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Manitowoc 500E2 Operator's Manual Supplement

Crane warm-up procedures
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© 2015 Manitowoc
Published 3-10-2015, Control # 571-00
OPERATOR MANUAL
Supplement
Crane Warm-up Procedures
!
An untrained operator subjects himself and others to death or
serious injury. Do not operate this crane unless:
•
You are trained in the safe operation of this crane.
responsible for qualifying personnel.
•
You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer's manuals and
load charts, your employer's work rules, and applicable government
regulations.
•
You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
•
The Operator Manual and Load Chart are in the holder provided on
crane.
DANGER
Manitowoc is not

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  • Page 1 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
  • Page 2 SECTION CONTENTS Crane Warm-up Procedures......... . . 1 Engine.

  • Page 3: Engine

    (40°F). Lubrication section of your crane’s Operator Manual, by Warm-up Procedures: contacting your local Manitowoc distributor, or by contacting Manitowoc Crane Care directly). Without operating the hoist function, warm the hydraulic oil (see Hydraulic Oil System, page 2).

  • Page 4: Axles

    Axles crane’s hydraulic pumps or motors, stop the operation and engine immediately and contact a Manitowoc NOTE: For National Crane axle warm-up procedures, refer distributor. to chassis manufacturer’s manual. • From 10°C to 4°C (50°F to 40°F): Crane operation with...
  • Page 5 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
  • Page 6 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.

  • Page 7: Table Of Contents

    500E2 OPERATOR’S MANUAL TABLE OF CONTENTS SECTION 1 ..........Introduction General .
  • Page 8 TABLE OF CONTENTS OPERATOR’S MANUAL 500E2 Overload Inspection ........... 2-25 Boom Inspection .
  • Page 9 500E2 OPERATOR’S MANUAL TABLE OF CONTENTS Work Site Selection..........4-2 Before Leaving the Cab .
  • Page 10 TABLE OF CONTENTS OPERATOR’S MANUAL 500E2 Precautions and Recommendations During Inspection..... . 6-4   Inspection ............6-4 Wire Rope Replacement .

  • Page 11: Section 1

    New Owner information to assist you in a timely manner. We request that If you are the new owner of a Manitowoc crane, please you first contact them for assistance. If you feel you need register it with Manitowoc Crane Care so we have the ability factory assistance, please ask the dealer ’s service...
  • Page 12 INTRODUCTION OPERATORS MANUAL 500E2 500E2 Series Major Components Item Component Item Component Stabilizers Hoist Hydraulic Reservoir Boom Control Console Sheaves Outriggers Boom Rest NOTICE TO OWNER/USER Should this crane become involved in a property damage accident, please contact your local National distributor immediately and relate details of incident including serial number of crane.

  • Page 13: Safety Messages

    500E2 OPERATORS MANUAL SAFETY PRECAUTIONS SECTION 2 SAFETY PRECAUTIONS SECTION CONTENTS Safety Messages......2-1 Environmental Protection.

  • Page 14: Signal Words

    CAUTION personal injury accident, immediately contact your   Manitowoc dealer. If the dealer is unknown and/or cannot be Without the safety alert symbol, identifies hazards that reached, contact Product Safety at: could result in property damage if the message is ignored.

  • Page 15: Operator's Qualifications

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

  • Page 16: Load Moment Indication (Lmi) Systems (If Equipped)

    SAFETY PRECAUTIONS OPERATORS MANUAL 500E2 kept in good working condition. The manuals that Manitowoc Under no condition should it be relied upon to replace the   p r o v i d e s t h a t a r e s p e c i f i c f o r e a c h c r a n e a n d t h e use of Load Charts and operating instructions.

  • Page 17: Work Area Definition System (Wads) (If Equipped)

    500E2 OPERATORS MANUAL SAFETY PRECAUTIONS Work Area Definition System (WADS) (If operating procedures and with the identification of symbol usage. Equipped) The work area definition system is intended as an aid to the If your crane is equipped with a WADS, you must read and operator.

  • Page 18: Load Charts

    SAFETY PRECAUTIONS OPERATORS MANUAL 500E2 Read and follow the following safety decal for cranes with   center front stabiliers.                 Carefully follow the procedures in this Operator’s Manual   when extending or retracting the outriggers. Death or serious KEEP THE BOOM SHORT.

  • Page 19: Lifting Operations

    SAFETY PRECAUTIONS upon the direction from which the wind is blowing (e.g., wind a loss of control in handling the load. Manitowoc on the rear of the boom can result in decreased forward recommends that, if the wind speed (velocity) is between 20...

