National Crane 500E2 Operators Manual

OPERATOR MANUAL
Supplement
Crane Warm-up Procedures
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! DANGER
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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
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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.
• You 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.
© 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
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This Supplement provides information regarding the proper Operating the transmission with a sump temperature below
warm-up procedures for operating the crane in colder normal operating temperature is limited to:
temperatures. The information provided here supplements
• operating in the neutral gear or
the Operator and Service Manuals and must be used in
conjunction with these manuals. • driving with an unloaded crane while not exceeding
1500 engine RPM and not exceeding half throttle.
CRANE WARM-UP PROCEDURES Alternate Warm-up Procedures for Truck Mount (TM/
The following procedures detail the actions that must be TMS) Cranes:
taken to properly warm the different crane components 1. Setup the crane on outriggers.
before operating the crane.
2. Engage the transmission and allow crane to run at idle
NOTE: For temperatures below -9°C (15°F) refer to arctic until the temperature of the transmission sump reaches
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lubricants and conditions in the Operator and normal operating temperature.
Service Manuals.
Hoist
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Before starting the crane, ensure the appropriate lubricants
are used to provide lubrication for the prevailing ambient Performing a warm-up procedure is recommended at every
temperatures in which the crane will operate in (a list of startup and is required at ambient temperatures below 4°C
lubricants and their temperature ranges can be found in the (40°F).
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Lubrication section of your crane’s Operator Manual, by
contacting your local Manitowoc distributor, or by contacting Warm-up Procedures:
Manitowoc Crane Care directly). 1. Without operating the hoist function, warm the hydraulic
oil (see Hydraulic Oil System, page 2).
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CAUTION 2. Once the hydraulic system is warm, operate the
unloaded hoist, in both directions, at low speeds several
Crane Damage Hazard!
times to prime all hydraulic lines with warm hydraulic oil
Operating the crane with the incorrect lubricants and and to circulate gear lubricant through the planetary
fluids for the prevailing ambient temperature and/or failing gear sets.
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to adequately warm the crane prior to cold weather

operation can lead to a failure of a crane component or Swing Drive and Turntable Bearing
system.
Warm-up Procedures for Temperatures Above -7°C
Always use Manitowoc recommended lubricants and
(20°F):
fluids for the prevailing ambient temperature and properly
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start and warm the crane using the cold weather 1. Setup the crane on fully extended outriggers, with the
procedures found in this Operator Manual and boom fully retracted and near maximum lift angle with no
supplement before operating the crane at full load. load applied.
2. Rotate the superstructure at a speed of less than one
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Engine RPM for at least one complete revolution in one

NOTE: For National Crane engine warm-up procedures, direction, then rotate the superstructure at a speed of
refer to chassis manufacturer’s manual. less than one RPM for at least one complete revolution
in the opposite direction.
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Warm-up Procedures for All Temperature Ranges:

Warm-up Procedures for Temperatures Below -7°C
1. Upon startup, allow the engine to idle for 3 to 5 minutes (20°F):
before operating with a load.
1. Ensure the boom is fully retracted and near maximum lift
2. Cold Engine Startup: After allowing the engine to warm angle with no load applied.
by idling it for 3 to 5 minutes, slowly increase the engine
speed to provide adequate lubrication to the bearings 2. Rotate the superstructure at a speed of less than one-
and to allow the oil pressure to stabilize. half RPM for at least two complete revolutions in one
direction, then rotate the superstructure at a speed of
Transmission less than one-half RPM for at least two complete
revolutions in the opposite direction.
NOTE: For National Crane transmission warm-up
procedures, refer to chassis manufacturer ’s
manual.
National Crane Published 3-10-2015, Control# 571-00 1

Axles crane’s hydraulic pumps or motors, stop the operation
and engine immediately and contact a Manitowoc
NOTE: For National Crane axle warm-up procedures, refer distributor.
to chassis manufacturer’s manual.
• From 10°C to 4°C (50°F to 40°F): Crane operation with
Hydraulic Oil System a load is allowed with medium engine RPM and medium
function speed (joystick position) until the fluid reaches
Operating Limits and Warm-up Procedures: at least 10°C (50°F).
• From 4°C to -10°C (40°F to 15°F): Crane operation • From 95°C to 10°C (200°F to 50°F): Crane operation
without a load is allowed with medium engine RPM and with a load is allowed with no restrictions.
medium function speed (joystick position) until the fluid
reaches at least 10°C (50°F). It is then recommended • Above 95°C (200°F): No crane operation is allowed. Let
that all crane functions be cycled to remove cold fluid the crane’s hydraulic oil cool by running the engine at
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from all components and cylinders of the hydraulic idle with no functions actuated.
system. If there is any unusual sound coming from the
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2 Published 3-10-2015, Control# 571-00

National Crane
OPERATOR MANUAL 1
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
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SECTION 4 SET-UP
SECTION 5 LUBRICATION PROCEDURE AND CHARTS
SECTION 6 MAINTENANCE CHECKLIST
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NOTICE
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The crane serial number is the only method your distributor or the factory
has of providing you with correct parts and service information.
The crane serial number is identified on the builder’s decal attached to the 3
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right side of the turret. Always furnish crane serial number when
ordering parts or communicating service problems with your distributor or
the factory.
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! DANGER
An untrained operator subjects himself and others to death or
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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.
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• 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.
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• You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
• The Operator’s Manual and Load Chart are in the holder provided on
crane.
© 2011 Manitowoc
10-20-2011 Control # 111-05
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CALIFORNIA
PROPOSITION 65 WARNING
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Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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CALIFORNIA
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PROPOSITION 65 WARNING
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
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other reproductive harm. Wash hands after handling.

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500E2 OPERATOR’S MANUAL TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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
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Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator’s Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
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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
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Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
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Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Outrigger Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Multiple Crane Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
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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
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
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Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
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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
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
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Swing Speed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
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Boom Telescope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Stabilizers Up/Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Stabilizers Extend/Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
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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
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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
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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
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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
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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
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HCA Load Range Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

HCA System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Pressure Sensing Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
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
SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set-Up
Equipment Familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Equipment Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Pre-Operation Inspection and Calibration Verification. . . . . . . . . . . . . . . . . . . . . . . 4-1
1-2
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
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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
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Deployment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
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Jib Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Jib Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Jib Jack Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Adjustable Swing Speed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
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SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Procedure and Charts
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Arctic Conditions Below -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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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
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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
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Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Inner Boom Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
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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
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Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
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

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
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Single Character Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Hydraulic System Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
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Jib Jack Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Tire Load And Inflation Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

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

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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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1-4

500E2 OPERATORS MANUAL INTRODUCTION
SECTION 1
INTRODUCTION 1
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information . . . . . . . . . . . . . . . . . . . 1-1 New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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GENERAL parts for options such as remote controls, augers, varying
control configurations, baskets, grapples, etc. is included in
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This manual has been compiled to assist you in properly separate sections of this manual, if applicable.
operating and maintaining your Model 500E2 Series Engine operating procedures and routine maintenance
National Crane. procedures are supplied in a separate manual with each
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Before placing the crane in service, all operators and crane, and should be referred to for detailed information.
persons working around the crane must thoroughly read and Whenever a question arises regarding your National product
understand the contents of the manual pertaining to Safety, or this publication, please consult your National Dealer for
Operation and Maintenance. Before moving a vehicle the latest information. Your National Dealer is equipped with
equipped with the crane, information relating to transporting
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the proper tools, necessary National parts and trained
the vehicle must be read and observed. service personnel to properly maintain and service your
This manual must be retained with the machine for use by crane.
subsequent operating personnel.
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Information in this manual does not replace federal, state or

local regulations, safety codes or insurance requirements. DANGER
The National Crane has been designed for maximum Failure to observe all the instructions contained in this
performance with minimum maintenance. With proper care, manual will result in death or serious injury to the operator
years of trouble-free service can be expected. or bystanders or damage to the equipment.
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Constant improvement and engineering progress makes it Safety Information

necessary that we reserve the right to make specification
and equipment changes without notice. A Safety Compact Disc (CD) which includes sections on
Operation, Safety and Maintenance for National Crane
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National Crane and our Dealer Network want to ensure your

operators and owners is supplied when the crane is
satisfaction with our products and customer support. Your
purchased new. Additional copies are available from your
local dealer is the best equipped and most knowledgeable to
local distributor.
assist you for parts, service and warranty issues. They have
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the facilities, parts, factory trained personnel, and the New Owner
information to assist you in a timely manner. We request that
you first contact them for assistance. If you feel you need If you are the new owner of a Manitowoc crane, please
factory assistance, please ask the dealer ’s service register it with Manitowoc Crane Care so we have the ability
management to coordinate the contact on your behalf. to contact you if the need arises. Go to:
www.manitowoccranes.com/MCG_CARE/Includes/EN/
Supplemental Information changeOfOwnership.cfm and complete the form.
Supplemental Information regarding Safety and Operation,
Specifications, Service and Maintenance, Installation, and
National Crane Published 10-20-2011 Control # 111-05 1-1

