LUBRICATION

Table 5-1 Carrier Lube Symbol Chart Symbol

Description

Lube Specification

EP-MPG

Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2.

A6-829-003477

SSGL-5

Semi-Synthetic Gear Lubricant - SAE Grade 80W-90, API Service Designation GL-5.

A6-829-012964

AFC

50/50 Blended Fully Formulated Antifreeze/Coolant, SAE J1941

A6-829-101130

EO

Engine Oil - SAE 15W-40, API Service Classification CI-4 or better

A6-829-103483

ASC

Anti-Seize Compound

A6-829-003689

BAS

Black Anti-Seize Moly Lubricant

A6-829-009568

AGMA EP-4

Extreme Pressure Gear Lubricant

A6-829100213

TranSynd™

Automatic Transmission Fluid

A6-829-101690

Table 5-2 Superstructure Symbol Chart Symbol

Description

Lube Specification

EP-MPG

Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2.

A6-829-003477

SSGL-5

Semi-Synthetic Gear Lubricant

A6-829-012964

AFC - 50/50

50/50 Blended Fully Formulated Antifreeze/Coolant, SAE J1941, ASTM D6210

A6-829-101130

HYDO

Hydraulic Oil - Must meet John Deere Standard JDM-J20C (Anti-brake chatter) and ISO 4406 cleanliness level 17/14

A6-829-006444

EO-15W/40

Engine Oil - SAE 15W-40, API Service Classification CI-4 or better

A6-829-003483

EP-OGL

Open Gear Lubricant, CEPLATTYN 300 Spray, NLGI Class 1-2

A6-829-102971

AGMA EP-4

Extreme Pressure Gear Lubricant.

A6-829-100213 2.

Engine Cooling System

CAUTION

Lube Type - AFC

The following lube intervals are to be used as a guideline only. Actual lube intervals should be formulated by the operator to correspond accordingly to conditions such as continuous duty cycles and/or hazardous environments.

Lube Interval -

CARRIER LUBRICATION NOTE: 1.

Carrier Lube Capacities will be added at a later date upon availability.

•

Check coolant level every 10 hours or daily; Refer to S e r v i c e M a n ua l S e c t i o n 7 - P o w e r Tra i n f or additional information.

•

Drain and fill per engine service manual.

Lube Amount - Capacity -

5

Carrier Engine Crankcase

CAUTION

Lube Type - EO - 15W40

Improper filling of the engine coolant system can result in engine damage.

Lube Interval •

Check fluid level every 10 hours or daily

•

Drain, fill and replace filter every 500 hours, 6 months or 9,000 miles; whichever interval occurs first.

Lube Amount - Capacity Application - Fill to full mark on dipstick.

Application a.

Open petcock in upper radiator tube to vent air during initial fill.

Fill slowly. Flows exceeding 12 l/min (3 gpm) can give a false level. When coolant squirts out, close petcock, then fill radiator to bottom of filler neck with mixture of 50% AFC and 50% water.

Published 01-15-2008, Control # 150-01

5-3

LUBRICATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Run engine through two (2) thermal cycles.

7.

Wait 1 minute and recheck coolant level and refill as required.

3.

Power Steering Reservoir Lube Interval - Check and fill every 10 hours or daily Lube Amount -

Transmission

Application -

Lube Type - TranSynd™ - Automatic Transmission Fluid

8.

Lube Interval -

Steer Connecting Rods Lube Type - EP-MPG

•

Initial fluid and filter change at 500 hours, thereafter at 1000 hours maximum or 18 months, whichever occurs first

Lube Interval - 1000 hours

•

Drain fluid when transmission is at operating temperature 71° to 93° (169° to 200°)

Application - 4 grease fittings

Lube Amount - Until grease extrudes

9.

Lube Amount - Capacity -

Front Aluminum Wheel Pilots Lube Type - ASC Lube Interval - When wheels are removed for service.

CAUTION Axle fluid levels shall be adjusted to bottom of fill plug threads. Check with crane on level ground, at it’s normal ride height.; cold or room temperature oil only.

