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Manitowoc National Crane 500E2 User Manual
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500E2 OPERATOR MANUAL
SAFETY PRECAUTIONS
2
National Crane
Published 07-26-2019 Control # 1
1
1-06
2-43
Carrier Inspection
3
1
1
1
2
2
2
3
3
4
4
5, 6
Illustration for refere
nce only
.
Y
our
crane
may
be
different.
54
56
Table of Contents
Default Chapter
5
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
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Manitowoc National Crane 500E2 Specifications
General
Brand
Manitowoc
Model
National Crane 500E2
Category
Construction Equipment
Language
English
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