INTRODUCTION OPERATORS MANUAL 500E2
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500E2 Series Major Components
Item Component Item Component

5 Stabilizers
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1 Hoist
2 Boom 6 Hydraulic Reservoir
3 Sheaves 7 Control Console
8 Outriggers
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4 Boom Rest
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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.
1-2 Published 10-20-2011 Control # 111-05

500E2 OPERATORS MANUAL SAFETY PRECAUTIONS
SECTION 2
SAFETY PRECAUTIONS
SECTION CONTENTS
Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Environmental Protection. . . . . . . . . . . . . . . . . . . 2-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . 2-1 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . 2-13
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
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Accidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
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Operator’s Information. . . . . . . . . . . . . . . . . . . . . . 2-2
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Operator’s Qualifications. . . . . . . . . . . . . . . . . . . . 2-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Transporting the Crane. . . . . . . . . . . . . . . . . . . . . 2-16
Load Moment Indication (LMI) Systems
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(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Anti-Two-Blocking Device . . . . . . . . . . . . . . . . . . . 2-4 Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Work Area Definition System (WADS) Personal Considerations . . . . . . . . . . . . . . . . . . . 2-18
(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
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Crane Stability/Structural Strength. . . . . . . . . . . . 2-5 Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
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Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Parking and Securing . . . . . . . . . . . . . . . . . . . . . . 2-22
Outrigger Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Multiple Crane Lifts . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . 2-8 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . 2-22
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Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . 2-10 Temperature Effects on Hydraulic Cylinders . . . 2-23

Electrocution Hazard Devices. . . . . . . . . . . . . . . 2-10 Overload Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-25
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
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Special Operating Conditions and Equipment . . 2-11 Superstructure Inspection . . . . . . . . . . . . . . . . . . 2-28

Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . 2-11 Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-30
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SAFETY MESSAGES 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. This safety alert symbol means ATTENTION!
Become alert - your safety is involved! Obey all safety
To alert personnel to hazardous operating practices and messages that follow this symbol to avoid possible death
maintenance procedures, safety messages are used or injury.
throughout the manual. Each safety message contains a

SAFETY PRECAUTIONS OPERATORS MANUAL 500E2
Signal Words failure or misuse and should not be relied upon in place of
good operating practices.
You are the only one who can be relied upon to assure the
safety of yourself and those around you. Be a professional
DANGER and follow the rules of safety.
hazards that will result in death or serious injury
Identifies Remember, failure to follow just one safety precaution could
if the message is ignored. 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.

WARNING ACCIDENTS
Identifies
hazards that may result in death or serious
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injury if the message is ignored. Following any accident or damage to equipment, the
Manitowoc dealer must be immediately advised of the

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incident and consulted on necessary inspections and
repairs. Should the dealer not be immediately available,
contact should be made directly with Manitowoc Product
CAUTION Safety at the address below. The crane must not be returned

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to service until it is thoroughly inspected for any evidence of
Identifies hazards that could result in minor or moderate
damage. All damaged parts must be repaired or replaced as
injury if the message is ignored.
authorized by your Manitowoc dealer and/or Manitowoc
Crane Care.

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If this crane becomes involved in a property damage and/or
CAUTION personal injury accident, immediately contact your
Without the safety alert symbol, identifies hazards that Manitowoc dealer. If the dealer is unknown and/or cannot be
could result in property damage if the message is ignored. reached, contact Product Safety at:
The Manitowoc Company, Inc.
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NOTE: Emphasizes operation or maintenance 1565 East Buchanan Trail

procedures. Shady Grove, PA 17256-0021
GENERAL Phone: 888-777-3378 (888-PSR.DEPT)

Fax: 717-593-5152
It is impossible to compile a list of safety precautions
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E-mail: product.safety@manitowoc.com
covering all situations. However, there are basic principles
that must be followed during your daily routine. Safety is OPERATOR’S INFORMATION
your primary
responsibility, since any piece of equipment
is only as safe as the person at the controls. You must read and understand this Operator’s Manual and
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the Load Chart before operating your new crane. You must
Read and follow the information located in Model Specific
also view and understand the supplied safety video. This
Information near the end of this section. manual and Load Chart must be readily available to the
operator at all times and must remain in the cab (if equipped)
This information has been provided to assist in promoting a
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safe working atmosphere for yourself and those around you. or operator’s station while the crane is in use.
It is not meant to cover every conceivable circumstance The Operator’s Manual supplied with and considered part of
which could arise. It is intended to present basic safety your crane must be read and completely understood by each
that should be followed in daily operation.
precautions person responsible for assembly, disassembly, operation
Because you are the only part of the crane that can think and and maintenance of the crane.
responsibility is not lessened by the addition of
reason, your No personnel shall be allowed to climb onto the crane or
operational aids or warning devices. Indeed, you must guard enter the crane cab or operator’s station unless performance

against acquiring a false sense of security when using them. of their duties require them to do so, and then only with
They are there to assist, not direct the operation. Operational knowledge of the operator or other qualified person.
aids or warning devices can be mechanical, electrical,

electronic, or a combination thereof. They are subject to Allow No One other than the operator to be on the crane
while the crane is operating or moving, unless they are
seated in a two-man cab.

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An untrained operator subjects himself and others to death
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or serious injury.
You must not operate this machine unless:
Do not remove the Load Chart, this Operator’s Manual, or • You have been trained in the safe operation of this
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any decal from this crane. machine.
Inspect the crane every day (before the start of each shift). • You read, understand, and follow the safety and
Ensure that routine maintenance and lubrication are being operating recommendations contained in the
dutifully performed. Don’t operate a damaged or poorly manufacturer’s manuals, your employer’s work rules,
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maintained crane. You risk lives when operating faulty and applicable government regulations.
machinery - including your own.
• You are sure the machine has been inspected and
If adjustments or repairs are necessary, the operator shall maintained in accordance with the manufacturer’s
notify the next operator. manuals and is operating properly.
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• You are sure that all safety signs, guards, and other
OPERATOR’S QUALIFICATIONS safety features are in place and in proper condition.
Qualified person is defined as one who by reason of Do not attempt to operate the crane unless you are trained
knowledge, training and experience is thoroughly familiar and thoroughly familiar with all operational functions.
with crane operations and the hazards involved. Such a
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Controls and design may vary from crane to crane; therefore,

person shall meet the operator qualifications specified in it is important that you have specific training on the particular
Occupational Safety and Health Administration (OSHA) crane you will be operating.
Regulations (United States Federal Law), in ASME B30.5
American National Standard, or in any other applicable Training is ESSENTIAL for proper crane operation. Never
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federal, state or local laws. jeopardize your own well-being or that of others by
attempting to operate a crane on which you have not been
Ensure that all personnel working around the crane are trained.
thoroughly familiar with safe operating practices. You must
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be thoroughly familiar with the location and content of all You must be mentally and physically fit to operate a crane.
placards and decals on the crane. Decals provide important Never attempt to operate a crane while under the influence
instructions and warnings and must be read prior to any of medication, narcotics, or alcohol. Any type of drug could
operational or maintenance function. i m pa i r p h y s i c a l , v i s u a l a n d m e n ta l r e a c t i o n s , a n d
capabilities.
You must be familiar with the regulations and standards
governing cranes and their operation. Work practice As operator of this crane, you are granted the authority to
requirements may vary slightly between government stop and refuse to lift loads until safety is assured.
regulations, industry standards, and employer policies so a
thorough knowledge of all such relevant work rules is OPERATIONAL AIDS
necessary.
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

kept in good working condition. The manuals that Manitowoc Under no condition should it be relied upon to replace the
p r o v i d e s t h a t a r e s p e c i f i c f o r e a c h c r a n e a n d t h e use of Load Charts and operating instructions. Sole reliance
manufacturer’s manuals for the operational aids shall be upon these electronic aids in place of good operating
followed. If an operational aid should fail to work properly, the practices can cause an accident.
crane user or owner must assure that repair or recalibration
Know the weight of all loads and always check the capacity
is accomplished as soon as is reasonably possible. If
of the crane as shown on the Load Chart before making any
immediate repair or recalibration of an operational aid is not
lifts.
possible and there are exceptional circumstances which

justify continued short-term use of the crane when NEVER exceed the rated capacity shown on the Load Chart.
operational aids are inoperative or malfunctioning, the Always check the Load Chart to ensure the load to be lifted
following requirements shall apply for continued use or at the desired radius is within the rated capacity of the crane.
shutdown of the crane:
For detailed information concerning the operation and

