PDF Operator Manual Manitowoc Grove TM500E-2 Crane Superstructure - 637 KB
This operator's manual specifically covers the superstructure of the Manitowoc Grove TM500E-2 crane.
It provides detailed instructions on operating the boom, winch, and swing functions safely and efficiently.
The manual also includes load charts and setup procedures critical for safe lifting operations.
Every crane operator must be thoroughly familiar with this guide.
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Grove
SUPERSTRUCTURE 1
OPERATOR’S MANUAL
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 INTRODUCTION
SECTION 2 SAFETY INFORMATION
SECTION 3 OPERATING CONTROLS
SECTION 4 SET-UP AND INSTALLATION
SECTION 5 LUBRICATION
SECTION 6 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
! DANGER
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 5
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’s Manual and Load Chart are in the holder provided on
crane.
6
© 2012 Manitowoc
Published 02-06-2012, Control # 150-06
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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL INTRODUCTION
1
24
13
19 11 20
7 12 14 8
5 6
9
6942-3
23 2 21
View for 95 Foot Boom Crane
FIGURE 1-1 continued
Grove Published 02-06-2012, Control # 150-06 1-3
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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL SAFETY INFORMATION
the mid-extend position, the outriggers must also be as indicated on the crane’s Load Chart, do not exceed 85%
pinned when operating from the mid-extend position. of the tipping load on outriggers as determined by SAE J765
OCT80 “Cranes Stability Test Code.” An outrigger pad may
• Cribbing under the outrigger pads is inadequate.
lift off the ground during operation of the crane within the
• The crane is improperly operated. capacity limits of the Load Chart, yet the crane will not have
reached instability. 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
Be sure the hoist line is vertical before lifting. Do not subject crane is equal to the maximum moment of the crane
the crane to side loading. A side load can tip the crane or available to resist overturning. This balance point or point of
cause it to fail structurally. instability for a crane does not depend on “lifting” of an
outrigger but rather on comparison of the “opposing” load
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
moments.
The occurrence of an outrigger lifting from the ground is often
2
lifting. attributed to the natural flex in the crane’s frame. This may
happen when lifting a load in certain configurations within the
If you should encounter a tipping condition, immediately capacity limits of the Load Chart and is not necessarily an
lower the load with the hoist line and retract or elevate the indication of an unstable condition.
boom to decrease the load radius. Never lower or extend the
boom; this will aggravate the condition. Provided the crane is properly set up, the crane is in good
working condition, that all operator’s aids are properly
Use tag lines whenever possible to help control the programmed, that the qualified crane operator adheres to
movement of the load. the instructions found in the applicable Load Chart,
When lifting loads, the crane will lean toward the boom and Operator’s Manual and decals on the crane, the crane
the load will swing out, increasing the load radius. Ensure the should not be unstable.
crane’s capacity is not exceeded when this occurs.
Multiple Crane Lifts
Do not strike any obstruction with the boom. If the boom
should accidentally contact an object, stop immediately. Multiple crane lifts are not recommended.
Inspect the boom. Remove the crane from service if the Any lift that requires more that one crane must be precisely
boom is damaged. planned and coordinated by a qualified engineer.
Never push or pull with the crane boom. If it is necessary to perform a multi-crane lift, the operator
Avoid sudden starts and stops when moving the load. The shall be responsible for assuring that the following minimum
inertia and an increased load radius could tip the crane over safety precautions are taken:
or cause it to fail structurally. • Secure the services of a qualified engineer to direct the
Use only one hoist at a time when lifting loads. operation.
Always use enough parts-of-line to accommodate the load to • Use one qualified signal person.
be lifted. Lifting with too few parts-of-line can result in failure • Coordinate lifting plans with the operators, engineer, and
of the wire rope. signal person prior to beginning the lift.
Counterweight • Maintain communication between all parties throughout
the entire operation. If possible, provide approved radio
On cranes equipped with removable counterweights, ensure equipment for voice communication between all parties
the appropriate counterweight sections are properly installed engaged in the lift.
for the lift being considered.
• Use cranes and rigging of equal capabilities and use the
Do not add material to the counterweight to increase same boom length.
capacity. United States Federal law prohibits modification or
additions which affect the capacity or safe operation of the • Use outriggers on cranes so equipped.
equipment without the manufacturer’s written approval.
