PDF Operator's Manual Manitowoc Grove Crane TM500E-2 Carrier - 957 KB
Ensure the safe and efficient operation of your Manitowoc Grove TM500E-2 crane carrier with this official operator's manual.
This guide covers all controls, safety systems, setup procedures, and daily maintenance checks.
It is mandatory reading for any operator to ensure compliance with safety standards and to get the best performance from the crane.
Keep this manual in the cab for quick reference.
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CARRIER OPERATOR’S MANUAL 1
This manual has been prepared for and is considered part of -
TM500E-2
Crane Model Number
2
3
4
! DANGER 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
load charts, your employer’s work rules, and applicable government
regulations. 6
• 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.
© 2012 Manitowoc
Published 3-30-2012 Control # 166-07
7
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TM500E-2 CARRIER OPERATOR’S MANUAL
by the addition of operational aids or warning times and must remain in the cab (if equipped) or
devices. Indeed, you must guard against acquiring operator’s station while the crane is in use.
a false sense of security when using them. They are
T h e O p e r a t o r ’s M a n u a l s u p p l i e d w i t h a n d
there to assist, not direct the operation. Operational
considered part of your crane must be read and
aids or warning devices can be mechanical,
completely understood by each person responsible
electrical, electronic, or a combination thereof. They
f o r a s s e m b l y, d i s a s s e m b l y, o p e r a t i o n a n d
are subject to failure or misuse and should not be
maintenance of the crane.
relied upon in place of good operating practices.
No personnel shall be allowed to climb onto the
You are the only one who can be relied upon to
crane or enter the crane cab or operator’s station
assure the safety of yourself and those around you.
unless performance of their duties require them to
Be a professional and follow the rules of safety.
do so, and then only with knowledge of the operator
Remember, failure to follow just one safety or other qualified person.
precaution could cause an accident that results in
Allow No One other than the operator to be on the
death or serious injury to personnel or damage to
crane while the crane is operating or moving, unless
equipment. You are responsible for the safety of
they are seated in a two-man cab.
yourself and those around you.
Accidents
Following any accident or damage to equipment,
the Manitowoc distributor must be immediately
advised of the incident and consulted on necessary
inspections and repairs. Should the distributor not
be immediately available, contact should be made
directly with Manitowoc Product Safety at the
address below. The crane must not be returned to
service until it is thoroughly inspected for any
evidence of damage. All damaged parts must be
repaired or replaced as authorized by your
Manitowoc distributor and/or Manitowoc Crane
Care.
If this crane becomes involved in a property
damage and/or personal injury accident, Do not remove the Load Chart, this Operator’s
immediately contact your Manitowoc distributor. If Manual, or any decal from this crane.
the distributor is unknown and/or cannot be
Inspect the crane every day (before the start of each
reached, contact Product Safety at:
shift). Ensure that routine maintenance and
The Manitowoc Company, Inc. lubrication are being dutifully performed. Don’t
1565 East Buchanan Trail operate a damaged or poorly maintained crane. You
Shady Grove, PA 17256-0021 risk lives when operating faulty machinery -
Phone:888-777-3378 (888-PSR.DEPT) including your own.
Fax:717-593-5152 If adjustments or repairs are necessary, the
E-mail:[email protected] operator shall notify the next operator.
Operator’s Information Operator’s Qualifications
You must read and understand this Operator’s Qualified person is defined as one who by reason
Manual and the Load Chart before operating your of knowledge, training and experience is thoroughly
new crane. You must also view and understand familiar with crane operations and the hazards
the supplied safety video. This manual and Load involved. Such a person shall meet the operator
Chart must be readily available to the operator at all qualifications specified in Occupational Safety and
Grove Published 03-30-2012, Control # 166-07 3
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TM500E-2 CARRIER OPERATOR’S MANUAL
• Sometimes the sensing portion of the proximity Special Operating Conditions and
devices becomes confused by complex or
differing arrays of power lines and power
Equipment
sources. Never operate the crane during an electrical
Do not depend on grounding. Grounding of a crane thunderstorm.
affords little or no protection from electrical hazards. When operating near transmitter/communication
The effectiveness of grounding is limited by the size towers where an electrical charge can be induced
of the conductor (wire) used, the condition of the into the crane or load:
ground, the magnitude of the voltage and current
• The transmitter shall be deenergized OR,
present, and numerous other factors.