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• Steps shall be taken to schedule repairs and maintenance of the load moment indicating system installed
recalibration immediately. The operational aids shall be on the crane, see the manufacturer’s manual supplied with

put back into service as soon as replacement parts, if the crane.
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required, are available and the repairs and recalibration
can be carried out. Every reasonable effort must be Anti-Two-Blocking Device
made to expedite repairs and recalibration.
This crane should have a functional Anti-Two-Block and
a Load Indicator, Rated Capacity Indicator, or
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• When Control Lock-Out System. Test daily for proper operation.
Rated Capacity Limiter is inoperative or malfunctioning,
Two-blocking occurs when the load block (hook block,
the designated person responsible for supervising the
headache ball, rigging, etc.) comes into physical contact with
lifting operations shall establish procedures for
the boom (boom nose, sheaves, boom extension, etc.). Two-

determining load weights and shall ascertain that the
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blocking can cause hoist lines (wire rope), rigging, reeving,
weight of the load does not exceed the crane ratings at
and other components to become highly stressed and
the radius
where the load is to be handled.
overloaded in which case the wire rope may fail allowing the
• When a Boom Angle or Radius Indicator is inoperative load, block, etc. to free fall.

or malfunctioning, the radius or boom angle shall be
Two-blocking is more likely to occur when both the main and
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determined by measurement.
auxiliary hoist lines are reeved over the main boom nose and
• When an Anti-Block Device, Two-Blocking Damage b o o m e x t e n s i o n n o s e r e s p e c t i v e l y. A n o p e r a t o r,
Prevention or Two-Block Warning Device is inoperative concentrating on the specific line being used, may telescope

or malfunctioning, the designated person responsible for or lower the boom allowing the other hoist line attachment to
supervising the lifting operations shall establish contact the boom or boom extension nose, thus causing
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procedures, such as assigning an additional signal damage to the sheaves, or causing the wire rope to fail,
person to furnish equivalent protection. This does not dropping the lifting device to the ground and possibly injuring
apply when lifting personnel in load-line supported personnel working below.
personnel platforms. Personnel shall not be lifted when
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Caution must be used when lowering the boom, extending

anti-two-block devices are not functioning properly.
the boom or hoisting up. Let out load line(s) simultaneously
• When a Boom Length Indicator is inoperative or to prevent two-blocking the boom tip(s) and the hook block,
malfunctioning,
the designated person responsible for etc. The closer the load is carried to the boom nose the more
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supervising the lifting operations shall establish the important it becomes to simultaneously let out wire rope as
boom lengths at which the lift will be made by actual the boom is lowered. Keep load handling devices a minimum

measurements or marking on the boom. of 42 in (107 cm) below the boom nose at all times.
• When a Level Indicator is inoperative or malfunctioning, Two-blocking can be prevented. Operator awareness of the
other means shall be used to level the crane. hazards of two-blocking is the most important factor in
preventing this condition. An Anti-Two-Block System is

Load Moment Indication (LMI) Systems (If intended to assist the operator in preventing dangerous two-
Equipped) block conditions. It is not a replacement for operator
awareness and competence.
Your crane may be equipped with an LMI system which is
intended to aid the operator. Test daily for proper operation. Never interfere with the proper functioning of operational
aids or warning devices.
Never interfere with the proper functioning of operational
aids or warning devices.


Work Area Definition System (WADS) (If operating procedures and with the identification of symbol
Equipped) usage.
The work area definition system is intended as an aid to the
If your crane is equipped with a WADS, you must read and
operator. It is not a substitute for safe crane operating
understand the manufacturer’s Operator’s Manual before
practices, experience and good operator judgements.
operating the system. Become familiar with all proper
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CRANE STABILITY/STRUCTURAL models equipped with outriggers that can be pinned at the
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STRENGTH mid-extend position (vertical strip, if applicable), the

outriggers must also be pinned when operating from the mid-
To avoid death or serious injury, ensure that the crane is on a extend position.
firm surface with load and crane’s configuration within
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Use adequate cribbing under outrigger floats to distribute

capacity as shown on the crane’s Load Chart and notes.
weight over a greater area. Check frequently for settling.
Ensure all pins and floats are properly installed and outrigger
beams are properly extended before lifting on outriggers. On

Read and follow the following safety decal for cranes with
stabiliers.
center front
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Carefully follow the procedures in this Operator’s Manual

when extending or retracting the outriggers. Death or serious
KEEP THE BOOM SHORT. Swinging loads with a long line
injury could result from improper crane setup on outriggers.
can create an unstable condition and possible structural
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The operator must select the proper Load Chart and Load failure of the boom.
Moment Indicating (LMI) System program for the outrigger

position selected. Load Charts
Before swinging
the superstructure over the side when the Load Charts represent the absolute maximum allowable
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outriggers are retracted, check the Load Chart for backwards loads, which are based on either tipping or structural
stability. limitations of the crane under specific conditions. Knowing
the precise load radius, boom length, and boom angle
Long cantilever booms can create a tipping condition when
should be a part of your routine planning and operation.

in an extended and lowered position. Retract the boom
Actual loads, including necessary allowances, should be
proportionally with reference to the capacity of the applicable
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kept below the capacity shown on the applicable Load Chart.

Load Chart.

Load Chart capacities are based on freely suspended loads.
Check crane stability before lifting loads. Ensure the
(or tires if lifting on rubber) are firmly positioned on
outriggers You must use the appropriate Load Chart when determining
solid surfaces. Ensure the crane is level, brakes are set, and the capability of the crane in the configuration required to
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the load is properly rigged and attached to the hook. Check perform the lift.
the Load Chart against the weight of the load. Lift the load
Maximum lifting capacity is available at the shortest radius,
slightly off the ground and recheck the stability before
minimum boom length, and highest boom angle.
proceeding with the lift. Determine the weight of the load
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before you attempt the lift. Do not remove the Load Charts from the crane.

Unless lifting within On Rubber capacities, outrigger beams
Work Site
and jack cylinders (plus center front stabilizer, if equipped)
must be properly extended and set to provide precise Prior to any operation, you must inspect the entire work site,
leveling of the crane. Tires must be clear of the ground including ground conditions, where the crane will travel and
on outriggers.
before lifting 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 adversely 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


upon the direction from which the wind is blowing (e.g., wind a loss of control in handling the load. Manitowoc
on the rear of the boom can result in decreased forward recommends that, if the wind speed (velocity) is between 20
stability, wind on the underside of the boom can result in mph (32 km/h) to 30 mph (48 km/h), the load capacities shall
decreased backward stability, wind on the side of the boom be reduced to account for the size and shape of the load and
can result in structural damages, etc.). To assist you in the wind direction in relation to the machine for all boom and
determining prevailing wind conditions, refer to Table 2-1. boom extension lengths. Further, operation of the crane in
wind velocities over 30 mph (48 km/h) is not recommended.
Wind forces can exert extreme dynamic loads. Manitowoc
recommends that a lift not be made if the wind can cause
Table 2-1
Wind Force
Wind Velocity Visible Indicator
2
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Beauford mph (km/h) Effects of wind as observed on land
Designation
Scale
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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
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3 Gentle Breeze 8-12 (13-19) Leaves/small twigs in constant motion: wind extends flag
Moderate
4 13-18 (21-29) Raises dust & loose paper; moves small branches
Breeze
Reduce crane load ratings and operating parameters at 20 mph (32 km/h)
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Small trees in leaf begin to sway; on ponds, crested wavelets
5 Fresh Breeze 19-24 (31-39)
form
Large branches in motion; telegraph wires whistle; umbrellas
6 Strong Breeze 25-31 (40-50)
used with difficulty
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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
Lifting Operations and remember that all rigging (slings, etc.) and lifting devices
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(hook block, boom extension, etc.) must be considered part

