Manitowoc 500E2 Instructions Manual

OPERATOR MANUAL

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.

• Y ou are sure that all safety signs, guards, and other safety features are
in place and in proper condition.

• The Operator Manual and Load Chart are in the holder provided on
crane.

DANGER

!

Supplement

Crane Warm-up Procedures

Reference Only

© 2015 Manitowoc

Published 3-10-2015, Control # 571-00

SECTION CONTENTS

Crane Warm-up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Swing Drive and Turntable Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Hydraulic Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Reference Only

This Supplement provides information regarding the proper
warm-up procedures for operating the crane in colder
temperatures. The information pro vided her e sup plements
the Operator and Service Manuals and must b e used in
conjunction with these manuals.

CRANE WARM-UP PROCEDURES

The following procedures detail the actions that must be
taken to properly warm the different crane components
before operating the crane.

NOTE: For temperatures below -9°C (15°F) refer to arctic

lubricants and conditions in th e Operator and
Service Manuals.

Before starting the crane, ensure the appropriate lubricants
are used to provide lubrica tion for th e prevailing ambient
temperatures in which the crane will operate in (a list of
lubricants and their temperature ranges can be found in the
Lubrication section of your crane’s Operator Manual, by
contacting your local Manitowoc distributor, or by contacting
Manitowoc Crane Care directly).

Operating the transmission with a sump temperature below
normal operating temperature is limited to:

• operating in the neutral gear or

• driving with an unloaded crane while not exceeding

1500 engine RPM and not exceeding half throttle.

Alternate Warm-up Procedures for Tr uck Mount (TM/
TMS) Cranes:

1. Setup the crane on outriggers.

2. Engage the transmission and allow crane to run at idle

until the temperature of the transmission sump reaches
normal operating temperature.

Hoist

Performing a warm-up procedure is recommended at every
startup and is required at ambient temperatures below 4°C
(40°F).

Warm-up Procedures:

1. Without operating the hoist function, warm the hydraulic

oil (see Hydraulic Oil System, page 2).

CAUTION

Crane Damage Hazard!

Operating the crane with the inc orrect lubricants and
fluids for the prevailing ambient temperature and/or fail ing
to adequately w arm the crane prior to cold weather
operation can lead t o a f ailu re o f a crane co mpo ne nt o r
system.

Always use Manitowoc recom mended lubrica nts and
fluids for the prevailing ambient temperature and properly
start and warm the crane using the cold weather
procedures found in this Operator Manual and
supplement before operating the crane at full load.

Engine

NOTE: For National Crane engine warm-up procedures,

refer to chassis manufacturer’s manual.

Warm-up Procedures for All Temperature Ranges:

1. Upon startup, allow the engine to idle for 3 to 5 minutes

before operating with a load.

2. Cold Engine Startup: After allowing the engine to warm
by idling it for 3 to 5 minutes, slowly increase the engine
speed to provide adequate lubrication to the bearings
and to allow the oil pressure to stabili ze.

Reference Only

T ransmission

NOTE: For National Crane transmission warm-up

procedures, refer to chassis manufacturer’s
manual.

2. Once the hydraulic system is warm, operate the
unloaded hoist, in both directions, at low speeds several
times to prime all hydraulic lines with warm hydraulic oil
and to circulate gear lubricant through the planetary
gear sets.

Swing Drive and T urnt able Bearing

Warm-up Procedures for Temperatures Above -7°C
(20°F):

1. Setup the crane on fully extended outriggers, with the

boom fully retracted and near maximum lift angle with no
load applied.

2. Rotate the superstructure at a speed of less than one
RPM for at least one complete revolution in one
direction, then rotate the superstructure at a speed of
less than one RPM for at least one complete revolution
in the opposite direction.

Warm-up Procedures for Temperatures Below -7°C
(20°F):

1. Ensure the boom is fully retracted and near maximum lift

angle with no load applied.

2. Rotate the superstructure at a speed of less than one­half RPM for at least two complete revolutions in one
direction, then rotate the superstructure at a speed of
less than one-half RPM for at least two complete
revolutions in the opposite direction.

National Crane Published 3-10-2015, Control# 571-00 1

Axles

NOTE: For National Crane axle warm-up procedures, refer

to chassis manufacturer’s manual.

Hydraulic Oil System

Operating Limits and Warm-up Procedures:

• From 4°C to -10°C (40°F to 15°F): Crane operation

without
medium function speed (joystick position) until the fluid
reaches at le a st 10 °C ( 50°F). It is th e n r eco mm en de d
that all crane functions be cycled to remove cold fluid
from all components and cylinders of the hydraulic
system. If there is any unusual sound coming from the

a load is allowed with medium engine RPM and

crane’s hydraulic pumps or motors, s top the ope ra tion
and engine immediately and contact a Manitowoc
distributor.

• From 10°C to 4°C (50°F to 40°F): Crane operation with
a load is allowed with medium engine RPM and medium
function speed (joystick position) until the fluid reaches
at least 10°C (50°F).

• From 95°C to 10°C (200°F to 50°F): Crane operation
with a load is allowed with no restrictions.

• Above 95°C (200°F): No crane operation is allowed. Let
the crane’s hydraulic oil cool by running the engine at
idle with no functions actuated.

Reference Only

2 Published 3-10-2015, Control# 571-00

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.

• Y ou are sure that all safety signs, guards, and other safety features are
in place and in proper cond

ition.

• The Operator’s Manual and Load Chart are in the holder provided on
crane.

DANGER

!

1

2

3

4

5

6

National Crane

OPERATOR MANUAL

This manual has been prepared for and is considered part of the

500E2

This Manual is divided into the following sections:

SECTION 1 INTRODUCTION
SECTION 2 SAFETY PRECAUTIONS
SECTION 3 OPERATING CONTROLS AND PROCEDURES
SECTION 4 SET-UP
SECTION 5 LUBRICATION PROCEDURE AND CHARTS
SECTION 6 MAINTENANCE CHECKLIST

NOTICE

The crane serial number is the only me thod your distribu tor or th e factor y
has of providing you with correct parts and service information.

The crane serial number is identified on the builder’s decal att ached to the
right side of the turret. Always furnish crane serial number when
ordering parts or communicating service problems with your distributor or
the factory.

Reference Only

© 2011 Manitowoc

10-20-2011 Control # 111-05

CALIFORNIA

PROPOSITION 65 WA RNING

Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

CALIFORNIA

PROPOSITION 65 WA RNING

Battery posts, terminals, and related accessories contain
chemical lead and lead compounds, chemicals known to
the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.

Reference Only

500E2 OPERATOR’S MANUAL TABLE OF CONTENTS

1

SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

New Owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions

Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Accidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operator’s Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operator’s Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Load Moment Indication (LMI) Systems (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . 2-4

Anti-Two-Blocking Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Work Area Definition System (WADS) (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Outrigger Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Multiple Crane Lifts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Set-Up and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Special Operating Conditions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Transporting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Reference Only

Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Personal Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Job Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Hand Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Parking and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Shut-Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Temperature Effects on Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

National Crane 1-1

TABLE OF CONTENTS OPERATOR’S MANUAL 500E2

Overload Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Superstructure Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . .Operating Controls And Procedures

Truck Cab Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Unattended Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Crane Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Swing Speed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Boom Telescope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Stabilizers Up/Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Stabilizers Extend/Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Foot Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hydraulic Capacity Alert System (HCA) Load Range Gauge . . . . . . . . . . . . . . . . . 3-3

HCA Overload Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Anti-Two-Block/Jib Overload Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Key Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Override Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Load Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Boom Angle Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Boom length Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Outrigger Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hoist System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Using Multiple Part Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

General Rules When Operating Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Lifting the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Optional Hoist Burst of Speed (BOS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Anti-Two Block System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Outrigger Monitoring System (OMS) (Optional—Standard in North America) . . . . . . . . 3-6

Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

HCA Load Range Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

HCA System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Pressure Sensing Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Reference Only

Jib Load Limiting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Anti-two-block Weight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Installing Cable On The Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Wedge Socket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

1-2

SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set-Up

Equipment Familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Equipment Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Pre-Operation Inspection and Calibration Verification. . . . . . . . . . . . . . . . . . . . . . . 4-1

1

500E2 OPERATOR’S MANUAL TABLE OF CONTENTS

Work Site Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Before Leaving the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Lifting Over the Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Lifting Over the Front with a Front Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Before Making the Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Reading and understanding the load Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Set-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Determining Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Load Determination Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Jib Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Side Folding-Swing Around Jib Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Deployment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Jib Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Jib Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Jib Jack Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Adjustable Swing Speed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Procedure and Charts

