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Manitowoc 500E2 Manuals
Manuals and User Guides for Manitowoc 500E2. We have
3
Manitowoc 500E2 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: 19.4 MB
Table of Contents
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
Hydraulic System Description
37
General Adjustment and Repair Procedures
37
Hydraulic System Maintenance Precautions
38
Label Parts When Disassembling
38
Welding Precautions
38
Hydraulic Oil Recommendations
38
Draining and Flushing
38
Hydraulic System Description
38
Removing Air from the Hydraulic System
39
Parts Replacement
40
Maintenance Records
40
Hydraulic Oil Reservoir
40
Hydraulic Filter
40
Oil Cooler Service & Maintenance (Optional)
40
Servicing the Control Valves
41
Disassembly and Reassembly of Control Valves to Replace Seals
41
Replacing Spool Seals
41
Unloader Valve Service
42
Control Valve Relief Adjustment
43
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
Boom Disassembly
68
Boom Disassembly Alternative #1
68
Boom Disassembly Alternative #2
69
Additional Maintenance, Disassembled Boom
70
Three Section Boom Assembly
70
Three Section Top/Bottom Pad Replacement (Assembled Boom)
72
Top Rear Pad Replacement
72
Front Bottom Pad Replacement
72
Inner Wear Pad Calibration
72
Cable Tensioning
74
Tensioning Setup Procedure
74
Cable Tension Sequence
74
3- Section Boom W/ 1 Stage Cylinder Cable Positioning
75
Cable Retention
76
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
Disassembly & Assembly Instructions
85
Swing Drive Disassembly
85
Tulsa Swing Drive Assembly Procedure
88
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
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Manitowoc 500E2 Operator's Manual (120 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 13.38 MB
Table of Contents
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
Rated Capacity Limiter (RCL) Systems (if Equipped)
16
Anti-Two-Blocking Device
16
Working Area Limiter (if Equipped)
17
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
Set-Up and Operation
34
Electrocution Hazard Devices
35
Electrical Contact
35
Special Operating Conditions and Equipment
36
Grounding the Equipment
36
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
Using Multiple Part Lines
63
General Rules When Operating Hoist
63
Lifting the Load
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
Internal Cable Sheave Lubrication
92
Inner Boom Pad Lubrication
93
Side and Bottom Boom Wear Pad Lubrication
93
Hoist Gearbox Oil
93
Hoist Brake Oil
94
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: 2.59 MB
Table of Contents
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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