Before lifting, position the crane on a firm surface, properly of the load.
extend and set the outriggers, and level the crane.
Depending on the nature of the supporting surface, Measure the load radius before making a lift and stay within
approved lifting areas based on the range diagrams and
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adequate cribbing may be required to obtain a larger bearing

surface. working area diagrams on the crane’s Load Chart.
The crane is equipped with a bubble level that should be Always keep the load as near to the crane and as close to
used to determine whether the crane is level. The load line the ground as possible.
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can also be used to estimate the levelness of the crane by Do not overload the crane by exceeding the capacities
checking to be sure it is in-line with the center of the boom at shown on the appropriate Load Chart. Death or serious
all points on the swing circle. injury could result from the crane tipping over or failing
If the boom extension, or auxiliary boom nose is to be used, structurally from overload.
ensure the electrical cable and the weight for the Anti-Two- The crane can tip over or fail structurally if:
Blo ck Swit ch are p rop erly ins ta lled an d t he LMI is
programmed for the crane configuration. Refer to the LMI • The load and crane’s configuration is not within the
handbook supplied with the crane. capacity as shown on the applicable Load Chart and
notes.
Verify the crane’s capacity by checking the Load Chart
against the weight of the load. Then, lift the load slightly at • The ground is soft and/or the surface conditions are
first to ensure stability before proceeding with the lift. poor.
Be sure the load is properly rigged and attached. Always • Outriggers are not properly extended and set. On
determine the weight of the load before you attempt to lift it models equipped with outriggers that can be pinned at

the mid-extend position, the outriggers must also be as indicated on the crane’s Load Chart, do not exceed 85%
when operating from the mid-extend position.
pinned of the tipping load on outriggers as determined by SAE J765
OCT80 “Cranes Stability Test Code.” An outrigger pad may
• Cribbing under the outrigger pads is inadequate.
lift off the ground during operation of the crane within the
• The crane is improperly operated. capacity limits of the Load Chart, yet the crane will not have
reached instability. The “balance point” for stability testing
on the crane’s tipping to determine your lifting
Do not rely
according to SAE and Manitowoc criteria is a condition of
capacity.
loading wherein the load moment acting to overturn the

Be sure the hoist line is vertical before lifting. Do not subject crane is equal to the maximum moment of the crane
the crane to side loading. A side load can tip the crane or available to resist overturning. This balance point or point of
fail structurally.
cause it to instability for a crane does not depend on “lifting” of an
outrigger but rather on comparison of the “opposing” load
Load Chart capacities are based on freely suspended loads.
moments.
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Do not pull posts, pilings, or submerged articles. Be sure the
load is not frozen or otherwise attached to the ground before The occurrence of an outrigger lifting from the ground is often
lifting. attributed to the natural flex in the crane’s frame. This may
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happen when lifting a load in certain configurations within the
If you should
encounter a tipping condition, immediately capacity limits of the Load Chart and is not necessarily an
lower the load with the hoist line and retract or elevate the indication of an unstable condition.
boom to decrease the load radius. Never lower or extend the

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boom; this will aggravate the condition. Provided the crane is properly set up, the crane is in good
working condition, that all operator’s aids are properly
Use tag lines whenever possible to help control the programmed, that the qualified crane operator adheres to
movement of the load. the instructions found in the applicable Load Chart,
loads, the crane will lean toward the boom and
When lifting Operator’s Manual and decals on the crane, the crane
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the load will swing out, increasing the load radius. Ensure the should not be unstable.
crane’s capacity
is not exceeded when this occurs.
Multiple Crane Lifts
Do not strike any obstruction with the boom. If the boom

should accidentally contact an object, stop immediately. Multiple crane lifts are not recommended.
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Inspect the boom. Remove the crane from service if the Any lift that requires more that one crane must be precisely

boom is damaged. planned and coordinated by a qualified engineer.
Never push or pull with the crane boom. If it is necessary to perform a multi-crane lift, the operator

Avoid sudden starts and stops when moving the load. The shall be responsible for assuring that the following minimum
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inertia and an increased load radius could tip the crane over safety precautions are taken:

or cause it to fail structurally. • Secure the services of a qualified engineer to direct the
Use only one hoist at a time when lifting loads. operation.
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Always use enough parts-of-line to accommodate the load to • Use one qualified signal person.
be lifted. Lifting with too few parts-of-line can result in failure • Coordinate lifting plans with the operators, engineer, and
of the wire rope. signal person prior to beginning the lift.

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Counterweight • Maintain communication between all parties throughout

equipped with removable counterweights, ensure the entire operation. If possible, provide approved radio
On cranes equipment for voice communication between all parties
the appropriate counterweight sections are properly installed engaged in the lift.
for the lift being considered.
• Use cranes and rigging of equal capabilities and use the
Do not add material to the counterweight to increase same boom length.
capacity. United States Federal law prohibits modification or
additions which affect the capacity or safe operation of the • Use outriggers on cranes so equipped.
equipment without the manufacturer’s written approval. • Be certain cranes are of adequate lifting capacity.
[29CFR 1926.1434]
• Calculate the amount of weight to be lifted by each crane

Outrigger Lift Off and attach slings at the correct points for proper weight
distribution.
Regarding “lifting” of an outrigger pad during craning
activities, be advised that the rated loads for these cranes,


• Ensure the load lines are directly over the attach points This crane is not designed or equipped for use within 10 feet
to avoid side loading and transfer of loading from one (3 meters) of energized power lines [Refer to
crane to the other. 29CFR1926.1410 Table A]. If operation within 10 feet (3
meters) of any power lines cannot be avoided, the power
• Do not travel. Lift only from a stationary position.
utility must be notified and the power lines must be de-
energized and grounded before performing any work.
ELECTROCUTION HAZARD
If contact is ever accidentally made with a power line and any
To avoid death or serious injury, keep all parts of the crane, part of this crane, its rigging or load, never touch the crane or
rigging and load at least 20 feet (6 meters) away from any even approach or come near the crane.
e n e r g i z e d p o w e r l i n e . Yo u m u s t f o l l o w t h e O S H A
requirements set forth in 29CFR 1926.1407 through Electrocution can occur even without direct contact with the
1926.1411. crane.
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Crane operation is dangerous when close to an energized If the load, wire rope, boom, or any portion of the crane
electrical power source. Exercise extreme caution and contacts or comes too close to an electrical power source,
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prudent judgement. Operate slowly and cautiously when in everyone in, on, and around the crane can be seriously
the vicinity of power lines. injured or killed.
Before operating this crane in the vicinity of electrical power Most overhead power lines are not insulated. Treat all
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lines or equipment, notify the power utility company. Obtain overhead power lines as being energized unless you have
positive and absolute assurance that the power has been reliable information to the contrary from the utility company
turned off. or owner.
This crane is not insulated. Always consider all parts of the The rules in this Operator’s Manual must be followed at all
load and the crane, including the wire rope, hoist cable, times, even if the electrical power lines or equipment have
pendant cables, and tag lines, as conductors. You, the been de-energized.
operator, are responsible for alerting all personnel of
The safest way to avoid electrocution is to stay away from
dangers associated with electrical power lines and
electrical power lines and electrical power sources.
equipment. Do not allow unnecessary personnel in the
vicinity of the crane while operating. Permit no one to lean It is not always necessary to contact a power line or power
against or touch the crane. Permit no one, including riggers source to become electrocuted. Electricity, depending on
and load handlers, to hold the load, load lines, tag lines, or magnitude, can arc or jump to any part of the load, load line,
rigging gear. or crane boom if it comes too close to an electrical power
source. Low voltages can also be dangerous.

Thoroughly read, understand, and abide by all applicable Electrocution Hazard Devices

federal, state, and local regulations.
The use of insulated links, insulated boom cages/guards,
Set-Up and Operation proximity warning devices, or mechanical limit stops does
not assure that electrical contact will not occur. Even if codes
During crane use, assume that every line is energized (“hot” or regulations require the use of such devices, failure to
or “live”) and take the necessary precautions. follow the rules listed here may result in serious injury or
Set up the crane in a position such that the load, boom, or death. You should be aware that such devices have
the crane and its attachments cannot be moved to
any part of limitations and you should follow the rules and precautions
within 20 ft (6 m) of electrical power lines or equipment. This outlined in this manual at all times even if the crane is
includes the crane boom (fully extended to maximum height, equipped with these devices.
radius, and length) and all attachments (boom extensions, Insulating links installed into the load line afford limited

rigging, loads, etc.). Overhead lines tend to blow in the wind
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protection from electrocution hazards. Links are limited in
so allow for lines’ movement when determining safe their lifting abilities, insulating properties, and other
operating distance. properties that affect their performance. Moisture, dust, dirt,
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A suitable barricade should be erected to physically restrain oils, and other contaminants can cause a link to conduct
the crane and all attachments (including the load) from electricity. Due to their capacity ratings, some links are not
entering into an unsafe distance from electrical power lines effective for large cranes and/or high voltages/currents.
or equipment.

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The only protection that may be afforded by an insulated link
Plan ahead and always plan a safe route before traveling is below the link (electrically downstream), provided the link

under power lines. Rider poles should be erected on each has been kept clean, free of contamination, has not been
side of a crossing to assure sufficient clearance is scratched or damaged, and is periodically tested (just before

maintained. use) for its dielectric integrity.
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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
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size, insulating characteristics, and operating environment

(e.g. dust, dirt, moisture, etc.). The insulating characteristics

of these devices can be compromised if not kept clean, free
of contamination, and undamaged.

