Manitowoc 500E2 Heavy-duty Crane Manuals

Manuals and User Guides for Manitowoc 500E2 Heavy-duty Crane. We have 3 Manitowoc 500E2 Heavy-duty Crane manuals available for free PDF download: Service Manual, Operator's Manual, Operator's Manual Supplement

Manitowoc 500E2 Service Manual (162 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 19 MB

Table of Contents
5
Section 1

11
- Supplemental Information
  11
- General
  11
- New Owner
  12
- Basic Nomenclature
  12
- General Maintenance
  12
  - Cleanliness
    13
  - Removal and Installation
    13
  - Disassembly and Assembly
    13
  - Pressing Parts
    13
  - Locks
    13
  - Shims
    13
  - Bearings
    13
  - Gaskets
    14
  - Hydraulic Systems
    14
- Electrical
  15
  - Batteries
    15
  - Jump Starting Hazard
    15
  - Charging the Batteries
    15
  - Connectors, Harnesses, Wires, and Connectors
    15
  - Dielectric Grease
    16
- Fatigue of Welded Structures
  16
- Loctite
  17
- Fasteners and Torque Values
  17
- Weld Studs
  30
  - Torque Wrenches
    30
  - Using Torque Wrench Extensions
    30
- Wire Rope
  31
  - General
    31
  - Keeping Records
    31
  - Environmental Conditions
    32
  - Dynamic Shock Loads
    32
  - Lubrication
    32
  - Precautions and Recommendations During Inspection
    32
  - Inspection
    33
  - Wire Rope Replacement
    33
  - Care of Wire Rope
    34
  - Boom Extension and Retraction Cables
    34
  - Wire Rope Replacement (All Wire Rope)
    35
  - Seizing Wire Rope
    35
Section 2

37
Section 3

45
- Anti-Two Block System Description
  45
  - Anti-Two Block Operation
    45
- Anti-Two Block Internal Wire Repair
  46
- Three Section Boom ATB Wire Repair
  46
  - Alternative #1
    46
  - Alternative #2
    47
- Hydraulic Capacity Alert System
  48
  - HCA Maintenance & Repair
    48
  - HCA System Adjustment
    48
- Jib Load Limiting Device
  49
  - Single Character Display
    49
  - Jib Load Limiting Device Troubleshooting
    50
- Outrigger Monitoring System (OMS) (Optional-Standard in North America)
  50
  - Operation
    50
  - Maintenance
    50
  - Outrigger Monitoring System (OMS)
    50
  - Standard in North America)
    50
- Remote Control
  53
  - Safety
    53
  - Danger Remote Start Hazard
    53
  - Operation
    53
  - Hydraulic System Description
    54
  - Service and Maintenance
    54
  - Troubleshooting, Repair and Replacement
    54
  - Installation
    55
- Radio Remote Controls
  55
  - Safety
    55
  - Operation
    55
  - Service and Maintenance
    55
  - Quick Test for Receiver Antenna and Cable
    56
  - Troubleshooting
    56
  - Specifications
    57
  - Installation
    57
Section 4

65
- Three Section Boom Operation
  66
  - Special Boom Inspection
    66
- Three Section Boom Maintenance
  66
  - Three Section Cable Tensioning
    66
- Hoist Removal
  67
- Boom Removal
  68
- Three Section Boom Assembly
  70
- Inner Wear Pad Calibration
  72
- Cable Tensioning
  74
- Lift Cylinder Repair
  77
  - Lift Cylinder Disassembly
    77
- Extend Cylinder Repair
  78
  - Extend Cylinder Disassembly
    78
  - Extend Cylinder Assembly
    79
- Jib Installation and Adjustment
  79
- Jib Jack Service and Maintenance
  81
  - Adding Oil
    81
  - Changing Oil
    81
  - Lubrication
    81
  - Rust Prevention
    81
Section 5

83
- Hoist Removal
  83
- Hoist Installation
  83
Section 6

85
- Swing Gearbox and Brake
  85
- Rotation Stop-Mechanical
  89
  - Rotation Stop Adjustment
    89
- Maintenance
  90
  - General
    90
- Torquing Swing Bearing Bolts
  90
  - Swing Bearing Bolts
    91
  - Torque Values
    93
- Bearing Clearance
  93
- Bearing Replacement
  95
  - Removal
    95
  - Installation
    95
  - Testing
    96
Section 7