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Arctic Conditions Below -18°C (0°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Chassis Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Extreme Pressure Multipurpose Gear Lubricant (EPGL) . . . . . . . . . . . . . . . . . . . . . 5-1

Open Gear Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Chassis Grease Low Temp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Anti-wear Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Hydraulic OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Standard Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Intermediate Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Wide Range Intermediate Hydraulic Oil.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Arctic Hydraulic Oil.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Inner Boom Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Side and Bottom Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Hoist Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Hoist Brake Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Wire Rope Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Reference Only

SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Checklist

Crane Inspection And Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Daily Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Weekly Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Monthly Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Periodic/Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

Special Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

Hoist Cable Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Keeping Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

National Crane 1-3

TABLE OF CONTENTS OPERATOR’S MANUAL 500E2

Precautions and Recommendations During Inspection. . . . . . . . . . . . . . . . . . . . . . 6-4

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Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Wire Rope Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Care of Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Rope Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Crane Adjustments and Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Jib Jack Service and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Rust Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Oil Cooler Service and Maintenance (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Jib Load Limiting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Single Character Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Hydraulic System Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Jib Jack Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Tire Load And Inflation Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

HCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Hoist Speed and Pull. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Crane Operating Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

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Reference Only

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500E2 OPERATORS MANUAL INTRODUCTION

1

SECTION 1

INTRODUCTION

SECTION CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Supplemental Information. . . . . . . . . . . . . . . . . . . 1-1

GENERAL

This manual has been compiled to assist you in properly
operating and maintaining your Model 500E2 Series
National Crane.

Before placing the crane in service, all operators and
persons working around the crane must thoroughly read and
understand the contents of the manual pertaining to Safety,
Operation and Maintenance. Before moving a vehicle
equipped with the crane, information relating to transporting
the vehicle must be read and observed.

This manual must be retained with the machine for use by
subsequent operating personnel.

Information in this manual does not rep lac e fe de ra l, state or
local regulations, safety codes or insurance requirements.

The National Crane has been designed for maximum
performance with minimum maintenance. With proper care,
years of trouble-free service can be expected.

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

parts for options such as remote controls, augers, varying
control configurations, baskets, grapples, etc. is included in
separate sections of this manual, if applicable.

Engine operating procedures and routine maintenance
procedures are supplied in a separate manual with each
crane, and should be referred to for detailed information.

Whenever a question arises regarding your National product
or this publication, please consult your National Dealer for
the latest information. Your National Dealer is equipped with
the proper tools, necessary National parts and trained
service personnel to properly maintain and service your
crane.

DANGER

Failure to observe all the instructions contained in this
manual will result in death or serious injury to the operator
or bystanders or damage to the equipment.

Constant improvement and engineering progress makes it
necessary that we reserve the right to make specification
and equipment changes without notice.

National Crane and our Dealer Network want to ensure your
satisfaction with our products and customer support. Your
local dealer is the best equipped and most knowledgeable to
assist you for parts, service and warranty issues. They have
the facilities, parts, factory trained personnel, and the
information to assist you in a timely manner. We request that
you first contact them for assistance. If you feel you need
factory assistance, please ask the dealer’s service
management to coordinate the contact on your behalf.

Reference Only

Supplemental Information

Supplemental Information regarding Safety and Operation,
Specifications, Service and Maintenance, Installation, and

National Crane Published 10-20-2011 Control # 111-05 1-1

Safety Information

A Safety Compact Disc (CD) which includes sections on
Operation, Safety and Maintenance for Nation al Crane
operators and owners is supplied when the crane is
purchased new. Additional copies are available from your
local distributor.

New Owner

If you are the new owner of a Manitowoc crane, please
register it with Manitowoc Crane Care so we have the ability
to contact you if the need arises. Go to:
www.manitowoccranes.com/MCG_CARE/Includes/EN/
changeOfOwnership.cfm and complete the form.

INTRODUCTION OPERATORS MANUAL 500E2

Item Component

1Hoist
2 Boom
3 Sheaves
4 Boom Rest

5 Stabilizers
6 Hydraulic Reservoir
7 Control Console
8 Outriggers

Item Component

NOTICE TO OWNER/USER

Should this crane become involved in a property damage accident,
please contact your local National distributor immediately and relate
details of incident including serial number of crane. The Dealer will notify
National Crane Corporation.

If accident involves personal injury notify your local distributor and
immediately contact the National Crane Corporation Manager of
Product Safety and Reliability at the contact numbers listed in the front
of this Handbook.

500E2 Series Major Components

Reference Only

1-2 Published 10-20-2011 Control # 111-05

2

500E2 OPERATORS MANUAL SAFETY PRECAUTIONS

SECTION 2

SAFETY PRECAUTIONS

SECTION CONTENTS

Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . 2-1

Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Accidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operator’s Information. . . . . . . . . . . . . . . . . . . . . . 2-2

Operator’s Qualifications. . . . . . . . . . . . . . . . . . . . 2-3

Operational Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Load Moment Indication (LMI) Systems

(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Anti-Two-Blocking Device. . . . . . . . . . . . . . . . . . . 2-4

Work Area Definition System (WADS)

(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Crane Stability/Structural Strength. . . . . . . . . . . . 2-5

Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Outrigger Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Multiple Crane Lifts. . . . . . . . . . . . . . . . . . . . . . . . 2-8

Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . 2-8

Set-Up and Operation. . . . . . . . . . . . . . . . . . . . . 2-10

Electrocution Hazard Devices. . . . . . . . . . . . . . . 2-10

Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Special Operating Conditions and Equipment . . 2-11

Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . 2-11

Environmental Protection. . . . . . . . . . . . . . . . . . . 2-12

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . 2-13

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Transporting the Crane. . . . . . . . . . . . . . . . . . . . . 2-16

Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Personal Considerations . . . . . . . . . . . . . . . . . . . 2-18

Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Parking and Securing . . . . . . . . . . . . . . . . . . . . . . 2-22

Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Cold Weather Operation . . . . . . . . . . . . . . . . . . . . 2-22

Temperature Effects on Hydraulic Cylinders . . . 2-23

Overload Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-25

Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Superstructure Inspection . . . . . . . . . . . . . . . . . . 2-28

Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-30

SAFETY MESSAGES

Reference Only

safety alert symbol and a signal word to identify the hazard’s
degree of seriousness.

General

Safety Alert Symbol

The importance of safe operation and maintenance cannot
be overemphasized. Carelessness or neglect on the part of
operators, job supervisors and planners, rigging personnel,
and job site workers can result in their death or injury and
costly damage to the crane and property.

To alert personnel to hazardous operating practices and
maintenance procedures, safety messages are used
throughout the manual. Each safety message contains a

National Crane Published 10-20-2011 Control # 111-05 2-1

Become alert - your safety is involved! Obey all safety
messages that follow this symbol to avoid possible death
or injury .

This safety alert symbol means ATTENTION!

SAFETY PRECAUTIONS OPERATORS MANUAL 500E2

Signal Words

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DANGER

Identifies hazards that will result in death or serious injury
if the message is ignored.

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WARNING

Identifies hazards that may result in death or serious
injury if the message is ignored.

Identifies hazards that could result in minor or moderate
injury if the message is ignored.

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CAUTION

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CAUTION

Without the safety alert symbol, identifies hazards that
could result in property damage if the message is ignored.

NOTE: Emphasizes operation or maintenance

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procedures.

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failure or misuse and should not be relied upo n in place of
good operating practices.

You are the only one who can be relied upon to assure the
safety of yourself and those ar ou nd you. Be a professional
and follow the rules of safety.

Remember, failure to follow just one safety precaution could
cause an accident that results in death or serious injury to
personnel or damage to equipment. You are responsible for
the safety of yourself and those around you.

ACCIDENTS

Following any accident or damage to equipment, the
Manitowoc dealer must be immediately advised of the
incident and consulted on necessary inspections and
repairs. Should the dealer 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 dealer and/or Manitowoc
Crane Care.

If this crane becomes involved in a property damage and/or
personal injury accident, immediately contact your
Manitowoc dealer. If the dealer is unknown and/or cannot be
reached, contact Product Safety at:

The Manitowoc Company, Inc.