Lube Amount - Generously coat the wheel pilot or hub pads with Anti-Seize (ASC) compound. Do not apply Anti-Seize compound to the face of the wheel of the hub.

Application - Brush on

•

4.

Application - Fill through dipstick opening only. Fluid levels shall be adjusted by indicating arrows dipstick markings or to filler plugs.

•

Clean magnetic drain plug when changing lubricant.

•

Initial main filter change required at 5000 miles/200 hours.

10. Front Axle Hubs Lube Type - GL-5 Lube Interval - Check fluid level and fill every 250 hours

CAUTION Use of non-semi-synthetic lubricant may damage components and/or invalidate published lubrication intervals.

Drive Line Slip and U-Joints Lube Type - EP-MPG Lube Interval - 500 hours or 16,090 km (10,000 mi); whichever interval occurs first.

NOTE:

Lube Amount - Until grease extrudes Application - 2 grease fittings 5.

Fuel Tank Lube Interval - Check fluid level and fill every 10 hours or daily, whichever interval occurs first

6.

90 Degree Miter Box

Any lubricant used in the field for either top-off or refill of the axles must be an “Extended Drain Lubricant” as approved by ArvinMeritor. These lubricants are listed in ArvinMeritor Technical Bulletin TP-9539 available at www.arvinmeritor.com or by contacting Manitowoc CraneCARE.

Lube Amount Application - Fill to the oil level mark on the housing with the fill plug and the oil level mark horizontal.

Lube Type - EP-MPG Lube Interval - 1000 hours or 12 months; whichever interval occurs first.

NOTE:

Lube Amount - Until grease extrudes

11. Front Axle Tie Rod Ends

Application - 2 grease fitting

Refer to (Figure 5-2) for proper checking of lube levels.

Lube Type - EP-MPG Lube Interval - 1000 hours Lube Amount - Until grease extrudes Application - 2 grease fittings

5-4

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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

LUBRICATION

3 2

22

1

22

21 16

4

16

4

4

5

7

21

8 23

18

23 13, 14 11 12

18

9, 10

7017-1

19, 20 Truck Carrier

FIGURE 5-1

Item Item

Description

Description

20

Rear Axle Brake Camshafts

1

Engine Crankcase

21

Outrigger Beams

2

Engine Coolant System

22

Jack Cylinder Support Tubes

3

Transmission

23

Jack Cylinder Barrels

4

Drive Line Slip

5

Fuel Tank

6

90 Degree Miter Box

7

Power Steering Reservoir

8

Steer Connecting Rods

9

Front Aluminum Wheel Pilots

10

Front Axle Hubs

11

Front Axle Tie Rod Ends

12

Front Axle King Pins

Lube Interval - 1000 hours

13

Front Axle Brake Slack Adjusters

Lube Amount - Until grease extrudes

14

Front Axle Brake Camshafts

Application - 2 grease fittings

15

Spring Eye Bushings

16

Rear Aluminum Wheel Pilots

Lube Type - EP-MPG

17

Front Rear Axle Differential

Lube Interval - 1000 hours

18

Rear Rear Axle Differential

Lube Amount - Until grease extrudes

19

Rear Axle Brake Slack Adjusters

Application - 2 grease fittings

12. Front Axle King Pins Lube Type - EP-MPG Lube Interval - 1000 hours Lube Amount - Until grease extrudes Application - 4 grease fittings 13. Front Axle Brake Slack Adjusters Lube Type - EP-MPG

5

14. Front Axle Brake Camshafts

Published 01-15-2008, Control # 150-01

5-5

LUBRICATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

15. Spring Eye Bushings

When checking lube level, also check and clean housing breathers.

Lube Type - BAS Lube Interval - 40,225 km (25,000 mi) or 1 year; whichever interval occurs first Application - Disassemble spring eye bushings. Clean and lubricate bushings. Install bushings. Refer to Service Manual Section 8 - Undercarriage in the service manual.

Correct

16. Rear Aluminum Wheel Pilots

Incorrect

Lube Type - ASC 6626

Lube Interval - When wheels are removed for service.

Lube Amount - Generously coat the wheel pilot or hub pads with Anti-Seize (ASC) compound. Do not apply Anti-Seize compound to the face of the wheel of the hub.