97
- Lubrication General
  97
- Environmental Protection
  97
  - Lubricants
    97
  - Arctic Conditions below -9°C (15°F)
    98
  - Chassis Grease
    98
  - Low Temperature Grease
    98
  - Extreme Pressure Multipurpose Gear Lubricant (EPGL)
    98
  - Open Gear Lubricant
    98
  - Antifreeze/Coolant (for Cab Heater)
    98
  - Anti-Wear Additives
    98
  - Hydraulic Oil
    98
  - Standard Hydraulic Oil
    98
  - Lubricants
    98
  - Arctic Hydraulic Oil
    99
  - Hydraulic Oil Inspection
    99
  - Surface Protection for Cylinder Rods
    99
- Lubrication
  99
- Lubrication Chart
  101
  - Internal Cable Sheave Lubrication
    102
  - Inner Boom Pad Lubrication
    103
  - Side and Bottom Boom Wear Pad Lubrication
    103
  - Hoist Gearbox Oil
    103
  - Hoist Brake Oil
    104
  - Swing Gearbox and Brake Oil
    105
- Hydraulic Oil Reservoir Level
  105
- Wire Rope Lubrication
  105
- Carwell© Rust Inhibitor
  106
  - Protecting Cranes from Corrosion
    106
  - Cleaning Procedures
    106
  - Inspection and Repair
    107
  - Application
    107
  - Areas of Application
    108
Section 8

111
- Hydraulic System Troubleshooting Chart
  111
- Jib Load Limiting Device Troubleshooting
  114
- Jib Jack Troubleshooting
  115
  - Systematic Troubleshooting
    115
- HCA Troubleshooting Flow Chart
  116
Section 9

117
- Crane to Truck Installation
  117
- Minimum Truck Requirements
  118
- Mounting Configurations
  118
  - Configuration 1 - 571E2
    119
  - Configuration 2 - 571E2
    120
  - Configuration 3 - 560E2
    121
  - Configuration 4 - 560E2 and Shorter Booms
    122
- PTO Horsepower Requirements
  123
  - Direct Mount Pump to PTO
    123
  - Pump Rotation
    123
- Truck Frame Strength
  124
- Section Modulus Tables
  125
  - Channel (Table A)
    125
  - Channel Reinforcement (Table A)
    125
  - Angle Reinforcement (Table B)
    125
  - Fish Plate Reinforcement (Table C)
    125
  - Angle under Reinforcement (Table D)
    125
- Requirements for Optional Single Front Outrigger
  130
- Requirements for Optional Single Front
  130
- Outrigger
  130
- Truck Frame Section Modulus Tables
  131
- Truck Preparation
  134
  - Welding Precautions
    134
- Positioning Crane on Truck
  134
- PTO Installation
  134
  - Hydraulic Pump Installation
    134
- Reinforcing/After Frame Extension
  135
- After Frame Modification
  138
- Crane Mounting Procedure
  138
  - Crane Component Installation Sequence
    138
  - Torsion Box and ASH Stabilizer Installation
    138
  - Install Torsion Box
    138
  - Mount the Turret and Torsion Box to the Frame Assembly
    138
  - Turret Mounting
    138
  - Torsion Box Mounting
    139
  - Mount the Outrigger Box
    140
- ASH to Torsion Box Mounting
  141
  - Assemble the Outriggers
    142
  - Hydraulic Reservoir Installation
    142
- Boom Installation
  143
  - Lift Cylinder Installation
    143
  - Wire Rope Installation
    144
  - Hoist to Truck Cab Clearance
    145
  - Painting
    145
- Pin Bearing Inspection and Installation Procedure
  145
  - Pin Inspection
    145
  - Bearing Installation
    145
  - Trunnion Inspection
    145
  - Bearing Inspection
    145
- Counterweighting
  145
  - Pin Bearing Inspection and Installation
    145
  - Procedure
    145
  - Counterweighting Determination Example
    146
  - Counterweighting Methods
    147
- Concrete Poured in the Bed Measures
  149
- Boom Rest Requirements
  150
- CAN Bus System Setup
  151
  - Required Equipment
    151
  - CAN Bus System Using Software
    151
  - CAN Bus System Using Programming Button
    152
- Initial Crane Run in Procedure
  153
- Stability Check
  153
- Specifications
  155
  - Hydraulic Pump
    155
  - Hydraulic System
    155
  - Reservoir
    155
  - Hca
    155
  - Hoist Speed and Pull
    155
  - Crane Operating Speeds
    155
Section 10

157

Manitowoc 500E2 Operator's Manual (120 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 13 MB

Table of Contents
5
Section 1

11
- Supplemental Information
  11
- New Owner
  11
- Basic Nomenclature
  11
Section 2