• Tests shall be made to determine if an electrical
Electrical Contact charge will be induced into the crane or load.
If the crane should come in contact with an • The crane must be provided an electrical
energized power source, you must: ground.
1. Stay in the crane cab. Don’t panic. • If taglines are used, they must be
non-conductive.
2. Immediately warn personnel in the vicinity to
stay away. • Every precaution must be taken to dissipate
induced voltages. Consult a qualified RF (radio
3. Attempt to move the crane away from the
frequency) Consultant. Also refer to local, state,
contacted power source using the crane’s
and federal codes and regulations.
controls which are likely to remain functional.
When operating cranes equipped with
4. Stay in the crane until the power company has
e l e c t r o m a g n e t s , y o u m u s t ta k e a d d i t i o n a l
been contacted and the power source has been
precautions. Permit no one to touch the magnet or
de-energized. No one must attempt to come
load. Alert personnel by sounding a warning signal
close to the crane or load until the power has
when moving a load. Do not allow the cover of the
been turned off.
electromagnet power supply to be open during
Only as a last resort should an operator attempt to operation or at any time the electrical system is
leave the crane upon contacting a power source. If it activated. Shut down the crane completely and
is absolutely necessary to leave the operator’s open the magnet controls switch prior to connecting
station, jump completely clear of the crane. Do or disconnec ting magnet l eads. Use only a
not step off. Hop away with both feet together. Do non-conductive device when positioning a load.
not walk or run. Lower the magnet to the stowing area and shut off
Following any contact with an energized electrical power before leaving the operator ’s cab (if
s o u r c e , th e M a ni t o w o c d i s t r i bu t o r m us t b e equipped) or operator’s station.
immediately advised of the incident and consulted
on necessary inspections and repairs. Thoroughly
inspect the wire rope and all points of contact on the PERSONNEL HANDLING
crane. Should the distributor not be immediately
available, contact Manitowoc Crane Care. The The American Society of Mechanical Engineers
crane must not be returned to service until it is issued a new American National Standard entitled,
thoroughly inspected for any evidence of damage Personnel Lifting Systems, ASME B30.23-2005.
and all damaged parts are repaired or replaced as This standard provides, “lifting and lowering of
authorized by your Manitowoc distributor or personnel using ASME B30 Standard hoisting
Manitowoc Crane Care. equipment shall be undertaken only in
circumstances when it is not possible to accomplish
the task by less hazardous means. Unless all of the
applicable requirements of this volume are met, the
lifting or lowering of personnel using ASME B30
Standard equipment is prohibited.” This new
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TM500E-2 CARRIER OPERATOR’S MANUAL
Ensure that all slings, ties, and hooks are correctly
placed and secured before raising or lowering the
load.
Be sure the load is well secured and attached to the
hook with rigging of proper size and in good
condition.
Check the hoist brake by raising the load a few
inches, stopping the hoist and holding the load. Be
sure the hoist brake is working correctly before
continuing the lift.
When lowering a load always slow down the load’s
descent before stopping the hoist. Do not attempt to
change speeds on multiple-speed hoists while the
hoist is in motion.
Watch the path of the boom and load when
swinging. Avoid lowering or swinging the boom and
load into ground personnel, equipment, or other
objects.
Lift one load at a time. Do not lift two or more
separately rigged loads at one time, even if the
loads are within the crane’s rated capacity.
Never leave the crane with a load suspended.
Should it become necessary to leave the crane,
lower the load to the ground and stop the engine
Lifting
before leaving the operator’s station.
Use enough parts of line for all lifts and check all R e m e m b e r, a l l r i g g i n g e q u i p m e n t m u s t b e
lines, slings, and chains for correct attachment.
considered as part of the load. Lifting capacities
To obtain maximum lifting capacities, the hook block vary with working areas. If applicable, permissible
must be set up with enough parts of line. Too few working areas are listed in the Load Chart. When
parts of line can result in failure of the wire rope or
swinging from one working area to another, ensure
hoist. No less than three wraps of wire rope Load Chart capacities are not exceeded. Know your
should remain on the hoist drum. When slings, ties, crane!
hooks, etc., are used, make certain they are
correctly positioned and secured before raising or Stop the hook block from swinging when unhooking
lowering the loads. a load.