Application - Brush on - 8 Places

___ Correct: Lube level at bottom of filler hole.

- - - Incorrect: Lube level below filler hole.

NOTE:

17. Front Rear Axle Differential Lube Type - 75W90 Synthetic Lube

Lube Type - 75W90 Synthetic Lube

•

Drain and fill every 250 hours

•

Check and fill every 80,450 km (50,000 mi) or 2 years; whichever interval occurs first.

•

Change filter when changing gear oil

•

Clean magnetic drain plug

NOTE:

Any lubricant used in the field for either top-off or refill of the axles must be an “Extended Drain Lubricant” as approved by ArvinMeritor. These lubricants are listed in ArvinMeritor Technical Bulletin TP-9539 available at www.arvinmeritor.com or by contacting Manitowoc CraneCARE.

Application - Check level using filler plug located on axle bowl.

•

Drain and fill every 250 hours

•

Check and fill every 80,450 km (50,000 mi) or 2 years; whichever interval occurs first.

•

Change filter when changing gear oil

•

Clean magnetic drain plug

NOTE:

Any lubricant used in the field for either top-off or refill of the axles must be an “Extended Drain Lubricant” as approved by ArvinMeritor. These lubricants are listed in ArvinMeritor Technical Bulletin TP-9539 available at www.arvinmeritor.com or by contacting Manitowoc CraneCARE.

NOTE:

Engine shall be running during lubrication to ensure equal distribution of grease.

Lube Amount - Capacity Application - Check level using filler plug located on axle bowl.

CAUTION Use of non-semi-synthetic lubricant may damage components and/or invalidate published lubrication intervals.

5-6

Lube Interval -

Engine shall be running during lubrication to ensure equal distribution of grease.

Lube Amount - Capacity -

NOTE:

(Figure 5-1) and instructions pertains to the Differentials and the Planetary Hubs and Wheel Bearings.

18. Rear Rear Axle Differential

Lube Interval -

NOTE:

FIGURE 5-2

Lube level (Figure 5-2) close enough to the hole to be seen or touched is not sufficient. It must be level with the hole.

CAUTION Use of non-semi-synthetic lubricant may damage components and/or invalidate published lubrication intervals.

NOTE:

Lube level (Figure 5-2) close enough to the hole to be seen or touched is not sufficient. It must be level with the hole.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

LUBRICATION

When checking lube level, also check and clean housing breathers.

CAUTION

19. Rear Axle Brake Slack Adjusters

When checking the swing gearbox oil level, remove dipstick and wipe clean. Insert dipstick into the level check sleeve until the cap is flush with the end of the sleeve. Do not screw the cap onto the sleeve to check the oil.

Lube Type - EP-MPG Lube Interval - 1000 hours Lube Amount - Until grease extrudes

Lube Interval -

Application - 4 grease fittings 20. Rear Axle Brake Camshafts.

Lube Type - EP-MPG Lube Interval - 1000 hours Lube Amount - Until grease extrudes

•

Check and fill every 50 hours.

•

Drain and fill after first 250 hours

•

Drain and fill every 500 hours or 12 months thereafter; whichever interval occurs first.

Lube Amount - 4.0 liters (4.25 quarts)

Application - 4 grease fittings

Application - Remove dipstick and observe level. If no dipstick is available, fill to top of case. Fill to top of case.

21. Outrigger Beams

25. Turntable Gear and Drive Pinion

Lube Type - EP-MPG Lube Interval - 50 hours or 1 week; whichever interval occurs first Lube Amount - Brush on bottom of outrigger boxes.

Application - Brush on; 8 places; extend beams fully and coat the bottom plate.

22. Jack Cylinder Support Tubes

Lube Type - EP-OGL Lube Interval - 500 hours or 6 months; whichever interval occurs first Lube Amount - Coat all teeth Application - Spray on 26. Turntable Bearing

Lube Type - EP-MPG

Lube Type - EP-MPG

Lube Interval - 50 hours or 1 week

Lube Interval - 500 hours or 6 months; whichever interval occurs first

Lube Amount - Brush lubricant on ID of jack cylinder support tubes and wear bands before installing jack cylinders.