  • Page 20: Counterweight

    The “balance point” for stability testing   Do not rely on the crane’s tipping to determine your lifting according to SAE and Manitowoc criteria is a condition of capacity. loading wherein the load moment acting to overturn the  ...

  • Page 21: Electrocution Hazard

    500E2 OPERATORS MANUAL SAFETY PRECAUTIONS • Ensure the load lines are directly over the attach points This crane is not designed or equipped for use within 10 feet to avoid side loading and transfer of loading from one ( 3 m e t e r s ) o f e n e r g i z e d p o w e r l i n e s [ R e f e r t o 29CFR1926.1410 Table A].

  • Page 22: Set-Up And Operation

    SAFETY PRECAUTIONS OPERATORS MANUAL 500E2 Thoroughly read, understand, and abide by all applicable Electrocution Hazard Devices   federal, state, and local regulations. The use of insulated links, insulated boom cages/guards, proximity warning devices, or mechanical limit stops does Set-Up and Operation  ...

  • Page 23: Electrical Contact

    L o c o m o t i v e C r a n e s , a n d i n O S H A r e g u l a t i o n s Manitowoc Crane Care. 29CFRI910.180 for General Industry and 29CFRI926.1431 for Construction. Special Operating Conditions and Use of a Manitowoc crane to handle personnel is acceptable Equipment provided: Never operate the crane during an electrical thunderstorm. •...

  • Page 24: Environmental Protection

    NEVER use this crane for bungee jumping or any form Manitowoc reminds crane owners to ensure that all safety of amusement or sport. decals are in place and legible. Manitowoc continues to urge   crane owners to upgrade their cranes with load moment •...

  • Page 25: Service And Repairs

    Use a piece of cardboard, or piece of paper, to search for leaks. Wear gloves to protect your hands from • Consult with Manitowoc Crane Care to determine if load spraying fluid. testing is required after a structural repair is performed.

  • Page 26: Tires

    Wire Rope should never be used as its working load.   Use only the wire rope specified by Manitowoc as indicated • Each type of fitting attached to a wire rope has a specific on the crane’s Load Chart. Substitution of an alternate wire efficiency rating which can reduce the working load of  ...

  • Page 27: Sheaves

    500E2 OPERATORS MANUAL SAFETY PRECAUTIONS periodically. Refer to the Service Manual for more • When a wire rope has been removed from service information. because it is no longer suitable for use, it must not be reused on another application.

  • Page 28: Batteries

    SAFETY PRECAUTIONS OPERATORS MANUAL 500E2 To attain maximum wire rope life and minimize hook block allow the radiator time to cool before removing the radiator   rotation, it is recommended that even numbers of parts-of- cap. line be used in multiple-part reeving whenever possible.
  • Page 29 500E2 OPERATORS MANUAL SAFETY PRECAUTIONS Death or serious injury could result from being crushed by Check load limit of bridges. Before traveling across bridges, revolving tires. ensure they will carry a load greater than the crane’s weight. If it is necessary to take the crane on a road or highway, “Stunt”...

  • Page 30: Work Practices

    SAFETY PRECAUTIONS OPERATORS MANUAL 500E2 WORK PRACTICES or walking/working surfaces could cause a slipping accident.   A shoe that is not clean might slip off a control pedal during Personal Considerations operation.   Do not allow ground personnel to store their personal...

  • Page 31: Lifting

    500E2 OPERATORS MANUAL SAFETY PRECAUTIONS Sparks from the crane’s electrical system and/or engine exhaust can cause an explosion. Do not operate this crane in an area with flammable dust or vapors, unless good ventilation has removed the hazard. Carbon monoxide fumes from the engine exhaust can cause suffocation in an enclosed area.

  • Page 32: Hand Signals

    SAFETY PRECAUTIONS OPERATORS MANUAL 500E2 Check the hoist brake by raising the load a few inches, If the boom should contact an object, stop immediately and   stopping the hoist and holding the load. Be sure the hoist inspect the boom. Remove the crane from service if the brake is working correctly before continuing the lift.
  • Page 33 500E2 OPERATORS MANUAL SAFETY PRECAUTIONS National Crane 2-21 Published 10-20-2011 Control # 111-05...

  • Page 34: Boom Extension

    The drive line can be instructions are intended to allow the crane to be placed in damaged when attempting to free a frozen crane. the most stable and secure position. However, Manitowoc   recognizes that certain jobsite conditions may not permit the...