13
- Safety Messages
  13
  - General
    14
  - Safety Alert Symbol
    14
  - Signal Words
    14
- Accidents
  14
- Operator Information
  14
- Operator Qualifications
  15
- Operational Aids
  16
- Equipment Stability/Structural Strength
  17
  - Load Charts
    18
  - Work Site
    18
- Wind Forces
  18
  - Wind Speeds
    19
  - Lifting Operations
    30
  - Counterweight
    31
  - Outrigger Lift off
    31
  - Multiple Equipment Lifts
    31
  - Tilt-Up Panel Lifting
    32
- Pile Driving and Extracting
  32
  - Equipment
    33
  - Equipment Inspection
    33
- Electrocution Hazard
  33
- Personnel Handling
  36
- Environmental Protection
  38
- Maintenance
  38
  - Service and Repairs
    38
  - Lubrication
    39
  - Tires
    39
- Hoist Rope
  39
  - Synthetic Hoist Rope
    39
  - Wire Rope
    40
  - Sheaves
    41
  - Batteries
    41
  - Engine
    42
- Transporting the Equipment
  42
- Travel Operation
  42
- Work Practices
  43
  - Personal Considerations
    43
  - Equipment Access
    43
  - Job Preparation
    44
- Working
  44
- Lifting
  45
- Hand Signals
  46
- Jib
  46
- Parking and Securing
  48
- Shut-Down
  48
- Cold Weather Operation
  48
- Temperature Effects on Hook Blocks
  48
- Temperature Effects on Hydraulic Cylinders
  48
- Overload Inspection
  50
  - Boom Inspection
    51
  - Superstructure Inspection
    53
  - Carrier Inspection
    55
Section 3

57
- Truck Cab Controls
  57
  - Power Take-Off
    57
  - Park Brake
    58
  - Cold Weather Operation
    58
- Crane Warm-Up Procedures
  58
  - Engine
    58
  - Transmission
    58
  - Power Take-Off
    58
  - Hoist
    59
  - Swing Drive and Turntable Bearing
    59
  - Axles
    59
  - Hydraulic Oil System
    59
- Jump Starting Hazard
  59
- Charging the Battery
  59
- Unattended Crane
  60
- Crane Controls
  60
  - Turn
    60
  - Swing Speed Adjustment
    60
  - Boom
    60
  - Boom Telescope
    60
  - Hoist
    60
  - Stabilizers Up/Down
    60
  - Stabilizers Extend/Retract
    60
  - Outriggers
    60
  - HCA Overload Light
    61
  - Anti-Two-Block/Jib Overload Light
    61
  - Key Override Switch
    61
  - Override Button
    61
  - Load Chart
    61
  - Boom Angle Indicator
    61
  - Boom Length Indicator
    61
  - Outrigger Status Indicator
    61
- Hoist System Operation
  63
- Optional Hoist Burst of Speed (BOS)
  64
- Anti-Two Block System
  64
- Outrigger Monitoring System (OMS) (Optional-Standard in North America)
  64
  - Outrigger Monitoring System (OMS)
    64
  - Hydraulic Capacity Alert System
    65
    
    System Description
    65
    
    Indicator Lights
    65
    
    HCA Load Range Gauge
    65
  - HCA System Operation
    66
    
    Pressure Sensing Switch
    66
  - Jib Load Limiting Device
    66
    
    System Description
    66
    
    System Operation
    66
  - Three Section Boom Operation
    67
    
    Anti-Two-Block Weight Installation
    68
  - Installing Cable on the Hoist
    68
  - Wedge Socket Installation
    68
    
    Dead-End Rigging
    69
  - Remote Control
    70
    
    Safety
    70
    
    Danger Remote Start Hazard
    70
    
    Operation
    71
    
    Hydraulic System Description
    71
  - Radio Remote Controls
    71
    
    Safety
    72
    
    Operation
    72
    
    Electrical Circuit Description
    72
    
    Emergency Stop Function
    73
    
    Frequently Asked Questions
    73
Section 4

75
- Equipment Checks
  75
- Pre-Operation Inspection and Calibration Verification
  75
- Work Site Selection
  76
- Before Leaving the Cab
  76
- Lifting over the Rear
  76
- Lifting over the Front with a Single Front Outrigger (SFO)
  77
- Before Making the Lift
  77
- Reading and Understanding the Load Charts
  77
  - Set-Up
    77
  - Operation
    78
  - Set-Up
    78
  - Definitions
    79
- Determining Load Capability
  80
  - Load Determination Examples
    80
- Jib Operation Safety
  82
- Side Folding-Swing Around Jib Operation
  84
  - Deployment Procedure
    84
- Stowing Procedure
  84
  - Jib Maintenance
    85
  - Jib Removal
    85
  - Jib Jack Procedures
    86
- Adjustable Swing Speed Valve
  86
Section 5