1565 East Buchanan Trail
Shady Grove, PA 17256-0021

GENERAL

It is impossible to compile a list of safety precautions
covering all situations. However, there are basic principles
that must be followed during your daily routine. Safety is
your primary responsibility, since any piece of equipment
is only as safe as the person at the controls.

Read and follow the information located in Model Specific
Information near the end of this section.

This information has been provided to assist in promoting a
safe working atmosphere for yourself and those around you.
It is not meant to cover every conceivable circumstance
which could arise. It is intended to present basic safety
precautions that should be followed in daily operation.

Because you are the only part of the crane that can think and
reason, your responsibility is not lessened by the addition of
operational aids or warning devices. Indeed, you must guard
against acquiring a false sense of security when using them.
They are there to assist, not direct the operation. Operational
aids or warning devices can be mechanical, electrical,
electronic, or a combination thereof. They are subject to

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Phone: [phone] (888-PSR.DEPT)
Fax: [phone]
E-mail: [e-mail]

OPERATOR’S INFORMATION

You must read and understand this Operator’s Manual and
the Load Chart before operating your new crane. You must
also view and understand the supplied safety video. This
manual and Load Chart must be readily available to the
operator at all times and must remain in the cab (if equipped)
or operator’s station while the crane is in use.

The Operator’s Manual supplied with and considered part of
your crane must be read and completely understood by each
person responsible for assembly, disassembly, operation
and maintenance of the crane.

No personnel shall be allowed to climb onto the crane or
enter the crane cab or operator’s station unless performance
of their duties require them to do so, and then only with
knowledge of the operator or other qualified person.

Allow No One
while the crane is operating or moving, unless they are
seated in a two-man cab.

other than the operator to be on the crane

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2

500E2 OPERATORS MANUAL SAFETY PRECAUTIONS

An untrained operator subjects himself and others to death
or serious injury.

Y ou must not operate this machine unless:

Do not remove the Load Chart, this Operator’s Manual, or

any decal from this crane.
Inspect the crane every day (before the start of each shift).

Ensure that routine maintenance an d lubricat ion are being
dutifully performed. Don’t operate a damaged or poorly
maintained crane. You risk lives when operating faulty
machinery - including your own.

If adjustments or repairs are necessary, the operator shall
notify the next operator.

OPERATOR’S QUALIFICATIONS

Qualified person is defined as one who by reason of

knowledge, training and experience is thoroughly familiar
with crane operations and the hazards involved. Such a
person shall meet the operat or qualif ications s pecified in
Occupational Safety and Health Administration (OSHA)
Regulations (United States Federal Law), in ASME B30.5
American National Standard, or in any other applicable
federal, state or local laws.

Ensure that all personnel working around the crane are
thoroughly familiar with safe operating practices. You must
be thoroughly familiar with the location and content of all
placards and decals on the crane. Decals provide important
instructions and warnings and must be read prior to any
operational or maintenance function.

You must be familiar with the regulations and standards
governing cranes and their operation. Work practice
requirements may vary slightly between governme nt
regulations, industry standards, and employer policies so a
thorough knowledge of all such relevant work rules is
necessary.

Reference Only

• You have been trained in the safe operation of this
machine.

• You read, understand, and follow the safety and
operating recommendations contained in the
manufacturer’s manuals, your employer’s work rules,
and applicable government regulations.

• You are sure the machine has been inspected and
maintained in accordance with the manufacturer’s
manuals and is operating properly .

• You are sure that all safety signs, guards, and other
safety features are in place and in proper condition.

Do not attempt to operate the crane unless you are trained
and thoroughly familiar with all operational functions.
Controls and design may vary from crane to crane; therefore,
it is important that you have specific training on the particular
crane you will be operating.

Training is ESSENTIAL for proper crane operation. Never
jeopardize your own well-being or that of others by
attempting to operate a crane on which you have not been
trained.

You must be mentally and physically fit to operate a crane.
Never attempt to operate a crane while under the influen ce
of medication, narcotics, or alcohol. Any type of drug could
impair physical, visual and mental reactions, and
capabilities.

As operator of this crane, you are granted the authority to
stop and refuse to lift loads until safety is assured.

OPERATIONAL AIDS

Manitowoc remains committed to providing reliable products
that enable users and operators to safely lift and position
loads. Manitowoc has been an industry leader in the
incorporation of operational aids into the design of its cranes.
Federal law requires that cranes be properly maintained and

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SAFETY PRECAUTIONS OPERATORS MANUAL 500E2

kept in good working condition. The manuals that Manitowoc
provides that are specific for each crane and the
manufacturer’s manuals for the operational aids shall be
followed. If an operational aid should fail to work properly , the
crane user or owner must assure that repair or recalibration
is accomplished as soon as is rea sonably possible. If
immediate repair or recalibration of an operational aid is not
possible and there are ex ceptional circu mstances whic h
justify continued short-term use of the crane when
operational aids are inoperative or malfunctioning, the
following requirements shall apply for continued use or
shutdown of the crane:

• Steps shall be taken to schedule repairs and

• When a Load Indicator, Rated Capacity Indicator, or

• When a Boom Angle or Radius Indicator is inoperative

• When an Anti-Block Device, Two-Blocking Damage

• When a Boom Length Indicator is inoperative or

• When a Level Indicator is inoperative or malfunctioning,

Load Moment Indication (LMI) Systems (If

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recalibration immediately. The operational aids shall be

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put back into service as soon as replacem ent parts, if
required, are available and the repairs and recalibration

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can be carried out. Every reasonable effort must be
made to expedite repairs and recalibration.

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Rated Capacity Limiter is inoperative or malfunctioning,

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the designated person responsible for supervising the
lifting operations shall establish procedures for
determining load weights and shall ascertain that the

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weight of the load does not exceed the crane ratings at
the radius where the load is to be handled.

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or malfunctioning, the radius or boom angle shall be
determined by measurement.

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Prevention or Two-Block Warning Device is inoperative

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or malfunctioning, the designated person responsible for
supervising the lifting operations shall establish
procedures, such as assigning an additional signal

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person to furnish equivalent protection . This d oes not
apply when lifting personnel in load-line supported

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personnel platforms. Personnel shall not be lifted when
anti-two-block devices are not functioning properly .

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malfunctioning, the designated person responsible for

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supervising the lifting operations shall establish the
boom lengths at which the lift will be made by actual

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measurements or marking on the boom.

Reference Only

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other means shall be used to level the crane.

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Equipped)

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Your crane may be equipped with an LMI system wh ich is
intended to aid the operator. Test daily for proper operation.
Never interfere with the proper funct ioning of opera tional
aids or warning devices.

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Under no condition should it be relied upon to replace the
use of Load Charts and operating instructions. Sole reliance
upon these electronic aids in place of good operating
practices can cause an accident.

Know the weight of all loads and always check the capacity
of the crane as shown on the Load Chart before making any
lifts.

NEVER exceed the rated capacity shown on the Load Chart.
Always check the Load Chart to ensure the load to be lifted
at the desired radius is within the rated capacity of the crane.

For detailed information concerning the operation and
maintenance of the load moment indicating system installed
on the crane, see the manufacturer’s manual supplied with
the crane.

Anti-T wo-Blocking Device

This crane should have a functional Anti-Two-Block and
Control Lock-Out System. T est daily for proper operation.

Two-blocking occurs when the load block (hook block,
headache ball, rigging, etc.) comes into physical contact with
the boom (boom nose, sheaves, boom extension, etc.). Two­blocking can cause hoist lines (wire rope), rigging, reeving,
and other components to become highly stressed and
overloaded in which case the wire rope may fail allowing the
load, block, etc. to free fall.

Two-blocking is more likely to occur when both the main and
auxiliary hoist lines are reeved over the main boom nose and
boom extension nose respectively. An operator,
concentrating on the specific line being used, may telescope
or lower the boom allowing the other hoist line attachment to
contact the boom or boom extension nose, thus causing
damage to the sheaves, or causing the wire rope to fail,
dropping the lifting device to the ground and possibly injuring
personnel working below.

Caution must be used when lowering the boom, extending
the boom or hoisting up. Let out load line(s) simultaneously
to prevent two-blocking the boom tip(s) and the hook block,
etc. The closer the load is carried to the boom nose the more
important it becomes to simultaneously let out wire rope as
the boom is lowered. Keep load handling devices a minimum
of 42 in (107 cm) below the boom nose at all times.