Proximity sensing and warning devices are available in
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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
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upon you, the operator, in selecting and properly setting the

sensitivity of these devices.
Never rely solely on a device to protect you and your fellow

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

Some variables you must know and understand are:
Appoint a reliable and qualified signal person, equipped with
a loud signal whistle or horn and voice communication • Proximity devices are advertised to detect the existence
to warn the operator when any part of the crane
equipment, of electricity and not its quantity or magnitude.
or load moves near a power source. This person should • Some proximity devices may detect only alternating

have no other duties while the crane is working. current (AC) and not direct current (DC).
Tag lines should always be made of non-conductive • Some proximity devices detect radio frequency (RF)
materials. Any tag line that is wet or dirty can conduct energy and others do not.
electricity.
• Most proximity devices simply provide a signal (audible,
Do not store materials under power lines or close to visual, or both) for the operator; this signal must not be
electrical power sources. ignored.


• Sometimes the sensing portion of the proximity devices • Every precaution must be taken to dissipate induced
becomes confused by complex or differing arrays of voltages. Consult a qualified RF (radio frequency)
power lines and power sources. Consultant. Also refer to local, state, and federal codes
and regulations.
Do not depend on grounding. Grounding of a crane affords
little or no p rotec tion f rom elect ric al h aza rds. The When operating cranes equipped with electromagnets, you
effectiveness of grounding is limited by the size of the must take additional precautions. Permit no one to touch the
conductor (wire) used, the condition of the ground, the magnet or load. Alert personnel by sounding a warning
magnitude of the voltage and current present, and numerous signal when moving a load. Do not allow the cover of the
other factors. electromagnet power supply to be open during operation or
at any time the electrical system is activated. Shut down the
Electrical Contact crane completely and open the magnet controls switch prior
to connecting or disconnecting magnet leads. Use only a
If the crane should come in contact with an energized power
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non-conductive device when positioning a load. Lower the
source, you must:
magnet to the stowing area and shut off power before
1. Stay in the crane cab. Don’t panic. leaving the operator’s cab (if equipped) or operator’s station.
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2. Immediately warn personnel in the vicinity to stay away.
PERSONNEL HANDLING
3. Attempt to move the crane away from the contacted
power source using the crane’s controls which are likely The American Society of Mechanical Engineers issued a
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to remain functional. new American National Standard entitled, Personnel Lifting
Systems, ASME B30.23-2005. This standard provides,
4. Stay in the crane until the power company has been “lifting and lowering of personnel using ASME B30 Standard
contacted and the power source has been de-energized. hoisting equipment shall be undertaken only in
No one must attempt to come close to the crane or load
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circumstances when it is not possible to accomplish the task
until the power has been turned off. by less hazardous means. Unless all of the applicable
Only as a last resort should an operator attempt to leave the requirements of this volume are met, the lifting or lowering of
crane upon contacting a power source. If it is absolutely personnel using ASME B30 Standard equipment is
necessary to leave the operator’s station, jump completely prohibited.” This new standard is consistent with the U.S.
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clear of the crane. Do not step off. Hop away with both feet Department of Labor, Occupational Safety and Health
together. Do not walk or run. Administration (OSHA) regulations for Construction that
state, in 29CFRI926.1431: “General requirements. The use
Following any contact with an energized electrical source, of a crane or derrick to hoist employees on a personnel
the Manitowoc dealer must be immediately advised of the platform is prohibited, except when the erection, use, and
incident and consulted on necessary inspections and dismantling of conventional means of reaching the worksite,
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repairs. Thoroughly inspect the wire rope and all points of such as a personnel hoist, ladder, stairway, aerial lift,
contact on the crane. Should the dealer not be immediately elevating work platform or scaffold, would be more
available, contact Manitowoc Crane Care. The crane must hazardous or is not possible because of structural design or
not be returned to service until it is thoroughly inspected for worksite conditions.” Additional requirements for crane
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any evidence of damage and all damaged parts are repaired o pe r a ti o ns ar e s ta te d i n A S M E B 3 0. 5 , M o b il e A nd

or replaced as authorized by your Manitowoc dealer or Locomotive Cranes, and in OSHA regulations
Manitowoc Crane Care. 29CFRI910.180 for General Industry and 29CFRI926.1431
for Construction.
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Special Operating Conditions and

Use of a Manitowoc crane to handle personnel is acceptable
Equipment provided:
Never operate the crane during an electrical thunderstorm.
• The requirements of the applicable national, state and
When operating near transmitter/communication towers local regulations and safety codes are met.
where an electrical charge can be induced into the crane or
• A determination has been made that use of a crane to
load:
handle personnel is the least hazardous means to
• The transmitter shall be deenergized OR, perform the work.
• Tests shall be made to determine if an electrical charge • The crane operator shall be qualified to operate the
will be induced into the crane or load. specific type of hoisting equipment used in the
personnel lift.
• The crane must be provided an electrical ground.
• The crane operator must remain at the crane controls at
• If taglines are used, they must be non-conductive. all times when personnel are off the ground.

• The crane operator and occupants have been instructed And Locomotive Cranes, and ASME B30.23, Personnel
recognized hazards of personnel platform lifts.
in the Lifting Systems, are available by mail from the ASME, 22
Law Drive, Fairfield, New Jersey, 0700-2900
• The crane is in proper working order.
• US DOL/OSHA Rules and Regulations are available by
• The crane must be equipped with a boom angle
mail from the Superintendent of Documents, PO Box
indicator
that is visible to the crane operator.
371954, Pittsburgh, PA, 15250-7954.
• The crane's Load Chart is affixed at the operator’s
and readily accessible to the operator. The total
station ENVIRONMENTAL PROTECTION
weight of the loaded personnel platform and related
rigging Dispose of waste properly! Improperly disposing of waste
shall not exceed 50 percent of the rated capacity can threaten the environment.
for the radius and configuration of the crane.
• The crane is level within one percent of level grade and Potentially harmful waste used in Manitowoc cranes includes
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located on a firm footing. Cranes with outriggers shall — but is not limited to — oil, fuel, grease, coolant, air
have them all deployed following manufacturer's conditioning refrigerant, filters, batteries, and cloths which
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specifications. have come into contact with these environmentally harmful
substances.
• The crane's Operator's Manual and other operating
manuals are at the operator ’s station and readily Handle and dispose of waste according to local, state, and

accessible to the operator. federal environmental regulations.
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• The platform meets the requirements as prescribed by When filling and draining crane components, observe the

applicable standards and regulations. following:
• For wire rope suspended platforms: • Do not pour waste fluids onto the ground, down any

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drain, or into any source of water.
- The crane is equipped with a hook that can be
• Always drain waste fluids into leak proof containers that
closed and locked, eliminating the throat opening.
are clearly marked with what they contain.
- The crane is equipped with a functional Anti-Two-
Block Device. • Always fill or add fluids with a funnel or a filling pump.
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- The platform is properly attached and secured to the • Immediately clean up any spills.
load hook.
MAINTENANCE
• For boom
mounted platforms:
The crane must be inspected prior to use on each work shift.
- Use only Manitowoc approved personnel platforms
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The owner, user, and operator must ensure that routine

attached to the boom.
maintenance and lubrication are being dutifully performed.
- The platform is properly attached and secure. Never operate a damaged or poorly maintained crane.