  • Page 35: Temperature Effects On Hydraulic Cylinders

    500E2 OPERATORS MANUAL SAFETY PRECAUTIONS If applicable to your crane, always handle propane tanks approximately 7 3/4 in (see chart below). A cylinder according to the supplier’s instructions. extended 5 feet in which the oil cools 60°F would only retract approximately 1 1/2 in.
  • Page 36 SAFETY PRECAUTIONS OPERATORS MANUAL 500E2     Coeff. = 0.00043 (in / °F) STROKE Temperature Change (°F)   (FT.) 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16  ...

  • Page 37: Overload Inspection

    Crane Care must be contacted publication for overloads up to 50%. for corrective action. • Stop operating the crane and contact Manitowoc Crane Care immediately for overloads of 50% and higher. NOTE: If your crane is equipped with CraneSTAR, an overload warning will be posted to the web site for review by the crane owner.

  • Page 38: Boom Inspection

    SAFETY PRECAUTIONS OPERATORS MANUAL 500E2 Boom Inspection           9, 10       2, 3           9, 10                           2-26 Published 10-20-2011 Control # 111-05  ...
  • Page 39 500E2 OPERATORS MANUAL SAFETY PRECAUTIONS Overload less than 25% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect for damage. Retainers Overload from 25% to 49% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect all for damage.

  • Page 40: Superstructure Inspection

    SAFETY PRECAUTIONS OPERATORS MANUAL 500E2 Superstructure Inspection                             10,11                         2-28 Published 10-20-2011 Control # 111-05...
  • Page 41 500E2 OPERATORS MANUAL SAFETY PRECAUTIONS Overload less than 25% Lift Cylinder Inspect for leaking. See topic in Introduction section Wire Rope Inspect all for damage. of Service Manual. Turntable See topic in Swing section of Check bolts for proper torque.

  • Page 42: Carrier Inspection

    SAFETY PRECAUTIONS OPERATORS MANUAL 500E2 Carrier Inspection                                   5, 6                   2-30 Published 10-20-2011 Control # 111-05...
  • Page 43 500E2 OPERATORS MANUAL SAFETY PRECAUTIONS Overload less than 25% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Overload from 25% to 49% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Outrigger Inspect for deformation and cracked welds.
  • Page 44 SAFETY PRECAUTIONS OPERATORS MANUAL 500E2                           THIS PAGE BLANK                           2-32 Published 10-20-2011 Control # 111-05...

  • Page 45: Section 3

    500E2 OPERATORS MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES SECTION CONTENTS Truck Cab Controls ......3-1 Boom length Indicator .

  • Page 46: Park Brake

    OPERATING CONTROLS AND PROCEDURES OPERATORS MANUAL 500E2 Park Brake complete control of boom rotation, boom elevation, boom   extension, hoist, outriggers, engine foot throttle, the engine The truck brake must be firmly set before leaving cab to emergency stop switch, and a horn switch. All control begin operation.

  • Page 47: Outriggers

    500E2 OPERATORS MANUAL OPERATING CONTROLS AND PROCEDURES Outriggers Key Override Switch Operate the lever to up to raise the outrigger legs. Operate Turn key switch to enable or disable HCAS, jib load limiting the lever to down to lower the outrigger legs.
  • Page 48 OPERATING CONTROLS AND PROCEDURES OPERATORS MANUAL 500E2                     NOTE: Item 20 is located behind the access door on the operators   console as shown.             Item...

  • Page 49: Hoist System Operation

    500E2 OPERATORS MANUAL OPERATING CONTROLS AND PROCEDURES HOIST SYSTEM OPERATION Using Multiple Part Lines The hoist is mounted at the rear of the boom and has The hoist load rating chart on each machine provides the capacities independent from the rest of the crane The hoist information for pull limitations on the hoist with various can normally pull more than the crane itself can withstand.

  • Page 50: Optional Hoist Burst Of Speed (Bos)

    OPERATING CONTROLS AND PROCEDURES OPERATORS MANUAL 500E2 OPTIONAL HOIST BURST OF SPEED (BOS) hoist cable and end attachments contact the underside of the   sheave case, whether by hoisting up or extending the boom The “Burst of Speed” increases hoist line speed 50% over...

  • Page 51: Hydraulic Capacity Alert System

    500E2 OPERATORS MANUAL OPERATING CONTROLS AND PROCEDURES The OMS utilizes an LED indicator to communicate to the the HCA and the Anti-Two-Block or jib load limiting systems operator the position of the outriggers and stabilizers. The as the cause of power loss.