Two-blocking can be prevented. Operator awareness of the
hazards of two-blocking is the most important factor in
preventing this condition. An Anti-Two-Block System is
intended to assist the operator in preventing dangerous two­block conditions. It is not a replacement for operator
awareness and competence.

Never interfere with the proper functioning of operational
aids or warning devices.

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500E2 OPERATORS MANUAL SAFETY PRECAUTIONS

2

Work Area Definition System (W ADS) (If Equipped)

If your crane is equipped with a WADS, you must read and
understand the manufacturer’s Operator’s Manual before
operating the system. Become familiar with all proper

operating procedures and with the identification of symbol
usage.

The work area definition system is intended as an aid to the
operator. It is not a substitute for safe crane operating
practices, experience and good operator judgements.

CRANE STABILITY/S TRUCTURAL STRENGTH

To avoid death or serious injury, ensure that the crane is on a
firm surface with load and crane’s configuration within
capacity as shown on the crane’s Load Chart and notes.

Ensure all pins and floats are properly installed and outrigger
beams are properly extended before lifting on outriggers. On

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Reference Only

models equipped with outriggers th at ca n be pinn ed at the
mid-extend position (vertical strip, if applicable), the
outriggers must also be pinned when operating from the mid­extend position.

Use adequate cribbing under outrigger floats to distribute
weight over a greater area. Check frequently for settling.

SAFETY PRECAUTIONS OPERATORS MANUAL 500E2

Read and follow the following safety decal for cranes with
center front stabiliers.

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Carefully follow the procedures in this Operator’s Manual
when extending or retracting the outriggers. Death or serious
injury could result from improper crane setup on outriggers.

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The operator must select the proper Load Chart and Load
Moment Indicating (LMI) System program for the outrigger
position selected.

Before swinging the superstructure over the side when the
outriggers are retracted, check the Load Chart for backwards
stability.

Long cantilever booms can create a tipping condition when
in an extended and lowered position. Retract the boom
proportionally with reference to the capacity of the applicable
Load Chart.

Check crane stability before lifting loads. Ensure the
outriggers (or tires if lifting on rubber) are firmly positioned on
solid surfaces. Ensure the crane is level, brakes are set, and
the load is properly rigged and attached to the hook. Check
the Load Chart against the weight of the load. L ift the load
slightly off the ground and recheck the stability before
proceeding with the lift. Determine the weight of the load
before you attempt the lift.

Unless lifting within On Rubber capacities, outrigger beams
and jack cylinders (plus center front stabilizer, if equipped)
must be properly extended and set to provide precise
leveling of the crane. Tires must be clear of the ground
before lifting on outriggers.

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KEEP THE BOOM SHORT. Swinging loads with a long line
can create an unstable condition and possible structural
failure of the boom.

Load Charts

Load Charts represent the absolute maximum allowable
loads, which are based on either tipping or structural
limitations of the crane under specific conditions. Knowing
the precise load radius, boom length, and boom angle
should be a part of your routine planning and operation.
Actual loads, including necessary allowances, should be
kept below the capacity shown on the applicable Load Chart.

Load Chart capacities are based on freely suspended loads.
You must use the appropriate Load Chart when determining

the capability of the crane in the configuration required to
perform the lift.

Maximum lifting capacity is available at the shortest radius,
minimum boom length, and highest boom angle.

Do not remove the Load Charts from the crane.

Work Site

Prior to any operation, you must inspect the entire work site,
including ground conditions, where the crane will travel and
operate. Be sure that the surfaces will support a load greater
than the crane’s weight and maximum capacity .

Be aware of all conditions that could adv ersely affect the
stability of the crane.

Wind Forces

Wind can have a significant affect on loads that may be lifted
by a crane. Wind forces act differently on a crane depending

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500E2 OPERATORS MANUAL SAFETY PRECAUTIONS

2

upon the direction from which the wind is blowing (e.g., wind
on the rear of the boom can res ult in decrea sed forward
stability, wind on the underside of the boom can result in
decreased backward stability, wind on the side of the boom
can result in structural damages, etc.). To assist you in
determining prevailing wind conditions, refer to Table 2-1.

Wind forces can exert extreme dynamic loads. Manitowoc

recommends that a lift not be made if the wind can cause
T able 2-1

Wind Force

Beauford

Scale

Zero (0) Calm less than 1 (<2) No wind; smoke rises vertically

1 Light Air 1-3 (2-5) Wind direction seen by smoke but not by wind vanes
2 Light Breeze 4-7 (6-11) Wind felt on face; leaves rustle; wind vane moves slightly
3 Gentle Breeze 8-12 (13-19) Leaves/small twigs in constant motion: wind extends flag

4

Reduce crane load ratings and operating parameters at 20 mph (32 km/h)

5 Fresh Breeze 19-24 (31-39)

6 Strong Breeze 25-31 (40-50)

Cease all craning operations at 30 mph (48 km/h); lower & retract boom

7 Moderate Gale 32-38 (52-61) Whole trees in motion; walking against wind is inconvenient

Designation

Moderate
Breeze

Wind V elocity

mph (km/h)

13-18 (21-29) Raises dust & loose paper; moves small branches

Small trees in leaf begin to sway; on ponds, crested wavelets
form

Large branches in motion; telegraph wires whistle; umbrellas
used with difficulty

a loss of control in handling the load. Manitowoc
recommends that, if the wind speed (velocity) is between 20
mph (32 km/h) to 30 mph (48 km/h), the load capacities shall
be reduced to account for the size and shape of the load and
the wind direction in relation to the machine for all boom and
boom extension lengths. Further, operation of the crane in
wind velocities over 30 mph (48 km/h) is not recommended.

Visible Indicator

Effects of wind as observed on land

Lifting Operations

Before lifting, position the crane on a firm surface, properly
extend and set the outriggers, and level the crane.
Depending on the nature of the supporting surface,
adequate cribbing may be required to obtain a larger bearing
surface.

The crane is equipped with a bubble level that sh ould be
used to determine whether the crane is level. The load line
can also be used to estimate the levelness of the crane by
checking to be sure it is in-line with the center of the boom at
all points on the swing circle.

If the boom extension, or auxiliary boom nose is to be used,
ensure the electrical cable and the weight f or the An ti-Two­Block Switch are properly installed and the LMI is
programmed for the cran e conf igura tion. Refe r to the LM I
handbook supplied with the crane.

Verify the crane’s capacity by checking the Load Chart
against the weight of the load. Then, lift the load slightly at
first to ensure stability before proceeding with the lift.

Be sure the load is properly rigged and attached. Always
determine the weight of the load be fo re you a tte mpt to lift it

Reference Only

and remember that all rigging (slings, etc.) and lifting devices
(hook block, boom extension, etc.) must be considered part
of the load.

Measure the load radius before making a lift and stay within
approved lifting areas based on the range diagrams and
working area diagrams on the crane’s Load Chart.

Always keep the load as near to the cra ne and as close to
the ground as possible.

Do not overload the crane by exceeding the capacities
shown on the appropriate Load Chart. Death or serious
injury could result from the crane tipping over or failing
structurally from overload.

The crane can tip over or fail structurally if:

• The load and crane’s configuration is not within the
capacity as shown on the applicable Load Chart and
notes.

• The ground is soft and/or the surface conditions are
poor.

• Outriggers are not properly extended and set. On
models equipped with outriggers that can be pinned at

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SAFETY PRECAUTIONS OPERATORS MANUAL 500E2

the mid-extend position, the outriggers must also be
pinned when operating from the mid-extend position.

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• Cribbing under the outrigger pads is inadequate.

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• The crane is improperly operated.
Do not rely on the crane’s tippin g to dete rmine y our lifting

capacity.
Be sure the hoist line is vertical before lifting. Do not subject

the crane to side loading. A side load can tip the crane or
cause it to fail structurally.

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
lifting.

If you should encounter a tipping condition, immediately
lower the load with the hoist line and retract or elevat e the
boom to decrease the load radius. Never lower or extend the
boom; this will aggravate the condition.

Use tag lines whenever possible to help control the
movement of the load.

When lifting loads, the crane will lean toward the boom and
the load will swing out, increasing the load radius. Ensure the
crane’s capacity is not exceeded when this occurs.

Do not strike any obstruction with the boom. If the boom
should accidentally contact an object, stop immediately.
Inspect the boom. Remove the crane from service if the
boom is damaged.

Never push or pull with the crane boom.