• Be certain cranes are of adequate lifting capacity.
[29CFR 1926.1434]
• Calculate the amount of weight to be lifted by each crane
Outrigger Lift Off and attach slings at the correct points for proper weight
distribution.
Regarding “lifting” of an outrigger pad during craning
activities, be advised that the rated loads for these cranes,
Grove Published 02-06-2012, Control # 150-06 2-7
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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL SAFETY INFORMATION
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.
Always adjust the seat and lock it in position, and fasten the Do not allow ground personnel to store their personal
seat belt securely before you start the engine. belongings (clothing, lunch boxes, water coolers, and the
like) on the crane. This practice will prevent ground
Do not wear loose clothing or jewelry that can get caught on personnel from being crushed or electrocuted when they
controls or moving parts. Wear the protective clothing and attempt to access personal belongings stored on the crane.
personal safety gear issued or called for by the job
conditions. Hard hat, safety shoes, ear protectors, reflective Job Preparation
clothing, safety goggles, and heavy gloves may be required.
Before crane use:
Crane Access • Barricade the entire area where the crane is working and
keep all unnecessary personnel out of the work area.
2
• Ensure that the crane is properly equipped including
access steps, covers, doors, guards, and controls.
WARNING
Fall Hazard! • Conduct a visual inspection for cracked welds, damaged
components, loose pins/bolts, and wire connections.
Working at elevated heights without using proper fall
Any item or component that is found to be loose or
protection can result in severe injury or death.
damaged (broken, chipped, cracked, worn-through, etc.)
Always use proper fall protection as required by local, must be repaired or replaced. Inspect for evidence of
state or federal regulations. improper maintenance (consult your Service Manual).
You must take every precaution to ensure you do not slip • Check for proper functioning of all controls and operator
and/or fall off the crane. Falling from any elevation could aids (e.g. LMI).
result in serious injury or death. • Check all braking (e.g. wheel, hoist, and swing brakes)
Never exit or enter the crane cab or deck by any other means and holding devices before operation.
than the access system(s) provided (i.e., steps and grab You must ensure that the outriggers and stabilizers are
handles). Use the recommended hand-holds and steps to properly extended and set before performing any lifting
maintain a three-point contact when getting on or off the operations. On models equipped with outriggers that can be
crane. pinned at the mid-extend position, the outriggers must also
If necessary, use a ladder or aerial work platform to access be pinned when operating from the mid-extend position.
the boom nose. Clear all personnel from the outrigger area before extending
Do not make modifications or additions to the crane’s access or retracting the outriggers. Carefully follow the procedures
system that have not been evaluated and approved by in this Operator’s Manual when extending or retracting the
Manitowoc Crane Care. outriggers. Death or serious injury could result from improper
crane set up on outriggers.
Do not step on surfaces on the crane that are not approved
or suitable for walking and working. All walking and working Be familiar with surface conditions and the presence of
surfaces on the crane should be clean, dry, slip-resistant, overhead obstructions and power lines.
and have adequate supporting capacity. Do not walk on a
surface if slip-resistant material is missing or excessively Working
worn. Operator shall be responsible for all operations under his/her
Do not use the top of the boom as a walkway. direct control. When safety of an operation is in doubt,
operator shall stop the crane’s functions in a controlled
Do not step on the outrigger beams or outrigger pads (floats) manner. Lift operations shall resume only after safety
to enter or exit the crane. concerns have been addressed or the continuation of crane
Use the hoist access platform (if equipped) when working in operations is directed by the lift supervisor.
the hoist area. Know the location and function of all machine controls.
Wear shoes with a highly slip-resistant sole material. Clean Make sure all persons are away from the crane and the
any mud or debris from shoes before entering the crane cab/ Travel Select Lever is in the “N” (Neutral) position with the
operator’s station or climbing onto the crane superstructure. parking brake engaged before starting the engine.
Excessive dirt and debris on the hand-holds, access steps,
Grove Published 02-06-2012, Control # 150-06 2-17
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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL SAFETY INFORMATION
Overload less than 25%
1 Sheaves Inspect all for damage.
Luffing
2 Mechanism/ Inspect for damage/leaks.
Cylinder
Collar-wear
3 Inspect all for damage.
pads
Overload from 25% to 49%
1 Sheaves Inspect all for damage. 2
Luffing
2 Mechanism/ Inspect for damage/leaks.
Cylinder
Collar-wear
3 Inspect all for damage.
pads
4 Collar-welds Inspect all for cracks.
Telescopic Inspect for bent or twisted sections. Check the boom
5
Sections for straightness.