Be sure the rigging is adequate before lifting. Use Swinging rapidly can cause the load to swing out
tag lines when possible to position and restrain and increase the load radius. Swing the load slowly.
loads. Personnel using tag lines should be on the Swing with caution and keep the load lines vertical.
ground. Look before swinging your crane. Even though the
Be sure good rigging practices are being used. original setup may have been checked, situations
Refuse to use any poorly maintained or damaged do change.
equipment. Never wrap the hoist cable around a Never swing or lower the boom into the carrier cab
load. (if applicable).
If using a clam bucket, do not exceed 80% of the Never push or pull loads with the crane’s boom;
crane’s capacity. never drag a load.
Make certain the boom tip is centered directly over Do not subject crane to side loading. A side load
the load before lifting. can tip the crane or cause it to fail structurally.
Grove Published 03-30-2012, Control # 166-07 23
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TM500E-2 CARRIER OPERATOR’S MANUAL
Velocity fuses are incorporated into the cab tilt
Figure 7
cylinder ports to control the cab's free fall past the
midpoint (top) when raising and lowering the cab.
The fuses also act as a safety valve to prevent the
cab from falling unchecked in the event of a
hydraulic system failure.
Never rely on the hydraulic pressure to
hold the cab in a partially open position.
Always use the safety pin in the cab tilt
lock tube to prevent serious personal
injury or death.
Figure 8 Lowering the Cab
Figure 8
Remove the safety lock pin. It may be necessary to
remove weight from the pin by operating the cab
jack pump. Do not use excessive force on either pin
or pump, pin should be free to turn in order to
remove it. Place the selector lever on the hydraulic
pump to the LOWER (pull circuit) position. Insert
the pump handle into the pump and operate the
handle in an up and down motion. The hydraulic
cylinders then lower the cab until the midpoint (top)
is reached. Once the cab has reached midpoint,
stop pumping and the cab will free fall rearward to
the fully lowered position. When the cab is lowered,
the crossbars of the cab brackets will automatically
engage the hydraulic cab latches. The weight of the
cab then triggers the hydraulic latches to lock. This
will be evident when the pins in the hydraulic
latches retract into the latch body.
AC-910-0706-01255-A
Figure 9
Remove the pump handle when not in
use. It may stick out and could cause
injury to passersby.
Remove the pump handle when not in use. It
may stick out and could cause injury to
passersby.
To stop the cab in a partially tilted position while
raising the cab, stop pumping and place the flow
valve selector in the HOLD position. Install the
safety pin in the cab tilt lock tube wherever the
holes line up.
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TM500E-2 CARRIER OPERATOR’S MANUAL
Tether straps are installed on some
Figure 21
suspension-type seats. Tether straps help secure
the seat to the floor and are intended to restrain the
seat and safety belt in case of an accident or
sudden stop.
The tethers are not adjustable.
Operating the Safety Belt
Figure 20
AC-884-0508-G010
Figure 22
If a Komfort Latch is used on the safety belt, always
adjust the belt so that there is a maximum of 1 in.
(25 mm) of slack between the belt and chest (about
two fingers’ width). If a larger slack is allowed, in
the event of a collision, the effectiveness of the
AC-884-0508-G009 safety belt is decreased. Operation of the clip is
described in Komfort Latch Operation.
Figure 21
Make sure the safety belt is completely retracted
To fasten the safety belt, pull the belt out from the and out of the way when not in use.
retractor and insert the latch into the buckle. Verify
proper lock of the latch by pulling on the latch. Inspection
Adjust the slack by pulling on the top part of the belt Check the belts, buckles, latch plates, retractors,
until the lower part, or the part that crosses the lap, anchors and guide loops to ensure that they are
is snugly adjusted. Release the top part and let the working properly. Look for loose/damaged parts
retractor pull the belt in. (without disassembling) that could keep the
restraint system from working properly. If the safety
The lap portion of the safety belt should be worn belt, retractor and hardware were in use during a
low across the pelvic region (hip bone) and collision, they must be replaced. The restraint
adjusted snugly. Never adjust the lap belt across system anchoring fasteners must be replaced if
the abdomen. A push button on the buckle is used necessary. If there is any doubt about the restraint
to release the safety belt latch by pushing in the system’s effectiveness, replace the entire safety
button release on the buckle. belt assembly.