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Avoid sudden starts and stops when moving the load. The
inertia and an increased load radius could tip the crane over
or cause it to fail structurally .

Use only one hoist at a time when lifting loads.
Always use enough parts-of-line to accommodate the load to

be lifted. Lifting with too few parts-of-line can result in failure
of the wire rope.

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Counterweight

On cranes equipped with removable counterweights, ensure
the appropriate counterweight sections are properly installed
for the lift being considered.

Do not add material to the count erweight to increase
capacity. United States Federal law prohibits modification or
additions which affect the capacity or safe operation of the
equipment without the manufacturer’s written approval.
[29CFR 1926.1434]

Outrigger Lift Off

Regarding “lifting” of an outrigger pad during craning
activities, be advised that the rated loads for these cranes,

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as indicated on the crane’s Load Chart, do not exceed 85%
of the tipping load on outriggers as determined by SAE J765
OCT80 “Cranes Stability Test Code.” An outrigger pad may
lift off the ground during operation of the crane within the
capacity limits of the Load Chart, yet the crane will not have
reached instability. The “balance point” for stability testing
according to SAE and Manitowoc criteria is a condition of
loading wherein the load moment acting t o overturn the
crane is equal to the maximum moment of the crane
available to resist overturning. This balance point or point of
instability for a crane does not depend on “lifting” of an
outrigger but rather on comparison of the “opposing” load
moments.

The occurrence of an outrigger lifting from the ground is often
attributed to the natural flex in the crane’s frame. This may
happen when lifting a load in certain configurations within the
capacity limits of the Load Chart and is not necessarily an
indication of an unstable condition.

Provided the crane is properly set up, the crane is in good
working condition, that all operator ’s aids are properly
programmed, that the qualified crane o perator a dheres to
the instructions found in the applicable Load Chart,
Operator’s Manual and decals on the crane, the crane
should not be unstable.

Multiple Crane Lifts

Multiple crane lifts are not recommended.
Any lift that requires more that one crane must be precisely

planned and coordinated by a qualified engineer .
If it is necessary to perform a multi-crane li ft, the operator

shall be responsible for assuring that the following minimum
safety precautions are taken:

• Secure the services of a qualified engineer to direct the
operation.

• Use one qualified signal person.

• Coordinate lifting plans with the operators, engineer, and

signal person prior to beginning the lift.

• Maintain communication between all parties throughout
the entire operation. If possible, provide approved radio
equipment for voice communication between all parties
engaged in the lift.

• Use cranes and rigging of equal capabilities and use the
same boom length.

• Use outriggers on cranes so equipped.

• Be certain cranes are of adequate lifting capacity.

• Calculate the amount of weight to be lifted by each crane

and attach slings at the correct points for proper weight
distribution.

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500E2 OPERATORS MANUAL SAFETY PRECAUTIONS

2

• Ensure the load lines are directly over the attach points

to avoid side loading and transfer of loading from one
crane to the other.

• Do not travel. Lift only from a stationary position.

ELECTROCUTION HAZARD

To avoid deat h or s eriou s in jury, keep all parts of the crane,
rigging and load at least 20 feet (6 meters) away from any
energized power line. You must follow the OSHA
requirements set forth in 29CFR 1926.1407 through

1926.1411.

This crane is not designed or equipped for use within 10 feet
(3 meters) of energized power lines [Refer to
29CFR1926.1410 Table A]. If operation within 10 feet (3
meters) of any power lines cannot be avoided, the power
utility must be notified and the power lines must be de­energized and grounded before performing any work.

If contact is ever accidentally made with a power line and any
part of this crane, its rigging or load, never touch the crane or
even approach or come near the crane.

Electrocution can occur even without direct contact with the
crane.

Crane operation is dangerous when close to an energized
electrical power source. Exercise extreme caution and
prudent judgement. Operate slowly and cautiously when in
the vicinity of power lines.

Before operating this crane in the vicinity of electrical power
lines or equipment, notify the power utility company. Obtain
positive and absolute assurance that the power has been
turned off.

This crane is not insulated. Always consider all parts of the
load and the crane, including the wire rope, hoist cable,
pendant cables, and tag lines, as conductors. You, the
operator, are responsible for alerting all personnel of
dangers associated with electrical power lines and
equipment. Do not allow unnecessary personnel in the
vicinity of the crane while operating. Permit no one t o le an
against or touch the crane. Permit no one, including riggers
and load handlers, to hold the load, load lines, tag lines, or
rigging gear.

National Crane Published 10-20-2011 Control # 111-05 2-9

Reference Only

If the load, wire rope, boom, or any portion of the crane
contacts or comes too close to an electrical power source,
everyone in, on, and around the cra ne can be serio usly
injured or killed.

Most overhead power lines are not insulated. Treat all
overhead power lines as being energized unless y ou ha ve
reliable information to the contrary from the utility company
or owner.

The rules in this Operator’s Manual must be followed at all
times, even if the electrical power lines or equipment have
been de-energized.

The safest way to avoid electrocution is to stay away from
electrical power lines and electrical power sources.

It is not always necessary to contact a power line or power
source to become electrocuted. Electricity, depending on
magnitude, can arc or jump to any part of the load, load line,
or crane boom if it comes too close to an electrical power
source. Low voltages can also be dangerous.

SAFETY PRECAUTIONS OPERATORS MANUAL 500E2

Thoroughly read, understand, and abide by all applicable
federal, state, and local regulations.

Set-Up and Operation

During crane use, assume that every line is energized (“hot”
or “live”) and take the necessary precautions.

Set up the crane in a positio n su ch that t he loa d, b oom, or
any part of the crane and its attachment s cannot be moved to
within 20 ft (6 m) of electrical power lines or equipment. This
includes the crane boom (fully extended to maximum height,
radius, and length) and all attachments (boom extensio ns,
rigging, loads, etc.). Overhead lines tend to blow in the wind
so allow for lines’ movement when determining safe
operating distance.

A suitable barricade should be erected to physically restrain
the crane and all attachments (including the load) from
entering into an unsafe distance from electrical power lines
or equipment.

Plan ahead and always plan a safe route before traveling
under power lines. Rider poles should be erected on each
side of a crossing to assure sufficient clearance is
maintained.

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Electrocution Hazard Devices

The use of insulated links, insulated boom cages/guards,
proximity warning devices, or mechanic al limit sto ps does
not assure that electrical contact will not occur . Even if codes
or regulations require the use of such devices, failure to
follow the rules listed here may result in serious injury or
death. You should be aware that such devices have
limitations and you should follow the rules and precautions
outlined in this manual at all times even if the crane is
equipped with these devices.

Insulating links installed into the load line afford limited
protection from electrocution hazards . Links are limited in
their lifting abilities, insulating properties, and other
properties that affect their performance. Moisture, dust, dirt,
oils, and other contaminants can cause a link to conduct
electricity. Due to their capacity ratings, some links are not
effective for large cranes and/or high voltages/currents.

The only protection that may be afforded by an insulated link
is below the link (electrically downstream), provided the link
has been kept clean, free of contamination, has not been
scratched or damaged, and is periodically tested (just before
use) for its dielectric integrity .

Boom cages and boom guards afford limited protection from
electrocution hazards. They are designed to cover only the
boom nose and a small portion of the boom. Performance of
boom cages and boom guards is limited by their physical
size, insulating characteristics, and operating environme nt
(e.g. dust, dirt, moisture, etc.). The insulating characteristics
of these devices can be compromised if not kep t cle an , fr ee
of contamination, and undamaged.

Proximity sensing and warning devices are available in
different types. Some use boom nose (localized) sensors
and others use full boom length sensors. No warning may be
given for components, cables, loads, and other attachments
located outside of the sensing area. Much reliance is placed
upon you, the operator, in selecting and properly setting the
sensitivity of these devices.

United States OSHA regulations require a flagman when
operating in close proximity to energized power lines.

Appoint a reliable and qualified signal person, equipped with
a loud signal whistle or horn and voice communication
equipment, to warn the operator when any part of the crane
or load moves near a power source. This person should
have no other duties while the crane is working.

Tag lines should always be made of non-conductive
materials. Any tag line that is wet or dirty can conduct
electricity.

Do not store materials under power lines or close to
electrical power sources.

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Reference Only

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Never rely solely on a device to protect you and your fellow
workers from danger.