Lift Cylinder
6 Inspect for bends or cracked welds.
Head Area
Turret-Base
7 Inspect for cracked welds.
Section
Locking Area
8 Inspect for elongated holes.
(Pin Booms)
9 Welds Inspect for cracks.
Inspect for cracked paint which could indicate twisted,
10 Paint
stretched, or compressed members.
Grove Published 02-06-2012, Control # 150-06 2-27
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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL OPERATING CONTROLS
SECTION 3
OPERATING CONTROLS
The following paragraphs describe all the available (standard pressure on a scale calibrated from zero (0) to 80 psi. It
and optional) controls and indicators located in the receives a signal from the crane’s electronic operating
superstructure cab. Some machines may not be equipped system which receives the signal from the engine ECM via
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 J1939.
international symbols to label the various controls.
Water Temperature Gauge
The numbers in parenthesis ( ) represent the index number
from (Figure 3-1, Figure 3-2 and Figure 3-3). The two types The engine coolant temperature (TEMP) gauge is located on
of controllers are shown in Figure 3-3. the lower left of the gauge cluster. The gauge indicates the
engine coolant temperature on a scale calibrated from 100°
NOTE: Unless otherwise noted, the “engine” called out in to 240° F. The gauge receives a signal from the crane’s
this section is the superstructure engine. electronic operating system which receives the signal from
the engine ECM via J1939.
SUPERSTRUCTURE CAB CONTROLS AND
Fuel Quantity Gauge
INDICATORS
The fuel quantity (FUEL) gauge is located on the upper left of
NOTE: The numbers in ( ) represent the index number
the gauge cluster. The gauge indicates the quantity of fuel in
from Figure 3-1.
the tank and has a scale calibrated from empty (E) to full (F).
All rocker switches contain one or two LEDs in the The fuel quantity gauge receives a signal from the crane’s
switch for illumination. electronic operating system which monitors a sending unit in
All indicators will light solid, all at the same time for
the fuel tank. 3
approximately two seconds as a diagnostic test Emergency Stop Switch
when the ignition switch is at on. If any indicator
fails to light, replace it immediately. The emergency stop switch (3) is located on the right side of
the front console. Push in on the switch to remove power and
Tachometer with Hourmeter stop the engine.
The tachometer/hourmeter (1) is located on the right side of Ignition Switch
the front console and registers engine RPM and speed of
rotation. The tachometer is calibrated in rpm x 100 with a The ignition switch (4) is located on the right side of the front
range of zero (0) to 35. It receives a signal from the crane’s console. The switch is key operated with four positions:
electronic operating system which receives the signal from accessory (left position), off (vertical position), run (position
the engine ECM via J1939. between vertical and right), and start (right position).
The hourmeter at the bottom of the tachometer is used to With the ignition switch in the off position, most electrical
register hours of engine operation. power is off except for the gauge and panel lights, work
lights, cab dome lights, and cab 12V accessory outlet.
Gauge Cluster
The accessory position energizes all electrical components
The gauge cluster (2) is located on the left side of the front except the engine ECM. The run position is the same as
console assembly and contains a voltmeter, oil pressure accessory except the engine ECM is energized. The start
gauge, water temperature gauge and a fuel quantity gauge. position energizes the starter relay which in turn energizes
the cranking motor solenoid and cranks the engine for
Voltmeter starting. The switch will return to run when the switch is
The voltmeter (VOLTS) is located on the lower right of the released after the engine is started. Turn the switch to off to
gauge cluster. With the ignition switch in the run (between shut down the engine.
vertical and far right) position and before starting the engine,
the voltmeter indicates the condition of the batteries. With Engine Stop/Module Off Line Indicator
the engine running, the voltmeter indicates output voltage of The engine stop/module off line indicator (5) is located on the
the alternator. The voltmeter scale is from 10 to 16 volts. top left side of the front console. The top portion of the switch
is the stop indicator. It lights red when energized by a signal
Engine Oil Pressure Gauge
from the engine ECM that signifies a serious engine problem
The engine oil pressure (OIL) gauge is located on the upper that requires the vehicle and the engine to be stopped as
right of the gauge cluster. The gauge indicates the engine oil
Grove Published 02-06-2012, Control # 150-06 3-1
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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL OPERATING CONTROLS
ADDITIONAL CONTROLS AND INDICATORS Extend/Retract Switch
The following paragraphs describe the outrigger control The extend/retract switch (3) will operate the outrigger
panels located on each side of the crane carrier. The beams or the stabilizers. After positioning the desired
numbers in parentheses () represent the index number from selector switch (beam or stabilizer), position the extend/
Figure 3-5. retract switch to move the selected component in the desired
direction.