  • Page 52: Hca System Operation

    OPERATING CONTROLS AND PROCEDURES OPERATORS MANUAL 500E2 The load range gauge is provided to aid the operator when   operating near the rated capacity of the crane. The gauge only provides accurate indication when the lift control lever is in neutral. The gauge movement is not proportional to the  ...

  • Page 53: Three Section Boom Operation

    500E2 OPERATORS MANUAL OPERATING CONTROLS AND PROCEDURES When trip force is reached, the jib load limiting device breaks These systems do not prevent structural or stability electrical continuity to the work port unloader solenoid in the overloads to the crane or hoist caused by: main control valve.

  • Page 54: Anti-Two-Block Weight Installation

    OPERATING CONTROLS AND PROCEDURES OPERATORS MANUAL 500E2 Insert the cable through the slot and position around the The retract cables attach to the tip end of the 1 boom   anchor wedge (1) Figure 3-1. section and are reeved around sheaves attached to the 2...
  • Page 55 500E2 OPERATORS MANUAL OPERATING CONTROLS AND PROCEDURES Do not attach dead end to live end or install wedge backwards. Wedge Socket Use a hammer to seat Wedge and Rope as deep into Live Dead socket as possible before applying first load.
  • Page 56 OPERATING CONTROLS AND PROCEDURES OPERATORS MANUAL 500E2                           THIS PAGE BLANK                           3-12 Published 10-20-2011 Control # 111-05...

  • Page 57: Section 4

    500E2 OPERATORS MANUAL SET-UP SECTION 4 SET-UP SECTION CONTENTS Definitions ....... 4-5 Equipment Familiarization .

  • Page 58: Work Site Selection

    SET-UP OPERATORS MANUAL 500E2 If the operator cannot see the load handling device Its best to select a location on the site such that most of the   approaching the boom nose, he shall have an assistant lifting can be done over the outrigger support or rear of the (signal person) watch the load handling device.

  • Page 59: Lifting Over The Front With A Front Stabilizer

    500E2 OPERATORS MANUAL SET-UP level indicator to insure that the crane is properly leveled. Always keep the load as close to the ground as possible. 180° Check to ensure that the jib, if so equipped, is stowed correctly on the first section boom.

  • Page 60: Set-Up

    SET-UP OPERATORS MANUAL 500E2 The load chart shows the maximum rated loads including • The correct loaded radius must be measured and not   load (weight being lifted), load handling equipment such as exceeded during any point of the lifting operation.

  • Page 61: Definitions

    500E2 OPERATORS MANUAL SET-UP Rated loads do not exceed 85% of the tipping load as 15. Do not allow personnel to ride on hook, hook block, load determined by SAE Crane Stability Test Code J765a or any device attached to the loadline. Use only National Crane approved baskets.

  • Page 62: Determining Load Capability

    SET-UP OPERATORS MANUAL 500E2 Boom Length Refer to crane load chart.   Starting point: Assuming the boom is fully retracted [27 ft' Length of the boom, from boom pivot pin to wire rope on last (8.23 m) boom length], the capacity at a 10 ft (3.04 m) radius main boom section.
  • Page 63 500E2 OPERATORS MANUAL SET-UP Starting Radius Given = 30 ft (9.14 m) Sling = 50 lb (22 kg) Ending Radius Given = 40 ft (12.19 m) Total Load = 9200 lb (4173 kg) Refer to Crane load chart. Starting Radius = 10 ft (3.04 m) To reach the load on the roof, the jib must be utilized to clear Ending Radius = 8 ft (2.43 m)

  • Page 64: Jib Operation Safety

    SET-UP OPERATORS MANUAL 500E2 JIB OPERATION SAFETY Area where jib swings around must be clear of   obstructions and power lines when stowing and The anti-two-block switch weight and cord must be unstowing jib. attached to the jib when deployed.
  • Page 65 500E2 OPERATORS MANUAL SET-UP Stop Pin Jib Swing Pin Jib Deployment Jib Deployment Stow Loop Load Line Attachment Point Jib in Stow Position JIb in Operating position Stow Jib Deployment Jib Swing Stow Loop Swing Around Extension Retaining Jib Deployment...