To avoid death or serious injury: Manitowoc continues to recommend that cranes be properly
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use this crane for bungee jumping or any form maintained, regularly inspected and repaired as necessary.
• NEVER
Manitowoc reminds crane owners to ensure that all safety
of amusement or sport.
decals are in place and legible. Manitowoc continues to urge
crane owners to upgrade their cranes with load moment
• NEVER handle personnel on the loadline unless the
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requirements of applicable national, state and local indicator (LMI) and control lever lockout systems for all lifting

regulations and safety codes are met. operations.
• NEVER permit anyone to ride loads, hooks, slings or Shut down the crane while making repairs or adjustments.

other rigging for any reason.
Always perform a function check after repairs have been
• NEVER
get on or off a moving crane. made to ensure proper operation. Load tests should be
performed when structural or lifting members are involved.
• NEVER allow anyone other than the operator to be on

this crane while the machine is operating or traveling. Follow all applicable safety precautions in this manual when
performing crane maintenance as well as crane operations.
The following standards and regulations regarding personnel
handling are available by mail at the following addresses: Keep the crane free of mud, dirt, and grease at all times.
Dirty equipment introduces hazards, wears-out faster, and
• ASME (formerly ANSI) B30 Series American National makes proper maintenance difficult. Cleaning solutions used
Standards For Cableways, Cranes, Derricks,
Safety
Hoists, Hooks, Jacks, and Slings; ASME B30.5, Mobile


should be non-flammable, non-toxic and appropriate for the • Do not attempt to repair or tighten any hydraulic hose or
job. fitting while the engine is running, or when the hydraulic
system is under pressure.
Routine maintenance and inspection of this crane must be
performed by a qualified person(s) according to the • Never disconnect any hydraulic lines unless the boom is
recommendations in the Manitowoc Crane Care fully lowered, the engine is shut off, and the hydraulic
Maintenance and Inspection Manual. Any questions pressure is relieved. To relieve hydraulic pressure, stop
regarding procedures and specifications should be directed the engine and move the hydraulic controls in both
to your Manitowoc dealer. directions several times.
Service and Repairs • 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
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appropriate eye protection.
Moving Parts:
WARNING
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• Do not place limbs near moving parts. Amputation of a
Fall Hazard!
body part may result. Turn off the engine and wait until
Working at elevated heights without using proper fall the fan and belts stop moving before servicing crane.
protection can result in severe injury or death.
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• Pinch points, which result from relative motion between
Always use proper fall protection as required by local,
mechanical parts, are areas of the machine that can
state or federal regulations.
cause personal injury or death. Do not place limbs or
your body in contact with pinch points either on or
Service and repairs to the crane must only be performed by a
around the machine. Care must be taken to prevent
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qualified person. All service and repairs must be performed
m o t i o n b e t w e e n p i n c h p o i n ts w h e n p e r f o r m i n g
in accordance with manufacturer’s recommendations, this
maintenance and to avoid such areas when movement
manual, and the service manual for this machine. If there is
is possible.
any question regarding maintenance procedures or
specifications, contact your Manitowoc dealer for assistance. • Do not allow persons to stand near extending or
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lowering outriggers. Foot crushing could occur

Qualified person is defined as one who by reason of
knowledge, training and experience is thoroughly familiar Before performing any maintenance, service or repairs on
with the crane’s operation and required maintenance as well the crane:
as the hazards involved in performing these tasks.
• The boom should be fully retracted and lowered and the
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Training and qualification of maintenance and repair load placed on the ground.
personnel are crane owner’s responsibility.
• Do not get under a raised boom unless the boom is
Any modification, alteration, or change to a crane which blocked up safely. Always block up the boom before
affects its original design and is not authorized and approved doing any servicing that requires the boom to be raised.
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by Manitowoc is strictly prohibited. All replacement parts

• Stop the engine and disconnect the battery.
must be Manitowoc approved. Such action invalidates all
warranties and makes the owner/user liable for any resultant • Controls should be properly tagged. Never operate the
accidents. crane if it is tagged-out nor attempt to do so until it is
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restored to proper operating condition and all tags have

Hydraulic Fluid:
been removed by the person(s) who installed them.
• Do not use your hand or any part of your body to check
After maintenance or repairs:
for hydraulic fluid leaks when the engine is running or
the hydraulic system is under pressure. Fluid in the • Replace all guards and covers that have been removed.
hydraulic system can be under enough pressure that it
• Remove all tags, connect the battery, and perform a
will penetrate the skin, causing serious injury or death.
function check of all operating controls.
Use a piece of cardboard, or piece of paper, to search
for leaks. Wear gloves to protect your hands from • Consult with Manitowoc Crane Care to determine if load
spraying fluid. testing is required after a structural repair is performed.
• If any hydraulic fluid is injected into the skin, obtain
Lubrication
medical attention immediately or gangrene may result.
The crane must be lubricated according to the
manufacturer’s recommendations for lubrication points, time

intervals, and types. Lubricate at more frequent intervals length of rope equal to thirty (30) times the rope

when working under severe conditions. diameter.
Exercise care when servicing the hydraulic system of the • For running ropes other than rotation resistant: six (6)
crane, as pressurized hydraulic oil can cause serious injury. broken wires in one rope lay or three (3) broken wires in
The following precautions must be taken when servicing the one strand.
hydraulic system:
• One valley break where the wire fractures between
• Follow the manufacturer’s recommendations when strands in a running rope is cause for removal.
oil to the system. Mixing the wrong fluids could
adding
• Abrasion of the rope resulting in wear of the individual
destroy seals, causing component failure.
outside wires of 1/3 of the original wire diameter.
• Be certain all lines, components, and fittings are tight
• Any kinking, bird caging, crushing, corrosion, or other
before resuming operation.
damage resulting in distortion of the rope structure.
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Tires • Rope that has been in contact with a live power line or
has been used as a ground in an electric circuit (eg.
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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

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WARNING rope lay in sections beyond the end connection or more
Possible equipment damage and/or than two (2) broken wires at an end connection.
personal injury!
• Core deterioration, usually observed as a rapid
Driving the crane with a tire and split-rim assembly under reduction in rope diameter, is cause for immediate
inflated at 80% or less of its recommended pressure can
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removal of the rope.
cause the wheel and/or tire to fail. Per OSHA Standard

1910.177(f)(2), when a tire has been driven under inflated The following is a brief outline of the basic information
at 80% or less of its recommended pressure, it must first required to safely use wire rope.
be com p l e t el y d e fl a t e d, r em o v ed f r o m t h e ax l e , • Wire ropes wear out. The strength of a wire rope begins
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disassembled, and inspected before re-inflation. to decrease when the rope is put to use and continues to
decrease with each use. Wire rope will fail if worn-out,
Inspect the tires for nicks, cuts, embedded material, and overloaded, misused, damaged or improperly
abnormal wear. maintained.

Ensure all lug nuts are properly torqued. • The nominal strength, sometimes called catalog
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Ensure pneumatic tires are inflated to the proper pressure strength, of a wire rope applies only to a new, unused
(refer to the Load Chart). When inflating tires, use a tire rope.

gauge, clip-on inflator, and extension hose which will permit • The nominal strength of a wire rope should be
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standing clear of the tire while inflating. considered the straight line pull which will actually break
a new unused rope. The nominal strength of a wire rope
Wire Rope should never be used as its working load.
Use only the wire rope specified by Manitowoc as indicated • Each type of fitting attached to a wire rope has a specific
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on the crane’s Load Chart. Substitution of an alternate wire efficiency rating which can reduce the working load of
rope may require the use of a different permissible line pull the wire rope assembly or rope system.
and, therefore, require different reeving.
• Never overload a wire rope. This means never use the
NOTE: Wire rope may be purchased by contacting wire rope where the load applied to it is greater than the
Manitowoc Crane Care. working load determined by the rope manufacturer.

Always make daily inspections of the wire rope, keeping in • Never “shock load” a wire rope. A sudden application of
mind that all wire rope will eventually deteriorate to a point force or load can cause both visible external and internal
where it is no longer usable. Refuse to work with worn or damage. There is no practical way to estimate the force
damaged wire rope. Wire rope shall be taken out of service applied by shock loading a rope. The sudden release of
when any of the following conditions exist: a load can also damage a wire rope.
• For rotation-resistant running ropes: more than two (2) • Lubricant is applied to the wires and strands of a wire
wires in a length of rope equal to six (6) times the
broken rope when it is manufactured. The lubricant is depleted
rope diameter, or more than four (4) broken wires in a when the rope is in service and should be replaced


periodically. Refer to the Service Manual for more • When a wire rope has been removed from service
information. because it is no longer suitable for use, it must not be
reused on another application.
• In the U.S.A., regular inspections of the wire rope and
keeping of permanent records signed by a qualified When installing a new rope:
person are required by OSHA for almost every wire rope
• Keep all parts of your body and clothing away from
application. The purpose of the inspection is to
rotating hoist drums and all rotating sheaves.
determine whether or not a wire rope may continue to be
safely used on the application. Inspection criteria, • Never handle the wire rope with bare hands.
including number and location of broken wires, wear and
• Follow proper instructions for removing rope from a reel.
elongation, have been established by OSHA, ANSI,
ASME and similar organizations. See the Service • Apply back tension to the storage/payoff reel of the new
Manual for inspection procedures. rope to insure tight, even spooling onto the hoist drum.
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When inspecting wire ropes and attachments, keep all • Operate the new rope - first through several cycles at
parts of your body and clothing away from rotating hoist light load and then through several cycles at
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drums and all rotating sheaves. Never handle the wire intermediate load to allow the rope to adjust to operating
rope with bare hands. conditions.
Some conditions that lead to problems in wire rope When using a wedge socket:
systems include:
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• Always inspect socket, wedge, and pin for correct size
- Sheaves that are too small, worn or corrugated and condition.
cause damage to a wire rope.
• Do not use parts that are damaged, cracked, or
- Broken wires mean a loss in strength. modified.
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- Kinks permanently damage a wire rope and must be • Assemble the wedge socket with live end of rope aligned
avoided. with the centerline of pin and assure proper length of tail
(dead end) protrudes beyond the socket.
- Wire ropes are damaged by knots. Wire rope with
knots must never be used.
Sheaves
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- Environmental factors such as corrosive conditions

and heat can damage a wire rope.
- Lack of lubrication can significantly shorten the
useful life of a wire rope.
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- Contact with electrical wires and resulting arcing will

damage a wire rope.
• An inspection should include verification that none of the
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specified removal criteria for this usage are met by

checking for such things as:
- Surface wear; nominal and unusual.
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- Broken wires; number and location.