Some variables you must know and understand are:

• Proximity devices are advertised to detect the existence
of electricity and not its quantity or magnitude.

• Some proximity devices may detect only alternating
current (AC) and not direct current (DC).

• Some proximity devices detect radio frequency (RF)
energy and others do not.

• Most proximity devices simply provide a signal (audible,
visual, or both) for the operator; this signal mu st not be
ignored.

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2-10 Published 10-20-2011 Control # 111-05

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500E2 OPERATORS MANUAL SAFETY PRECAUTIONS

2

• Sometimes the sensing portion of the proximity devices

becomes confused by complex or differing arrays of
power lines and power sources.

Do not depend on grounding. Grounding of a crane affords
little or no protection from electrical hazards. The
effectiveness of grounding is limited by the size of the
conductor (wire) used, the condition of the ground, the
magnitude of the voltage and current present, and numerous
other factors.

Electrical Contact

If the crane should come in contact with an energized power
source, you must:

1. St ay in the crane cab. Don’t panic.

2. Immediately warn personnel in the vicinity to stay away.

3. Attempt to move the crane away from the contacted

power source using the crane’s controls which are likely
to remain functional.

4. Stay in the crane until the power company has been
contacted and the power source has been de-energized.
No one must attempt to come close to the crane or load
until the power has been turned off.

Only as a last resort should an operator attempt to leave the
crane upon contacting a power source. If it is absolutely
necessary to leave the operator’s station, jump completely
clear of the crane. Do not step off. Hop away with both feet
together. Do not walk or run.

Following any contact with an energized electrical source,
the Manitowoc dealer must be immediately advised of the
incident and consulted on necessary inspections and
repairs. Thoroughly inspect the wire rope and all points of
contact on the crane. Should the dealer not be immediately
available, contact Manitowoc Crane Care. The crane must
not be returned to service until it is thoroughly inspected for
any evidence of damage and all damaged parts are repaired
or replaced as authorized by your Manitowoc dealer or
Manitowoc Crane Care.

Special Operating Conditions and Equipment

Reference Only

Never operate the crane during an electrical thunderstorm.
When operating near transmitter/communication towers

where an electrical charge can be induced into the crane or
load:

• The transmitter shall be deenergized OR,

• Tests shall be made to determine if an electrical charge

will be induced into the crane or load.

• The crane must be provided an electrical ground.

• If taglines are used, they must be non-conductive.

• Every precaution must be taken to dissipate induced

voltages. Consult a qualified RF (radio frequency)
Consultant. Also refer to local, state, and federal codes
and regulations.

When operating cranes equipped with elec trom agne ts, you
must take additional precautions. Permit no one to touch the
magnet or load. Alert personnel by sounding a warning
signal when moving a load. Do not allow the co ver of the
electromagnet power supply to be open during operation or
at any time the electrical system is activated. Shut down the
crane completely and open the magnet controls switch prior
to connecting or disconnecting magnet lead s. Use only a
non-conductive device when positioning a load. Lower the
magnet to the stowing area and shut off power before
leaving the operator’s cab (if equipped) or operator’s station.

PERSONNEL HANDLING

The American Society of Mechanical Engineers issued a
new American National Standard entitled, Personnel Lifting
Systems, ASME B30.23-2005. This standard provides,
“lifting and lowering of personnel using ASME B30 Standard
hoisting 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 standard is consistent with the U.S.
Department of Labor, Occupational Safety and Health
Administration (OSHA) regulations for Construction that
state, in 29CFRI926.1431: “General requirements. The use
of a crane or derrick to hoist employees on a personnel
platform is prohibited, except when the erection, use, and
dismantling of conventional means of reaching the worksite,
such as a personnel hoist, ladder, stairway, aerial lift,
elevating work platform or scaffold, would be more
hazardous or is not possible because of structural design or
worksite conditions.” Additional requirements for crane
operations are stated in ASME B30.5, Mobile And

Locomotive Cranes, and in OSHA regulations
29CFRI910.180 for General Industry and 29CFRI926.1431
for Construction.

Use of a Manitowoc crane to handle personnel is acceptable
provided:

• The requirements of the applicable national, state and
local regulations and safety codes are met.

• A determination has been made that use of a crane to
handle personnel is the least hazardous means to
perform the work.

• The crane operator shall be qualified to operate the
specific type of hoisting equipment used in the
personnel lift.

• The crane operator must remain at the crane controls at
all times when personnel are off the ground.

National Crane Published 10-20-2011 Control # 111-05 2-11

SAFETY PRECAUTIONS OPERATORS MANUAL 500E2

• The crane operator and occupants have been instructed

in the recognized hazards of personnel platform lifts.

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• The crane is in proper working order .

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• The crane must be equipped with a boom angle
indicator that is visible to the crane operator.

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• The crane's Load Chart is affixed at the operator’s
station and readily accessible to the operator. The total

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weight of the loaded personnel platform and related
rigging shall not exceed 50 percent of the rated capacity

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for the radius and configuration of the crane.

• The crane is level within one percent of level grade and

• The crane's Operator's Manual and other operating

• The platform meets the requirements as prescribed by

• For wire rope suspended platforms:

• For boom mounted platforms:

To avoid death or serious injury:

• NEVER use this crane for bungee jumping or any form

• NEVER handle personnel on the loadline unless the

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located on a firm footing. Cranes with outriggers shall
have them all deployed following manufacturer's

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specifications.

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manuals are at the operator’s station and readily
accessible to the operator.

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applicable standards and regulations.

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- The crane is equipped with a hook that can be

closed and locked, eliminating the throat opening.

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- The crane is equipped with a functional Anti-Two-

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Block Device.

- The platform is properly attached and secured to the

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load hook.

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- Use only Manitowoc approved personnel platforms

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attached to the boom.

- The platform is properly attached and secure.

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of amusement or sport.

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requirements of applicable national, state and local

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regulations and safety codes are met.

Reference Only

• NEVER permit anyone to ride loads, hooks, slings or

• NEVER get on or off a moving crane.

• NEVER allow anyone other than the operator to be on

The following standards and regulations regarding personnel
handling are available by mail at the following addresses:

• ASME (formerly ANSI) B30 Series American National

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other rigging for any reason.

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this crane while the machine is operating or traveling.

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Safety Standards For Cableways, Cranes, Derricks,
Hoists, Hooks, Jacks, and Slings; ASME B30.5, Mobile

And Locomotive Cranes, and ASME B30.23, Personnel
Lifting Systems, are available by mail from the ASME, 22

Law Drive, Fairfield, New Jersey , 0700-2900

• US DOL/OSHA Rules and Regulations are available by
mail from the Superintendent of Documents, PO Box
371954, Pittsburgh, P A, 152 50-7954.

ENVIRONMENTAL PROTECTION

Dispose of waste properly! Improperly disposing of waste

can threaten the environment.
Potentially harmful waste used in Manitowoc cranes includes

— but is not limited to — oil, fuel, grease, coolant, air
conditioning refrigerant, filters, batteries, and cloths which
have come into contact with these environmentally harmful
substances.

Handle and dispose of waste according to local, state, and
federal environmental regulations.

When filling and draining crane components, observe the
following:

• Do not pour waste fluids onto the ground, down any
drain, or into any source of water .

• Always drain waste fluids into leak proof containers that
are clearly marked with what they contain.

• Always fill or add fluids with a funnel or a filling pump.

• Immediately clean up any spills.

MAINTENANCE

The crane must be inspected prior to use on each work shift.
The owner, user, and operator must ensure that routine
maintenance and lubrication are being dutifully performed.
Never operate a damaged or poorly maintained crane.

Manitowoc continues to recommend that cranes be properly
maintained, regularly inspected and repaired as necessary.
Manitowoc reminds crane owners to ensure that all safety
decals are in place and legible. Manitowoc continues to urge
crane owners to upgrade their cranes with load moment
indicator (LMI) and control lever lockout systems for all lifting
operations.

Shut down the crane while making repairs or adjustments.
Always perform a function check after repairs have been

made to ensure proper operation. Load tests should be
performed when structural or lifting members are involved.

Follow all applicable safety precautions in this manual when
performing crane maintenance as well as crane operations.

Keep the crane free of mud, dirt, an d grease at a ll times.
Dirty equipment introduces hazards, wears-out faster, and
makes proper maintenance difficult. Cleaning solutions used

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2-12 Published 10-20-2011 Control # 111-05

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500E2 OPERATORS MANUAL SAFETY PRECAUTIONS

2

should be non-flammable, non-toxic and appropriate for the
job.