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TM500E-2 CARRIER OPERATOR’S MANUAL
Figure 43
Failure to take necessary action when
the Stop Engine telltale is on can result
in automatic engine shutdown and loss
of power steering assist. Crane crash
can occur causing serious personal
injury or death. Figure 44
If the fuel level is depleted to a specific level, the
Low Fuel telltale will illuminate. An alarm will sound
to indicate that the fuel level is low.
Failure to observe correct precautions
when the Stop Engine telltale lights up
solidly could result in serious damage to
the engine and/or other components.
Use ultra low sulfur diesel fuel only.
Fuel Level Using a diesel fuel that is not ultra low
Figure 42 sulfur will damage the diesel particulate
filter and can damage the other emission
system components.
Note: Ultra low sulfur diesel is not required
ULTRA with the Export Engine Option.
LOW SULFUR
E FUEL ONLY F Reserve Pressure “A” & “B”
Figure 44
FUEL
LEVEL D
AC-380-0701-01155-A
Figure 43
The gauge is connected to a sending unit in the fuel
tank via the gateway module on the right-side
frame rail.
AC-382-0505-00863-B
Figure 45
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TM500E-2 CARRIER OPERATOR’S MANUAL
Note: The wiper motor contains a built-in 2. When the desired crane speed has been
protective thermal switch that will shut down reached, move the SET/RES switch to the SET
the motor if it is overloaded. The continued position.
operation of the wipers over a dry 3. If the crane speed needs to be increased, push
windshield for an extended period may the SET/RES switch upward to accelerate the
overload the wiper motor sufficiently to trip crane. The crane speed will increase as long as
the thermal switch. the switch is held. Release the switch when the
The electric windshield washer is also operated by desired speed has been reached.
the Windshield Wiper/Washer switch. Depress and 4. To reduce the crane speed, push the SET/RES
hold the rocker switch to operate the washer. switch downward to decelerate the crane. The
Release the switch to stop. crane speed will decrease as long as the switch
is held. Release the switch when the desired
Cruise Control speed has been reached.
Note: As an option, some cranes may be
Figure 71
equipped with Base PTO Mode. Base PTO
Mode allows the crane to be operated with
the cruise control engaged below 30 mph.
This feature is a function of the electronic
engine control unit. Refer to the engine
manufacturer’s operator’s manual for more
information.
Note: The Cruise Control switches may be
used to control more functions than just the
cruise control. Ensure that you are familiar
with the operating characteristics of the
crane and any additional functions the
Cruise Control switches have control over.
Figure 72
Figure 72
Engine Diagnostic Active Regeneration
Figure -2
7176-4
Figure 73
Figure 74
The Cruise Control switches are located on the
center switch panel. This switch enables the operator to start manual
exhaust regeneration. (Despite its label, this switch
To engage the cruise control and set the crane is not involved in engine diagnostics.)
speed: Note: The Engine Diagnostic Active
1. Set the cruise control ON/OFF switch to the ON Regeneration Switch is not used with the
position. Export Engine Option.
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TM500E-2 CARRIER OPERATOR’S MANUAL
Cold weather operation does require changes in
Figure 87
operating practices, maintenance procedures,
lubrication and fuel. Additions to the crane, such as
heated fuel filters, fuel tank heater, engine block
heater, etc., can make winter operation easier.
Contact your Manitowoc dealer for the correct
accessories and installation information.
If satisfactory engine temperature is not 120 V, 20 A 120 V, 30A
maintained, increased engine wear will result in
higher maintenance cost. Accessories should be AC-333-0509-G016
designed to be easily disconnected when switching
to driving in warmer weather so they do not affect Figure 92
the operation of the engine.
The engine block heater runs on 120 V and has an
Recommendations for cold weather operations: easily accessible plug, typically located around the
grille area. The plug will hook up to a normal
• When starting the engine in temperatures below extension cable. Your engine may be equipped with
32°F (0°C), use engine lubricants of lower a 20 amp or 30 amp power receptacle.