87
- General
  87
- Environmental Protection
  87
  - Lubricants
    87
  - Arctic Conditions below -9°C (15°F)
    87
  - Chassis Grease
    88
  - Low Temperature Grease
    88
- Extreme Pressure Multipurpose Gear Lubricant (EPGL)
  88
- Open Gear Lubricant
  88
- Antifreeze/Coolant (for Cab Heater)
  88
- Anti-Wear Additives
  88
- Hydraulic Oil
  88
- Standard Hydraulic Oil
  88
- Lubricants
  88
- Arctic Hydraulic Oil
  89
- Hydraulic Oil Inspection
  89
- Surface Protection for Cylinder Rods
  89
- Lubrication
  89
- Lubrication Chart
  91
- Hydraulic Oil Reservoir Level
  95
- Wire Rope Lubrication
  95
- Carwell© Rust Inhibitor
  96
  - Protecting Cranes from Corrosion
    96
  - Cleaning Procedures
    97
  - Inspection and Repair
    97
  - Application
    98
  - Areas of Application
    98
Section 6

101
- Crane Inspection and Maintenance
  101
  - Inspection
    101
  - Daily Inspections
    102
  - Weekly Inspections
    102
  - Monthly Inspections
    102
  - Periodic/Annual Inspection
    103
  - Special Boom Inspection
    103
  - Stability
    103
- Hoist Cable Inspection and Maintenance
  103
  - Keeping Records
    103
  - Environmental Conditions
    104
  - Dynamic Shock Loads
    104
  - Precautions and Recommendations During Inspection
    104
  - Inspection
    104
  - Wire Rope Replacement
    105
  - Care of Wire Rope
    105
  - Rope Construction
    106
- Crane Adjustments and Repairs
  106
- Jib Jack Service and Maintenance
  106
  - Adding Oil
    106
  - Changing Oil
    106
  - Lubrication
    106
  - Rust Prevention
    107
- Oil Cooler Service and Maintenance (Optional)
  107
- Jib Load Limiting Device
  107
  - Single Character Display
    107
- Hydraulic System Trouble Diagnosis
  108
  - Jib Jack Troubleshooting
    111
  - Tire Load and Inflation Table
    112
- Specifications
  115
  - Hydraulic Pump
    115
- Hydraulic System
  115
- Reservoir
  115
- Hca
  115
- Hoist Speed and Pull
  115
- Crane Operating Speeds
  116

Manitowoc 500E2 Operator's Manual Supplement (94 pages)