Routine maintenance and inspection of this crane must be
performed by a qualified person(s) according to the
recommendations in the Manitowoc Crane Care
Maintenance and Inspection Manual. Any questio ns
regarding procedures and specifications should be directed
to your Manitowoc dealer.

Service and Repairs

WARNING

Fall Hazard!

Working at elevated heights without using proper fall
protection can result in severe injury or death.

Always use proper fall protection as required by local,
state or federal regulations.

Service and repairs to the crane must only be performed by a
qualified person. All service and repairs must be performed
in accordance with manufacturer’s recommendations, this
manual, and the service manual for this machine. If there is
any question regarding maintenance procedures or
specifications, contact your Manitowoc dealer for assistance.

Qualified person is defined as one who by reason of
knowledge, training and experience is thoroughly familiar
with the crane’s operation and required maintenance as well
as the hazards involved in performing these tasks.

Training and qualification of maintenance and repair
personnel are crane owner’s responsibility.

Any modification, alteration, or change to a crane which
affects its original design and is not authorized and approved
by Manitowoc is strictly prohibited. All replacement parts
must be Manitowoc approved. Such action invalidates all
warranties and makes the owner/user liable for any resultant
accidents.

Hydraulic Fluid:

• Do not use your hand or any part of your body to check
for hydraulic fluid leaks when the engine is running or
the hydraulic system is under pressure. Fluid in the
hydraulic system can be under enough pressure that it
will penetrate the skin, causing serious injury or death.
Use a piece of cardboard, or piece of paper, to search
for leaks. Wear gloves to protect your hands from
spraying fluid.

• If any hydraulic fluid is injected into the skin, obtain
medical attention immediately or gangrene may result.

Reference Only

• Do not attempt to repair or tighten any hydraulic hose or
fitting while the engine is running, or when the hydraulic
system is under pressure.

• Never disconnect any hydraulic lines unless the boom is
fully lowered, the engine is shut off, and the hydraulic
pressure is relieved. To relieve hydraulic pressure, stop
the engine and move the hydraulic controls in both
directions several times.

• Hot hydraulic fluid will cause severe burns. Wait for the
fluid to cool before disconnecting any hydraulic lines.

• Hydraulic fluid can cause permanent eye injury. Wear
appropriate eye protection.

Moving Parts:

• Do not place limbs near moving parts. Amputation of a
body part may result. Turn off the engine and wait until
the fan and belts stop moving before servicing crane.

• Pinch points, which result from relative motion between
mechanical parts, are areas of the machine that can
cause personal injury or death. Do not place limbs or
your body in contact with pinch points either on or
around the machine. Care must be taken to prevent
motion between pinch points when performing
maintenance and to avoid such areas when mov eme nt
is possible.

• Do not allow persons to stand near extending or
lowering outriggers. Foot crushing could occur

Before performing any maintenance, service or repairs on
the crane:

• The boom should be fully retracted and lowered and the
load placed on the ground.

• Do not get under a raised boom unless the boom is
blocked up safely. Always block up the boom before
doing any servicing that requires the boom to be raised.

• Stop the engine and disconnect the battery .

• Controls should be properly tagged. Never operate the

crane if it is tagged-out nor attempt to do so until it is
restored to proper operating condition and all tags have
been removed by the person(s) who installed them.

After maintenance or repairs:

• Replace all guards and covers that have been removed.

• Remove all tags, connect the battery, and perform a

function check of all operating controls.

• Consult with Manitowoc Crane Care to determine if load
testing is required after a structural repair is performed.

Lubrication

The crane must be lubricated according to the
manufacturer’s recommendations for lubrication points, time

National Crane Published 10-20-2011 Control # 111-05 2-13

SAFETY PRECAUTIONS OPERATORS MANUAL 500E2

intervals, and types. Lubricat e at more frequent intervals
when working under severe conditions.

Exercise care when servicing the hydraulic system of the
crane, as pressurized hydraulic oil can cause serious injury.
The following precautions must be taken when servicing the
hydraulic system:

• Follow the manufacturer’s recommendations when

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adding oil to the system. Mixing the wrong fluids could
destroy seals, causing component failure.

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• Be certain all lines, components, and fittings are tight
before resuming operation.

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Tires

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Possible equipment damage and/or

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Driving the crane with a tire and split-rim assembly under
inflated at 80% or less of its recommended pressure can
cause the wheel and/or tire to fail. Per OSHA Standard

1910.177(f)(2), when a tire has been driven under inflated
at 80% or less of its recommended pressure, it must first
be completely deflated, removed from the axle,
disassembled, and inspected before re-inflation.

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WARNING

personal injury!

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Inspect the tires for nicks, cuts, embedded material, and
abnormal wear.

Ensure all lug nuts are properly torqued.
Ensure pneumatic tires are inflated to the proper pressure

(refer to the Load Chart). When inflating tires, use a tire
gauge, clip-on inflator, and extension hose which will permit
standing clear of the tire while inflating.

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Wire Rope

Use only the wire rope specified by Manitowoc as indicated
on the crane’s Load Chart. Substitution of an alternate wire
rope may require the use of a different permissible line pull
and, therefore, require different reeving.

NOTE: Wire rope may be purchased by contacting

Always make daily inspections of the wire rope, keeping in
mind that all wire rope will eventually deteriorate to a point
where it is no longer usable. Refuse to work with worn or
damaged wire rope. Wire rope shall be taken out of service
when any of the following conditions exist:

• For rotation-resistant running ropes: more than two (2)

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Reference Only

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Manitowoc Crane Care.

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broken wires in a length of rope equal to six (6) times the

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rope diameter, or more than four (4) broken wires in a

length of rope equal to thirty (30) times the rope
diameter.

• For running ropes other than rotation resistant: six (6)
broken wires in one rope lay or three (3) broken wires in
one strand.

• One valley break where the wire fractures between
strands in a running rope is cause for removal.

• Abrasion of the rope resulting in wear of the individual
outside wires of 1/3 of the original wire diameter.

• Any kinking, bird caging, crushing, corrosion, or other
damage resulting in distortion of the rope structure.

• Rope that has been in contact with a live power line or
has been used as a ground in an electric circuit (eg.
welding) may have wires that are fused or annealed and
must be removed from service.

• In standing ropes, more than three (3) breaks in one
rope lay in sections beyond the end connection or more
than two (2) broken wires at an end connection.

• Core deterioration, usually observed as a rapid
reduction in rope diameter, is cause for immediate
removal of the rope.

The following is a brief outline of the basic information
required to safely use wire rope.

• Wire ropes wear out. The strength of a wire rope begins
to decrease when the rope is put to use and continues to
decrease with each use. Wire rope will fail if worn-out,
overloaded, misused, damaged or improperly
maintained.

• The nominal strength, sometimes called catalog
strength, of a wire rope applies only to a new, unused
rope.

• The nominal strength of a wire rope should be
considered the straight line pull which will actually break
a new unused rope. The nominal strength of a wire rope
should never be used as its working load.

• Each type of fitting attached to a wire rope has a specific
efficiency rating which can reduce the working load of
the wire rope assembly or rope system.

• Never overload a wire rope. This means never use the
wire rope where the load applied to it is greater than the
working load determined by the rope manufacturer .

• Never “shock load” a wire rope. A sudden application of
force or load can cause both visible external and internal
damage. There is no practical way to estimate the force
applied by shock loading a rope. The sudden release of
a load can also damage a wire rope.

• Lubricant is applied to the wires and strands of a wire
rope when it is manufactured. The lubricant is depleted
when the rope is in service and should be replaced

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2-14 Published 10-20-2011 Control # 111-05

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500E2 OPERATORS MANUAL SAFETY PRECAUTIONS

2

periodically. Refer to the Service Manual for more
information.

• In the U.S.A., regular inspections of the wire rope and
keeping of permanent records signed by a qualified
person are required by OSHA for almost every wire rope
application. The purpose of the inspection is to
determine whether or not a wire rope may continue to be
safely used on the application. Inspection criteria,
including number and location of broken wires, wear and
elongation, have been established by OSHA, ANSI,
ASME and similar organizations. See the Service
Manual for inspection procedures.