  • Page 66: Side Folding-Swing Around Jib Operation

    SET-UP OPERATORS MANUAL 500E2 SIDE FOLDING-SWING AROUND JIB 15. Route loadline over jib sheave and install keeper. Install   line block to end of loadline. OPERATION 16. Remove anti-two-block weight/chain assembly from   Deployment Procedure boom tip switch and install on jib tip switch. Be certain to use keeper provided with switch.

  • Page 67: Jib Maintenance

    500E2 OPERATORS MANUAL SET-UP attaching loadline wedge socket to attachment point F 15. Remove pins C1 from upper and lower jib ears. A slight on the jib sheave case. Slowly activate the hoist up hammer strike may be necessary to remove pins.

  • Page 68: Jib Jack Procedures

    SET-UP OPERATORS MANUAL 500E2 Jib Jack Procedures When Jib is stowed on side of crane, always leave ram and   handle sleeve pushed all the way down to reduce exposure The Jib Pin alignment device (Jib Jack) is an aid for installing to rusting.

  • Page 69: General

    Manitowoc distributor or Manitowoc Crane Care. the frequency of lubrication, and other information. This NOTE:...

  • Page 70: Open Gear Lubricant

      NOTE: All fluids and lubricants may be purchased by rusting, resists oxidation and helps prevent wear. contacting the Manitowoc Crane Care Parts   Hydraulic OIL Department. Oil in a hydraulic system serves as the power transmission  ...

  • Page 71: Surface Protection For Cylinder Rods

    ® protected using Boeshield T-9 Premium Metal Protectant. continuous duty cycles and/or hazardous environments. Manitowoc CraneCARE has Boeshield T-9 Premium Metal Protectant available in 12 oz. cans that can be ordered Surface Protection for Cylinder Rods through the Parts Department.
  • Page 72 LUBRICATION PROCEDURE AND CHARTS OPERATORS MANUAL 500E2         Oil Fill/Breather     Oil Drain                       NOTE: Torque diffuser to 51 lb-ft (69 Nm). Openings must face bottom of tank.

  • Page 73: Internal Cable Sheave Lubrication

    (National P/N 955047). Extend boom to position the wear pad access holes • Contact the Manitowoc Crane Care to obtain this tip. directly above the wear pads on the third boom section, • Observation through the sheave case for the extend apply grease to the pads using the brush or gun.

  • Page 74: Hoist Gearbox Oil

    LUBRICATION PROCEDURE AND CHARTS OPERATORS MANUAL 500E2 Fully extend the boom and apply grease to the side and Extend and retract the boom several times until the   grease is evenly spread. bottom of the 2 and 3 sections with a brush.

  • Page 75: Hydraulic Oil Reservoir Level

    500E2 OPERATORS MANUAL LUBRICATION PROCEDURE AND CHARTS Hydraulic Oil Level Brake Vent/Fill Plug Sight Gauge Brake Drain Plug WIRE ROPE LUBRICATION A wire rope cannot be lubricated sufficiently during manufacture to last it’s entire life. Therefore, new lubricant must be added throughout the life of a rope to replace factory lubricant which is used or lost.
  • Page 76 LUBRICATION PROCEDURE AND CHARTS OPERATORS MANUAL 500E2 It should be of a viscosity capable of penetrating the • dripping   interstices between wires and strands. • pouring It should not be soluble in the medium surrounding it • swabbing  ...

  • Page 77: Crane Inspection And Maintenance

    500E2 OPERATORS MANUAL MAINTENANCE CHECKLIST SECTION 6 MAINTENANCE CHECKLIST SECTION CONTENTS Crane Inspection And Maintenance ... 6-1 Jib Jack Service and Maintenance ... . 6-6 Inspection .

  • Page 78: Daily Inspections

    MAINTENANCE CHECKLIST OPERATORS MANUAL 500E2 21. All fasteners retaining loadline centering block are in   place and tight. WARNING 22. All safety covers for proper installation.   If any defect determined during the inspection is a safety 23. Boom lift and outrigger holding valves for proper hazard the machine must be removed from service and operation.

  • Page 79: Periodic/Annual Inspection

    Leaks at rod seals, welds, or holding valves state and local regulatory agencies. PTO drive line system for proper alignment, lubrication NOTE: Wire rope may be purchased through Manitowoc and tightness. Crane Care. Hydraulic hose and tubing for evidence of damage such Any deterioration observed in the wire rope should be noted as blistering, crushing or abrasion.

  • Page 80: Environmental Conditions

    MAINTENANCE CHECKLIST OPERATORS MANUAL 500E2 Environmental Conditions period of a month or more must be given a thorough   inspection before it is placed in service. These inspections The life expectancy of wire rope may vary due to the degree...