Crane warm-up procedures

Brand: Manitowoc | Category: Construction Equipment | Size: 2 MB

Engine
3
Axles
4
- Table of Contents
  7
- New Owner
  11
- Safety Information
  11
- Section 1
  11
- Supplemental Information
  11
- General
  13
- Safety Alert Symbol
  13
- Safety Messages
  13
- Accidents
  14
- General
  14
- Operator's Information
  14
- Signal Words
  14
- Operational Aids
  15
- Operator's Qualifications
  15
- Anti-Two-Blocking Device
  16
- Load Moment Indication (LMI) Systems (if Equipped)
  16
- Crane Stability/Structural Strength
  17
- Work Area Definition System (WADS) (if Equipped)
  17
- Load Charts
  18
- Wind Forces
  18
- Work Site
  18
- Lifting Operations
  19
- Counterweight
  20
- Multiple Crane Lifts
  20
- Outrigger Lift off
  20
- Electrocution Hazard
  21
- Electrocution Hazard Devices
  22
- Set-Up and Operation
  22
- Electrical Contact
  23
- Personnel Handling
  23
- Special Operating Conditions and Equipment
  23
- Environmental Protection
  24
- Maintenance
  24
- Lubrication
  25
- Service and Repairs
  25
- Tires
  26
- Wire Rope
  26
- Sheaves
  27
- Batteries
  28
- Engine
  28
- Transporting the Crane
  28
- Travel Operation
  28
- Crane Access
  30
- Job Preparation
  30
- Personal Considerations
  30
- Work Practices
  30
- Working
  30
- Lifting
  31
- Hand Signals
  32
- Boom Extension
  34
- Cold Weather Operation
  34
- Parking and Securing
  34
- Shut-Down
  34
- Temperature Effects on Hydraulic Cylinders
  35
- Overload Inspection
  37
- Boom Inspection
  38
- Superstructure Inspection
  40
- Carrier Inspection
  42
- Power Take-Off
  45
- Section 3
  45
- Truck Cab Controls
  45
- Boom
  46
- Boom Telescope
  46
- Cold Weather Operation
  46
- Crane Controls
  46
- Hoist
  46
- Park Brake
  46
- Stabilizers Up/Down
  46
- Swing Speed Adjustment
  46
- Turn
  46
- Unattended Crane
  46
- Anti-Two-Block/Jib Overload Light
  47
- Emergency Stop Switch
  47
- Foot Throttle
  47
- HCA Overload Light
  47
- Horn
  47
- Hydraulic Capacity Alert System (HCA) Load Range Gauge
  47
- Key Override Switch
  47
- Load Chart
  47
- Outriggers
  47
- Override Button
  47
- General Rules When Operating Hoist
  49
- Hoist System Operation
  49
- Lifting the Load
  49
- Using Multiple Part Lines
  49
- Anti-Two Block System
  50
- Optional Hoist Burst of Speed (BOS)
  50
- Outrigger Monitoring System (OMS)
  50
- Outrigger Monitoring System (OMS) (Optional-Standard in North America)
  50
- HCA Load Range Gauge
  51
- Hydraulic Capacity Alert System
  51
- Indicator Lights
  51
- System Description
  51
- HCA System Operation
  52
- Jib Load Limiting Device
  52
- Pressure Sensing Switch
  52
- System Description
  52
- System Operation
  52
- Three Section Boom Operation
  53
- Anti-Two-Block Weight Installation
  54
- Installing Cable on the Hoist
  54
- Wedge Socket Installation
  54
- Equipment Checks
  57
- Equipment Familiarization
  57
- Pre-Operation Inspection and Calibration Verification
  57
- Section 4
  57
- Before Leaving the Cab
  58
- Lifting over the Rear
  58
- Work Site Selection
  58
- Before Making the Lift
  59
- Lifting over the Front with a Front Stabilizer
  59
- Reading and Understanding the Load Charts
  59
- Set-Up
  59
- Operation
  60
- Set-Up
  60
- Definitions
  61
- Determining Load Capability
  62
- Load Determination Examples
  62
- Jib Operation Safety
  64
- Deployment Procedure
  66
- Side Folding-Swing Around Jib Operation
  66
- Stowing Procedure
  66
- Jib Maintenance
  67
- Jib Removal
  67
- Adjustable Swing Speed Valve
  68
- Jib Jack Procedures
  68
- Arctic Conditions below -18°C (0°F)
  69
- Chassis Grease
  69
- Extreme Pressure Multipurpose Gear Lubricant (EPGL)
  69
- General
  69
- Lubricants
  69
- Anti-Wear Additives
  70
- Arctic Hydraulic Oil
  70
- Chassis Grease Low Temp
  70
- Hydraulic OIL
  70
- Intermediate Hydraulic Oil
  70
- Lubrication Points
  70
- Open Gear Lubricant
  70
- Standard Hydraulic Oil
  70
- Wide Range Intermediate Hydraulic Oil
  70
- Surface Protection for Cylinder Rods
  71
- Inner Boom Pad Lubrication
  73
- Internal Cable Sheave Lubrication
  73
- Side and Bottom Boom Wear Pad Lubrication
  73
- Hoist Brake Oil
  74
- Hoist Gearbox Oil
  74
- Hydraulic Oil Reservoir Level
  75
- Wire Rope Lubrication
  75
- Crane Inspection and Maintenance
  77
- Daily Inspections
  78
- Monthly Inspections
  78
- Weekly Inspections
  78
- Hoist Cable Inspection and Maintenance
  79
- Keeping Records
  79
- Periodic/Annual Inspection
  79
- Special Boom Inspection
  79
- Stability
  79
- Dynamic Shock Loads
  80
- Environmental Conditions
  80
- Inspection
  80
- Precautions and Recommendations During Inspection
  80
- Care of Wire Rope
  81
- Wire Rope Replacement
  81
- Adding Oil
  82
- Changing Oil
  82
- Crane Adjustments and Repairs
  82
- Jib Jack Service and Maintenance
  82
- Lubrication
  82
- Rope Construction
  82
- Rust Prevention
  82
- Jib Load Limiting Device
  83
- Oil Cooler Service and Maintenance (Optional)
  83
- Single Character Display
  83
- Hydraulic System Trouble Diagnosis
  84
- Jib Jack Troubleshooting
  87
- Tire Load and Inflation Table
  88
- Hca
  91
- Hoist Speed and Pull
  91
- Hydraulic Pump
  91
- Hydraulic System
  91
- Reservoir
  91
- Specifications
  91
- Crane Operating Speeds
  92

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