Application - Brush on; 4 places.

Lube Amount - Until grease extrudes the whole circumference of the bearing.

Application - 2 grease fittings - Rotate the turntable 90° and apply grease to fittings. Continue rotating 90° and grease the fittings until the whole bearing is greased.

23. Jack Cylinder Barrels Lube Type - EP-MPG

27. Upper Lift Cylinder Pivot Pin

Lube Interval - 50 hours or 1 week; whichever interval occurs first Lube Amount - Fully extend outriggers and brush lubricant onto cylinder barrels.

Application - Brush lubricant on I.D. of jack cylinder support tube and rear bands before installing jack cylinder - 4 places

Lube Type - EP-MPG Lube Interval - 500 hours or every 3 months; whichever interval occurs first

5

Lube Amount - Until grease extrudes Application - 2 grease fitting 28. Lower Lift Cylinder Pivot Pin Lube Type - EP-MPG

SUPERSTRUCTURE LUBRICATION 24. Turntable Gearbox Lube Type - GL-5

Lube Interval - 500 hours or 3 months; whichever interval occurs first Lube Amount - Until grease extrudes Application - 2 grease fittings

Published 01-15-2008, Control # 150-01

5-7

LUBRICATION

33

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

29

30

35 28

32

27

31

34 26

25 24

7017-2

Superstructure

FIGURE 5-3 30. Auxiliary Hoist (Optional) Item

Description

25

Turntable Gear and Drive Pinion

26

Turntable Bearing

27

Upper Lift Cylinder Pivot Pins

28

Lower Lift Cylinder Pivot Pins

29

Main Hoist

30

Auxiliary Hoist

31

Engine Crankcase

32

Engine Cooling System

33

Hydraulic Tank

34

Hydraulic Filter

35

Fuel Tank

Lube Type - AGMA EP-4 Lube Interval - Check and fill every 1000 hours or 12 months; whichever interval occurs first. Drain and fill annually.

Lube Amount - Capacity - 5.2 liters (5.5 quarts) Application - Fill until level with the check plug opening, indicating arrows or dipstick 31. Engine Crankcase Lube Type - EO - 15W40 Lube Interval -

29. Main Hoist

5-8

•

Drain and fill every 250 hours

•

Check and fill every 10 hours or daily; whichever interval occurs first.

•

Change filter every 250 hours

Lube Type - AGMA EP-4

Lube Amount - Capacity - 6.1 liters (6.5 quarts)

Lube Interval - Check and fill every 1000 hours or 12 months; whichever interval occurs first. Drain and fill annually.

Application - Fill to full mark on dipstick.

32. Engine Cooling System

Lube Amount - Capacity - 5.2 liters (5.5 quarts)

Lube Type - AFC

Application - Fill until level with the check plug opening, indicating arrows or dipstick.

Lube Interval •

Check coolant level every 10 hours or daily; whichever occurs first.

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL •

Drain and fill per engine service manual.

Lube Amount - Capacity - 17.3 liters (18 quarts)

LUBRICATION

35. Fuel Tank Lube Interval - Check fluid level and fill daily Lube Amount - 136.3 liters (30 gallons)

CAUTION Improper filling of the engine coolant system can result in engine damage.

50. Hook Block Swivel Bearing.

Application a.

BOOM, BOOM EXTENSION, AND BOOM ACCESSORIES LUBRICATION

Open petcock in upper radiator tube to vent air during initial fill.

Fill slowly. Flows exceeding 12 l/min (3 gpm) can give a false level. When coolant squirts out, close petcock, then fill radiator to bottom of filler neck with mixture of 50% AFC and 50% water.

Run engine through two (2) thermal cycles.

Wait 1 minute and recheck coolant level and refill as required.

33. Hydraulic Reservoir

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months; whichever interval occurs first Lube Amount - Until grease extrudes Application - 2 grease fitting 51. Hook Block Sheaves.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months; whichever interval occurs first

Lube Type - HYDO

Lube Amount - Until grease extrudes

Lube Interval -

Application - 1 grease fitting per sheave

•

-

3 fittings total - (35 ton)

-

4 fittings total - (35 ton)

• NOTE:

Check fluid level every 10 hours or daily, using sight gauge on side of tank, with boom retracted and in boom rest and all outrigger cylinders retracted.