- Reduction in diameter.
Inspect the boom nose and hook block sheaves for proper
- Rope stretch (elongation). operation, excessive wear, and damage every 50 hours or
- Integrity of end attachments. weekly. Inoperable, damaged and/or worn sheaves cause
rapid deterioration of wire rope.
- Evidence of abuse or contact with another object.
Ensure sheaves carrying ropes that can be momentarily
- Heat damage. unloaded are equipped with close fitting guards or other
- Corrosion. devices to guide the rope back into the groove when the load
is reapplied. Ensure sheaves in the lower load block are
NOTE: A more detailed wire rope inspection procedure is equipped with close fitting guards that will prevent the ropes
given in the Service Manual. from becoming fouled when the block is lying on the ground
with loose ropes.

To attain maximum wire rope life and minimize hook block allow the radiator time to cool before removing the radiator
rotation, it is recommended that even numbers of parts-of- cap.
line be used in multiple-part reeving whenever possible.
Shut down the engine and disconnect the battery before
The use of nylon (nylatron) sheaves, as compared with performing maintenance. If unable to do so for the task
metallic sheaves, may change the replacement criteria of required, keep hands clear of the engine fan and other

rotation-resistant wire rope. moving parts while performing maintenance.
NOTE: The use of cast nylon (nylatron) sheaves will Be careful of hot surfaces and hot fluids when performing
substantially increase the service life of wire rope. maintenance on or around the engine.
However, conventional rope retirement criteria
based only upon visible wire breaks may prove Do not use ether to start the engine on cranes equipped with
intake manifold grid heaters.
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 TRANSPORTING THE CRANE
upon the user’s experience and the demands of his Before transporting the crane, check the suitability of the
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application. proposed route with regard to the crane height, width, length,
and weight.
Batteries
Check load limits of bridges on the travel route and ensure
Battery electrolyte
must not be allowed to contact the skin or
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they are greater than the combined weight of the crane and
eyes. If this occurs, flush the contacted area with water and transporting vehicle.
consult a doctor immediately.
When loading or unloading the crane on a trailer or railroad
When checking and maintaining batteries, exercise the car, use a ramp capable of supporting the weight of the
following procedures and precautions:
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crane.
• Wear safety glasses when servicing batteries. Ensure the crane is adequately secured to the transporting

• If equipped, disconnect battery with the battery vehicle.
disconnect switch before disconnecting the ground Before transporting the crane on a road or highway, first

battery cable.
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check state and local restrictions and regulations.

• Do not break a live circuit at the battery terminal. When using hookblock tie downs, excessive loading can be
Disconnect the ground battery cable first when removing applied by pulling the cable too tight, particularly when
a battery
and connect it last when installing a battery. reeved with multiple part lines. When the cable is hooked
• Do not short across the battery posts to check charge. into the hookblock tie down, the cable should be merely
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circuit, spark, or flame could cause battery

Short “snugged-up” with slack provided at the center line of sheave
explosion. to anchor point. Care must be exercised anytime any crane
function is being performed while the cable is hooked into the
•
Maintain battery electrolyte at the proper level. Check hookblock tie down. Do not draw cable taut.
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the electrolyte with a flashlight.

• If applicable to your crane, check battery test indicator TRAVEL OPERATION
on maintenance-free batteries.
Only the crane operator shall occupy the crane when
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• Check battery condition only with proper test equipment. traveling.

Batteries
shall not be charged except in an open, well-
When traveling, the boom should be completely retracted
ventilated area that is free of flame, smoking, sparks,
and lowered to the travel position and the turntable pin swing
and fire.
lock should be engaged. If equipped with boom rest, lower
Engine the boom into the boom rest and engage the turntable lock.
Strictly adhere to the guidelines and restrictions in the Load
Fuel the crane only with the engine turned off. Do not smoke
Chart for pick and carry operations.
while fueling the crane. Do not store flammable materials on

the crane. This machine is manufactured with no axle suspension
system. Traveling at high speeds, especially on rough
Be familiar with the location and use of the nearest fire

extinguisher.
ground, may create a bouncing affect that can result in loss
of control. If bouncing occurs, reduce travel speed. (RT and
Be careful
when checking the engine coolant level. The fluid Shuttle Lift Only)
may be hot and under pressure. Shut down the engine and


Death or serious injury could result from being crushed by Check load limit of bridges. Before traveling across bridges,
revolving tires. 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,
“Stunt” driving and “horse-play” are strictly prohibited. Never check state and local restrictions and regulations.
allow anyone to hitch a ride or get on or off a moving crane.
Keep lights on, use traffic warning flags and signs, and use
Follow the instructions in this manual when preparing the front and rear flag vehicles when necessary. Check state and
crane for travel. local restrictions and regulations.
If using a boom dolly/trailer, thoroughly read and understand Always drive the crane carefully obeying speed limits and
all the steps and safety precautions in this manual for setup highway regulations.
and travel.
Stay alert at the wheel.
When driving the crane, ensure the cab is level, if equipped
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with a tilting cab. If equipped, ensure that the hoist access platform hand rail
and step are in the travel configuration.
Secure the hook block and other items before moving the
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crane. Slopes:
Watch clearances when traveling. Do not take a chance of - Pick and carry on level surfaces only.
running into overhead or side obstructions. - Refer to the Operation Section for more detailed
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When moving in tight quarters, post a signal person to help information on traveling on slopes.
guard against collisions or bumping structures. - Driving across a slope is dangerous, as unexpected
Before traveling a crane, check suitability of proposed route changes in slope can cause tip over. Ascend or
with regard to crane height, width, and length. descend slopes slowly and with caution.
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Never back up without the aid of a signal person to verify the - Ascend or descend slopes with the boom pointing
area behind the crane is clear of obstructions and/or up the slope.
personnel. - When operating on a downhill slope, reduce travel
On cranes equipped with air-operated brakes, do not attempt speed and downshift to a low gear to permit
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to move the crane until brake system air pressure is at compression braking by the engine and aid the
operating level. application of the service brakes.
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WORK PRACTICES or walking/working surfaces could cause a slipping accident.

A shoe that is not clean might slip off a control pedal during
Personal Considerations operation.
Do not allow ground personnel to store their personal
Always adjust the seat and lock it in position, and fasten the
seat belt securely before you start the engine. belongings (clothing, lunch boxes, water coolers, and the
like) on the crane. This practice will prevent ground
Do not wear loose clothing or jewelry that can get caught on personnel from being crushed or electrocuted when they
controls or moving parts. Wear the protective clothing and attempt to access personal belongings stored on the crane.
personal safety gear issued or called for by the job
conditions. Hard hat, safety shoes, ear protectors, reflective Job Preparation
clothing, safety goggles, and heavy gloves may be required.
Before crane use:
Crane Access
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• Barricade the entire area where the crane is working and
keep all unnecessary personnel out of the work area.

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• Ensure that the crane is properly equipped including
access steps, covers, doors, guards, and controls.
WARNING
Fall Hazard! • Conduct a visual inspection for cracked welds, damaged

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components, loose pins/bolts, and wire connections.
Working at elevated heights without using proper fall
Any item or component that is found to be loose or
protection can result in severe injury or death.
damaged (broken, chipped, cracked, worn-through, etc.)
Always use proper fall protection as required by local, must be repaired or replaced. Inspect for evidence of
state or federal regulations. improper maintenance (consult your Service Manual).