When inspecting wire ropes and attachments, keep all
parts of your body and clothing away from rotating hoist
drums and all rotating sheaves. Never handle the wire
rope with bare hands.

Some conditions that lead to problems in wire rope
systems include:

- Sheaves that are too small, worn or corrugated

cause damage to a wire rope.

- Broken wires mean a loss in strength.

- Kinks permanently damage a wire rope and must be

avoided.

- Wire ropes are damaged by knots. Wire rope with

knots must never be used.

- Environmental factors such as corrosive conditions

and heat can damage a wire rope.

• When a wire rope has been removed from service
because it is no longer suitable for use, it must not be
reused on another application.

When installing a new rope:

• Keep all parts of your body and clothing away from
rotating hoist drums and all rotating sheaves.

• Never handle the wire rope with bare hands.

• Follow proper instructions for removing rope from a reel.

• Apply back tension to the storage/payoff reel of the new

rope to insure tight, even spooling onto the hoist drum.

• Operate the new rope - first through several cycles at
light load and then through several cycles at
intermediate load to allow the rope to adjust to operating
conditions.

When using a wedge socket:

• Always inspect socket, wedge, and pin for correct size
and condition.

• Do not use parts that are damaged, cracked, or
modified.

• Assemble the wedge socket with live end of rope aligned
with the centerline of pin and assure proper length of tail
(dead end) protrudes beyond the socket.

Sheaves

- Lack of lubrication can significantly shorten the

useful life of a wire rope.

- Contact with electrical wires and resulting arcing will
damage a wire rope.

• An inspection should include verification that none of the
specified removal criteria for this usage are met by
checking for such things as:

- Surface wear; nominal and unusual.

- Broken wires; number and location.

- Reduction in diameter.

Reference Only

- Rope stretch (elongation).

- Integrity of end attachments.

- Evidence of abuse or contact with another object.

- Heat damage.

- Corrosion.

NOTE: A more detailed wire rope inspection procedure is

given in the Service Manual.

Inspect the boom nose and hook block sheav es fo r proper
operation, excessive wear, and damage every 50 hours or
weekly. Inoperable, damaged and/or worn sheaves cause
rapid deterioration of wire rope.

Ensure sheaves carrying ropes that can be momentarily
unloaded are equipped with close fitting guards or other
devices to guide the rope back into the groove when the load
is reapplied. Ensure sheaves in the lower load block are
equipped with close fitting guards that will prevent the ropes
from becoming fouled when the block is lying on the ground
with loose ropes.

National Crane Published 10-20-2011 Control # 111-05 2-15

SAFETY PRECAUTIONS OPERATORS MANUAL 500E2

To attain maximum wire rope life and minimize hook block
rotation, it is recommended that even numbers o f parts-of­line be used in multiple-part reeving whenever possible.

The use of nylon (nylatron) sheaves, as compared with
metallic sheaves, may change the replacement criteria of
rotation-resistant wire rope.

NOTE: The use of cast nylon (nylatron) sheaves will

Batteries

Battery electrolyte must not be allowed to contact the skin or
eyes. If this occurs, flush the contacted area with water and
consult a doctor immediately .

When checking and maintaining batteries, exercise the
following procedures and precautions:

• Wear safety glasses when servicing batteries.

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substantially increase the service life of wire rope.
However, conventional rope retirement criteria



based only upon visible wire breaks may prove
inadequate in predicting rope failure. The user of
cast nylon sheaves is therefore cautioned that a

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retirement criteria should be established based
upon the user’s experience and the demands of his



application.

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• If equipped, disconnect battery with the battery
disconnect switch before disconnecting the ground



battery cable.

• Do not break a live circuit at the battery terminal.

• Do not short across the battery posts to check charge.

• Maintain battery electrolyte at the proper level. Check

• If applicable to your crane, check battery test indicator

• Check battery condition only with proper test equipment.



Disconnect the ground battery cable first when removing
a battery and connect it last when installing a battery.



Short circuit, spark, or flame could cause battery



explosion.



the electrolyte with a flashlight.

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on maintenance-free batteries.



Batteries shall not be charged except in an open, well-



ventilated area that is free of flame, smoking, sparks,
and fire.

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Reference Only

Engine

Fuel the crane only with the engine turned off. Do not smoke
while fueling the crane. Do not store flammable materials on
the crane.

Be familiar with the location and use of the nearest fire
extinguisher.

Be careful when checking the engine coolant level. The fluid
may be hot and under pressure. Sh ut do wn the eng in e a nd

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allow the radiator time to cool before removing the radiator
cap.

Shut down the engine and disconnect the battery before
performing maintenance. If unable to do so for the task
required, keep hands clear of the engine fan and other
moving parts while performing maintenance.

Be careful of hot surfaces and hot fluid s when perf orming
maintenance on or around the engine.

Do not use ether to start the engine on cranes equipped with
intake manifold grid heaters.

TR ANSPORTING THE CRANE

Before transporting the crane, check the suitability of the
proposed route with regard to the crane height, width, length,
and weight.

Check load limits of bridges on the travel route and ensure
they are greater than the combined weight of the crane and
transporting vehicle.

When loading or unloading the crane on a trailer or railroad
car, use a ramp capable of supporting the weight of the
crane.

Ensure the crane is adequately secured to the transporting
vehicle.

Before transporting the crane on a road or high way, first
check state and local restrictions and regulations.

When using hookblock tie downs, excessive loading can be
applied by pulling the cable too tight, particularly when
reeved with multiple part lines. When the cable is hooked
into the hookblock tie down, the cable should be merely
“snugged-up” with slack provided at the center line of sheave
to anchor point. Care must be exercised anytime any crane
function is being performed while the cable is hooked into the
hookblock tie down. Do not draw cable taut.

TRAVEL OPERATION

Only the crane operator shall occupy the crane when
traveling.

When traveling, the boom should be completely retracted
and lowered to the travel position and the turntable pin swing
lock should be engaged. If equipped with boom rest, lower
the boom into the boom rest and engage the turntable lock.

Strictly adhere to the guidelines and restrictions in the Load
Chart for pick and carry operations.

This machine is manufactured with no axle suspension
system. Traveling at high speeds, especially on rough
ground, may create a bouncing affect that can result in loss
of control. If bouncing occurs, reduce travel speed. (RT and
Shuttle Lift Only)

2-16 Published 10-20-2011 Control # 111-05

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500E2 OPERATORS MANUAL SAFETY PRECAUTIONS

2

Death or serious injury could result from being crushed by
revolving tires.

“Stunt” driving and “horse-play” are strictly prohibited. Never
allow anyone to hitch a ride or get on or off a moving crane.

Follow the instructions in this manual when preparing the
crane for travel.

If using a boom dolly/trailer, thoroughly read and understand
all the steps and safety precautions in this manual for setup
and travel.

When driving the crane, ensure the cab is level, if equipped
with a tilting cab.

Secure the hook block and other items before mov ing the
crane.

Watch clearances when traveling. Do not take a chance of
running into overhead or side obstructions.

When moving in tight quarters, post a signal p erso n to he lp
guard against collisions or bumping structures.

Before traveling a crane, check suitability of proposed route
with regard to crane height, width, and length.

Never back up without the aid of a signal person to verify the
area behind the crane is clear of obs tructions and/or
personnel.

On cranes equipped with air-operated brakes, do not attempt
to move the crane until brake system air pressure is at
operating level.

Check load limit of bridges. Before traveling across bridge s,
ensure they will carry a load greater than the crane’s weight.

If it is necessary to take the crane on a road or highway,
check state and local restrictions and regulations.

Keep lights on, use traffic warning flags and signs, an d u se
front and rear flag vehicles when necessary . Check state and
local restrictions and regulations.

Always drive the crane carefully obeyin g speed limits and
highway regulations.

Stay alert a t the wheel.
If equipped, ensure that the hoist access platform hand rail

and step are in the travel configuration.
Slopes:

- Pick and carry on level surfaces only.

- Refer to the Operation Section for more detailed

information on traveling on slopes.

- Driving across a slope is dangerous, as unexpected
changes in slope can cause tip over. Ascend or
descend slopes slowly and with caution.

- Ascend or descend slopes with the boom pointing
up the slope.

- When operating on a downhill slope, reduce travel
speed and downshift to a low gear to permit
compression braking by the engine and aid the
application of the service brakes.

Reference Only

National Crane Published 10-20-2011 Control # 111-05 2-17