52. Telescope Cylinder Wear Pads.

Drain and refill as necessary.

After 2000 hours or 2 years of service, an oil sample should be taken and laboratory analyzed. If it continues to meet a minimum cleanliness level of ISO 19/17/14, the service interval can be increased to 3000 hours or 3 years.

Lube Amount - 436.4 liters (96 gal.) (tank only), to FULL mark on sight gauge.

Application - Fill through breather/fill cap on top of tank.

When tank is drained, clean the magnetic pipe plug.

Replace breather every 500 hours or 6 months; whichever interval occurs first.

34. Hydraulic Filter Replace the hydraulic filter element when the restriction indicator gauge on the filter head is in the red

Lube Type - EP-MPG Lube Interval - 125 hours or 3 months; whichever interval occurs first Lube Amount - Thoroughly coat all areas the wear pads move on.

Application - Brush on: 2 places; extend boom for entry through access holes.

53. Side Wear Pads.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months Lube Amount - Thoroughly coat all areas the wear pads move on.

Application -Brush on: 12 places; extend boom for entry through access holes.

Published 01-15-2008, Control # 150-01

5-9

5

LUBRICATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

56

54 59

60

52

60

56

61

53

58 63

55 64 57

60 55

62

50

51

Boom, Boom Extension, and Boom Accessories Lubrication Diagram

FIGURE 5-4 54. Boom Section Upper Wear Pads.

Item

Description

Lube Type - EP-MPG

50

Headache Ball Swivel Top

51

Hook Block Sheaves

52

Telescope Cylinder Wear Pads

53

Side Wear Pads

54

Boom Section Upper Wear Pads

55

Boom Section Lower Wear Pads

56

Extend Cable Sheaves

57

Retract Cable Sheaves

58

Boom Pivot Shaft

59

Boom Extension Sheave

60

Boom Extension Roller

61

Upper Boom Nose Sheave

62

Lower Boom Nose Sheave

63

Auxiliary Boom Nose Sheave

56. Extend Cable Sheaves.

64

Boom Extension Mast Sheave

Lube Type - EP-MPG

Lube Interval - 50 hours or 1 week; whichever interval occurs first Lube Amount - Thoroughly coat all areas the wear pad moves on.

Application - By brush: 6 places; extend boom for entry through access holes.

55. Boom Section Lower Wear Pads.

Lube Type - EP-MPG Lube Interval - 50 hours or 1 week; whichever interval occurs first Lube Amount - Thoroughly coat all areas the wear pad moves on.

Application - By brush; 3 places; extend boom for entry through access holes.

Lube Interval - 250 hours or 3 months; whichever interval occurs first Lube Amount - Until grease extrudes Application - 3 grease fitting; extend boom for entry through access holes.

5-10

Published 01-15-2008, Control # 150-01

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

LUBRICATION

57. Retract Cable Sheaves.

62. Lower Boom Nose Sheave.

Lube Type - EP-MPG

Lube Type - EP-MPG

Lube Interval - 250 hours or 3 months; whichever interval occurs first

Lube Interval - 250 hours or 3 months; whichever interval occurs first

Lube Amount - Until grease extrudes

Lube Amount - Until grease extrudes

Application - 4 grease fittings; extend boom for entry through access holes.

Application - 1 grease fitting per sheave

58. Boom Pivot Shaft.

63. Auxiliary Boom Nose Sheave.

Lube Type - EP-MPG

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months; whichever interval occurs first Lube Amount - Until grease extrudes

Lube Interval - 250 hours or 3 months; whichever interval occurs first Lube Amount - Until grease extrudes Application - 1 grease fitting

Application - 2 grease fittings, one on each side 59. Boom Extension Sheave.