  • Page 81: Wire Rope Replacement

    500E2 OPERATORS MANUAL MAINTENANCE CHECKLIST • Inspect for severely corroded or broken wires at end connections. • Inspect wire rope in areas subjected to rapid deterioration such as: Sections in contact with saddles, equalizer sheaves, or other sheaves where wire rope travel is limited.

  • Page 82: Rope Construction

      trained. Use only parts supplied by your National Crane 16.8 tons (15,241 kg) Distributor or Manitowoc Crane Care to repair the crane.   If wire rope replacement is required for crane extension system, replacement ropes must be obtained through the JIB JACK SERVICE AND MAINTENANCE Manitowoc Crane Care.

  • Page 83: Oil Cooler Service And Maintenance (Optional)

    500E2 OPERATORS MANUAL MAINTENANCE CHECKLIST OIL COOLER SERVICE AND MAINTENANCE • error codes (OPTIONAL) • current angle reading. The heat exchanger must be kept clean to allow for efficient On power-up, the unit first displays startup codes. The operation of the cooler system. Frequent washing of the...

  • Page 84: Hydraulic System Trouble Diagnosis

    MAINTENANCE CHECKLIST OPERATORS MANUAL 500E2 HYDRAULIC SYSTEM TROUBLE possible cause and possible solution. These are not all   inclusive but are designed to help isolate the problem and DIAGNOSIS should be checked before calling the factory Service The following chart lists malfunctions which may occur Department  ...
  • Page 85 500E2 OPERATORS MANUAL MAINTENANCE CHECKLIST Condition Possible Cause Possible Solution Loose turntable bearing. Torque bearing mounting bolts. Loose swing gearbox mounting bolts. Tighten bolts. Replace worn parts or adjust gearbox Worn gears or bearing. spacing. Operator control of lever too erratic.
  • Page 86 MAINTENANCE CHECKLIST OPERATORS MANUAL 500E2 Condition Possible Cause Possible Solution   Check load and change to applicable Load too heavy. multipart reeving.   Relief valve setting too low. Check and adjust if required.   Motor worn excessively. Replace motor. Hoist will not lift or hold load Counterbalance valve defective or  ...

  • Page 87: Jib Jack Troubleshooting

    500E2 OPERATORS MANUAL MAINTENANCE CHECKLIST Condition Possible Cause Possible Solution To set the zero point, remove all force from the load cell. Remove the electronics from the housing. Set the switch position 8 to ON. Power the system. Do not turn off power...

  • Page 88: Tire Load And Inflation Table

    MAINTENANCE CHECKLIST OPERATORS MANUAL 500E2 Tire Load And Inflation Table NOTE: The values in the tables below are as published by   the Tire and Rim Association 2005. Your vehicle Definite tire inflation pressures are established for each tire may be equipped with other tire sized or the same size depending upon the load imposed on the tires.
  • Page 89 500E2 OPERATORS MANUAL MAINTENANCE CHECKLIST Radial Ply Metric Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15° Drop Center Rims Tire and Rim Association Standard Radial Ply Metric Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15°...
  • Page 90 MAINTENANCE CHECKLIST OPERATORS MANUAL 500E2   Metric Wide Base Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Tires Used as Singles Mounted on 15° Drop Center Rims   Tire and Rim Association Standard        ...

  • Page 91: Specifications

    500E2 OPERATORS MANUAL MAINTENANCE CHECKLIST SPECIFICATIONS Hydraulic Pump Displacements: Section P1 ..............34 GPM (128.7 LPM) at 2400 RPM Section P2 ..............18 GPM (68.1 LPM) at 2400 RPM Section P3 ..............10 GPM (37.8 LPM) at 2400 RPM Hydraulic System Requirements: Boom and Outrigger System .........

  • Page 92: Crane Operating Speeds

    MAINTENANCE CHECKLIST OPERATORS MANUAL 500E2 Crane Operating Speeds   Rotation 375°................. 15 ± 5 sec (1.8 ± 0.2 rpm) Swing speed based on and adjustment knob in closed position.   Boom up -10° to 80° .............. 25 ± 5 sec Boom Down 80°...
  • Page 93 500E2 OPERATORS MANUAL ALPHABETICAL INDEX Accidents ............. 2-2 Adjustable Swing Speed Valve .
  • Page 94 OPERATORS MANUAL 500E2                           THIS PAGE BLANK                           APL-2 Published 10-20-2011 Control # 111-05  ...

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