Outrigger Control Summary
In addition, when the switch is positioned to either position, a
There is an outrigger control panel located on each side of signal is sent to the engine ECM to increase engine speed
the crane carrier. Each control panel contains switches for above idle for operation of the outriggers.
extending and retracting the outrigger beams and for raising
and lowering the outrigger stabilizer (jack) cylinders on all Stabilizer Selector Switch
sides of the crane.
The stabilizer selector switch (4) selects which stabilizer is to
A push button emergency stop switch (5) is installed on the be operated.
panel.
Emergency Stop Switch
A level (6) is installed on a bracket near the outrigger
controls. The emergency stop switch (5) is located on the center of the
outrigger panel. Push the switch to remove all electrical
Outrigger Control Panel power from the controls and stop the engine.
There is one outrigger control panel (1) on each side of the Pull switch out to resume operation.
unit’s frame. The panel on the right side operates the
If the emergency stop switch on either outrigger control
outrigger beams for that side only. The panel on the left side
operates the outrigger beams for that side only. The
panel or in the superstructure cab is not pulled out for normal
operation, the emergency stop indicator in the
3
stabilizers may be operated from the left or right side of the
superstructure cab will light red if operation of any function is
unit.
attempted.
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.
Grove Published 02-06-2012, Control # 150-06 3-11
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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL OPERATING CONTROLS
Elevating and Lowering the Boom Extending the Boom
Elevating the Boom
WARNING
WARNING When extending the boom, simultaneously let out the
Keep the area above and below the boom clear of all hoist cable to prevent two-blocking the boom nose and
obstructions and personnel when elevating the boom. hookblock.
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. DANGER
Check the load chart for the maximum load at a given
Lowering the Boom
radius, boom angle, and length before extending the
boom with a load.
WARNING
Keep the area beneath the boom clear of all obstructions
CAUTION
and personnel when lowering the boom. Before extending the boom, ensure the large access
cover on top of the boom base section is installed.
WARNING
1. To extend the boom push the controller on the left hand
armrest forward and hold until the boom reaches the
3
Long cantilever booms can create a tipping condition, desired length.
even when unloaded and in an extended, lowered Retracting the Boom
position.
WARNING WARNING
When retracting the boom, the load will lower unless the
When lowering the boom, simultaneously let out the hoist
hoist cable is taken in at the same time
cable to prevent two-blocking the boom nose and hook
block.
To retract the boom, pull the controller on the left armrest
back and hold until the boom retracts to the desired position.
Telescope Control Pedal
CAUTION
The telescope control pedal located to the left of the throttle
The closer the load is carried to the boom nose, the more
pedal is used on cranes equipped with an auxiliary hoist.
important it becomes to simultaneously let out the hoist
Push on the top of the pedal to extend the boom or push on
cable as the boom is lowered.
the bottom of the pedal to retract the boom.
To lower the boom, push the controller on the right hand Lowering And Raising The Hoist Cable
armrest to the right (lowers the boom) and hold until the
boom is lowered to the desired position.
Telescoping the Boom
WARNING
NOTE: The telescope function is controlled by a foot pedal Keep the area beneath the load clear of all obstructions
if the crane is equipped with an auxiliary hoist. and personnel when lowering or raising the cable (load).
Grove Published 02-06-2012, Control # 150-06 3-21
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TM500E-2 SUPERSTRUCTURE OPERATOR’S MANUAL SET-UP AND INSTALLATION
To Hoist
6710-2
7.9 M (26 Ft) Telescope
Boom Extension
To Hoist
4
6685-7
13.7 M (45 Ft) Telescope
Boom Extension
FIGURE 4-4 continued
Grove Published 02-06-2012, Control # 150-06 4-5
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TM500E-2 OPERATOR’S MANUAL LUBRICATION