64. Boom Extension Mast Sheave.

Lube Type - EP-MPG

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months; whichever interval occurs first

Lube Interval - 500 hours or 12 months; whichever interval occurs first Lube Amount - Until grease extrudes

Lube Amount - Until grease extrudes Application - 1 grease fitting

WIRE ROPE LUBRICATION

60. Boom Extension Roller.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months; whichever interval occurs first Lube Amount - Until grease extrudes Application - 4 grease fitting 61. Upper Boom Nose Sheave.

Wire rope is lubricated during manufacturing so that the strands, and individual wires in strands, may move as the rope moves and bends. A wire rope cannot be lubricated sufficiently during manufacture to last its entire life.

Therefore, new lubricant must be added periodically throughout the life of a rope to replace factory lubricant which is used or lost. For more detailed information concerning the lubrication and inspection of wire rope, refer to WIRE ROPE in Section 1- INTRODUCTION in the Service Manual.

Lube Type - EP-MPG Lube Interval - 250 hours or 3 months; whichever interval occurs first Lube Amount - Until grease extrudes Application - 1 grease fitting per sheave

5

Published 01-15-2008, Control # 150-01

5-11

LUBRICATION

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

THIS PAGE BLANK

5-12

Published 01-15-2008, Control # 150-01

SECTION 6 MAINTENANCE CHECKLIST TABLE OF CONTENTS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6 6-i

MAINTENANCE CHECKLIST

6-ii

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

MAINTENANCE CHECKLIST

SECTION 6 MAINTENANCE CHECKLIST GENERAL

INSTRUCTIONS

This section contains a list of daily inspection and maintenance checks. Performing the checks will help maintain the safety, dependability, and productivity designed into your crane.

S e e S e rv i c e M a n ua l f or s pe c i f i c m a i nt e n an c e an d adjustment procedures.

Refer to your Maintenance Inspection Manual for all inspection intervals.

See Section 5 (in this handbook) for lubrication intervals, types of fluids, and lube point locations.

6 Published 01-15-2008, Control # 150-01

6-1

MAINTENANCE CHECKLIST

TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL

Items to be Inspected Daily December

D

1

Verify Outrigger Float Pads are properly installed & show no signs of structural damage

D

2

Verify Tire Condition has no excessive wear and Pressure is at the proper level

D

Interval

Reference

INSPECTION SERVICE LOG

Visually check machine for any Hydraulic 3 Components (including Hoses) with excessive wear, loose fittings, or leaks

D

4 Visually check for any loose or damaged Wiring

D

5 Verify Engine Coolant is at the proper level

D

6

Verify Crankcase and Transmission have the proper fluid levels

7

Verify Hoists are installed properly with no signs of D damage, or leaks D

Verify that the "Operator Aids" are working 9 properly - Boom Angle Indicator, Load Moment Indicator (LMI), Antitwo-Block.

D

10 Gauges and Instruments are functional

D

Back-up Alarm operates properly when operating machine

12 Swing Brake operates properly

13

Verify Brakes and Air System (if equipped) are working properly

Lights and Horn are in good working order and not 14 damaged

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

D

8 Operator's Manual installed properly on machine.

11

DAY OF INSPECTION

D

D

D D

15 Verify Hydraulic Reservoir has the proper fluid level D

16 Hydraulic Oil Filter (check back pressure)

D

17

Verify Boom and Attachments are properly installed with no signs of damage, or leaks

D

18

Verify Wire Rope has no damaged, frayed, or broken strands

D

19

D

20

D

Inspector's Initials 22 0

D

23 0

D

24 0

D

25 0

D

Inspector's Initials

6-2

Published 01-15-2008, Control # 150-01

19

20

21

22

23

24

25

26

27

28

29

30

31

TM500E-2

SUPERSTRUCTURE OPERATOR’S MANUAL

Alphabetical Index Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Additional Controls And Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Battery Posts, Terminals, and Related Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . . 5-9 Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Crushing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Dead-end Rigging/wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Diesel Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Erecting And Stowing The Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Installing Cable On The Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Load Moment Indicating (LMI) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Noise/vibration Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Operator’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Operator’s Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Superstructure Cab Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Superstructure Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Superstructure Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Temperature Effects On Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Transporting The Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

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SUPERSTRUCTURE OPERATOR’S MANUAL

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TM500E-2