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You must take every precaution to ensure you do not slip • Check for proper functioning of all controls and operator
off the crane. Falling from any elevation could
and/or fall aids (e.g. LMI).
result in serious injury or death. • Check all braking (e.g. wheel, hoist, and swing brakes)
or enter the crane cab or deck by any other means
Never exit and holding devices before operation.
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than the access system(s) provided (i.e., steps and grab You must ensure that the outriggers and stabilizers are
handles). Use the recommended hand-holds and steps to properly extended and set before performing any lifting
maintain a three-point contact when getting on or off the operations. On models equipped with outriggers that can be
crane. pinned at the mid-extend position, the outriggers must also
be pinned when operating from the mid-extend position.
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If necessary, use a ladder or aerial work platform to access

the boom nose. Clear all personnel from the outrigger area before extending
Do not make modifications or additions to the crane’s access or retracting the outriggers. Carefully follow the procedures
in this Operator’s Manual when extending or retracting the
system that have not been evaluated and approved by
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Manitowoc Crane Care. outriggers. Death or serious injury could result from improper
crane set up on outriggers.
Do not step on surfaces on the crane that are not approved
or suitable Be familiar with surface conditions and the presence of
for walking and working. All walking and working overhead obstructions and power lines.
surfaces on the crane should be clean, dry, slip-resistant,
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and have adequate supporting capacity. Do not walk on a

surface if slip-resistant material is missing or excessively Working
worn. Operator shall be responsible for all operations under his/her
direct control. When safety of an operation is in doubt,
Do not use the top of the boom as a walkway.
operator shall stop the crane’s functions in a controlled
on the outrigger beams or outrigger pads (floats)
Do not step manner. Lift operations shall resume only after safety
to enter or exit the crane. concerns have been addressed or the continuation of crane

Use the hoist access platform (if equipped) when working in operations is directed by the lift supervisor.
the hoist area. Know the location and function of all machine controls.
with a highly slip-resistant sole material. Clean
Wear shoes Make sure all persons are away from the crane and the
any mud or debris from shoes before entering the crane cab/ Travel Select Lever is in the “N” (Neutral) position with the
station or climbing onto the crane superstructure.
operator’s parking brake engaged before starting the engine.
Excessive dirt and debris on the hand-holds, access steps,


Sparks from the crane’s electrical system and/or engine

exhaust can cause an explosion. Do not operate this crane
in an area with flammable dust or vapors, unless good
ventilation has removed the hazard.
Carbon monoxide fumes from the engine exhaust can cause
suffocation in an enclosed area. Good ventilation is very
important when operating the crane.
Before actuating swing or any other crane function, sound
the horn and verify that all personnel are clear of rotating and
moving parts.
Never operate the crane when darkness, fog, or other
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visibility restrictions make operation unsafe. Never operate a
crane in thunderstorms or high winds.
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Always be aware of your working environment during
operation of the crane. Avoid contacting any part of the crane
with external objects.
Clear all personnel from the counterweight and
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superstructure area before removing the counterweight.
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Lifting
Use enough parts of line for all lifts and check all lines,
slings, and chains for correct attachment. To obtain
maximum lifting capacities, the hook block must be set up
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Keep unauthorized personnel clear of the working area

during operation. with enough parts of line. Too few parts of line can result in
failure of the wire rope or hoist. No less than three wraps of
Only the crane operator shall occupy the crane when in wire rope should remain on the hoist drum. When slings, ties,
operation. hooks, etc., are used, make certain they are correctly
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You must always be aware of everything around the crane positioned and secured before raising or lowering the loads.
while lifting or traveling. If you are unable to clearly see in the Be sure the rigging is adequate before lifting. Use tag lines
direction of motion, you must post a look out or signal person when possible to position and restrain loads. Personnel
before moving the crane or making a lift. Sound the horn to
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using tag lines should be on the ground.

warn personnel
Be sure good rigging practices are being used. Refuse to
Operate the crane only from the operator’s seat. Do not use any poorly maintained or damaged equipment. Never
reach in a window or door to operate any controls. wrap the hoist cable around a load.
Operate the crane slowly and cautiously, looking carefully in If using a clam bucket, do not exceed 80% of the crane’s
the direction of movement. capacity.
A good practice is to make a “dry run” without a load before Make certain the boom tip is centered directly over the load
making the first lift. Become familiar with all factors peculiar before lifting.
to the job site.
Ensure that all slings, ties, and hooks are correctly placed
Ensure the wire rope is properly routed on the hook block and secured before raising or lowering the load.
and boom nose and that all rope guards are in place.
Be sure the load is well secured and attached to the hook
with rigging of proper size and in good condition.

Check the hoist brake by raising the load a few inches, If the boom should contact an object, stop immediately and
stopping the hoist and holding the load. Be sure the hoist inspect the boom. Remove the crane from service if the
brake is working correctly before continuing the lift. boom is damaged.

When lowering a load always slow down the load’s descent When lifting a load the boom may deflect causing the load
before stopping the hoist. Do not attempt to change speeds radius to increase—this condition is made worse when the

on multiple-speed hoists while the hoist is in motion. boom is extended. Ensure weight of load is within crane’s
capacity on Load Chart.
Watch the path of the boom and load when swinging. Avoid
lowering or swinging the boom and load into ground Avoid sudden starts and stops when moving the load. The
personnel, equipment, or other objects. inertia and an increased load radius could tip the crane over
or cause it to fail structurally.
Lift one load at a time. Do not lift two or more separately
rigged loads at one time, even if the loads are within the Use tag lines (as appropriate) for positioning and restraining

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crane’s rated capacity. loads. Check the load slings before lifting.
Never leave
the crane with a load suspended. Should it Be sure everyone is clear of the crane and work area before
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become necessary to leave the crane, lower the load to the making any lifts.
ground and stop the engine before leaving the operator’s
Never swing over personnel, regardless of whether load is
station.
suspended from or attached to the boom.
Remember, all rigging equipment must be considered as
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part of the load. Lifting capacities vary with working areas. If Hand Signals
applicable,
permissible working areas are listed in the Load A single qualified signal person shall be used at all times
Chart. When swinging from one working area to another,
when:
ensure Load Chart capacities are not exceeded. Know your

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crane! • Working in the vicinity of power lines.
Stop the hook block from swinging when unhooking a load. • The crane operator cannot clearly see the load at all
times.
Swinging rapidly can cause the load to swing out and
increase the load radius. Swing the load slowly. Swing with • Moving the crane in an area or direction in which the
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caution and keep the load lines vertical. operator cannot clearly see the path of travel.
swinging your crane. Even though the original
Look before At all times use standardized hand signals - previously
setup may have been checked, situations do change. agreed upon and completely understood by the operator and
signal person.
Never swing or lower the boom into the carrier cab (if
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applicable). If communication with the signal person is lost, crane

movement must be stopped until communications are
Do not pull posts, pilings, or submerged articles. Be sure the
restored.
load is not
frozen or attached to the ground before lifting.
Keep your attention focused on the crane’s operation. If for
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Never push or pull loads with the crane’s boom; never drag a
some reason you must look in another direction, stop all
load.
crane movement first.
Do not subject crane to side loading. A side load can tip the

crane or cause it to fail structurally.
Obey a signal to stop from anyone.
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BOOM EXTENSION the ground. When a qualified person at a jobsite determines

that it is not practical to lower the boom to the ground, we
To avoid death or serious injury, follow the procedures in this recommend the following additional instructions be followed:
manual during erection, stowage, and use of the boom
• The crane should be left in the smallest, most stable,
extension.
valid operational configuration that the job site
Install and
secure all pins properly. practically allows.
Control movement of boom extension at all times. • The crane can not be left running, with a load on the
hook, or in erection mode, or in wind conditions in
Do not remove right side boom nose pins unless boom
extension is properly pinned and secured on front and rear excess of allowed values.

stowage brackets. • The boom should be retracted as far as is practical, the
crane configured in as stable a configuration as possible

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(boom angle, superstructure orientation, boom
extension angle, etc.)
DANGER
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• In high winds the boom and boom extensions should be
Boom Extension Hazard! lowered, or secured. Changing weather conditions

To avoid death or serious injury, follow procedures in Load including but not limited to: wind, ice accumulation,
Chart, safety, and operation manuals during erection, precipitation, flooding, lightning, etc. should be

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stowage and use of boom extension. Install and secure all c on s id e r e d w he n d et e r m i n i ng t h e l oc a ti o n a nd
pins properly and control boom extension movement at all configuration of a crane when it is to be left unattended.
times.
SHUT-DOWN

Do not remove all the pins from both front and rear stowage
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brackets unless the boom extension is pinned to the right Use the following steps when shutting down the crane:
side of the
boom nose. • Engage the parking brake.
Properly inspect, maintain, and adjust boom extension and • Fully retract and lower the boom.

mounting.
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• Engage the swing lock pin or 360 degree swing lock.

When assembling and disassembling boom extension

sections, use blocking to adequately support each section • Place controls in neutral position.
and to provide proper alignment. • Shut down the engine and remove the ignition key.

Stay outside of boom extension sections and lattice work. • Chock the wheels, if not on outriggers.
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Watch for falling or flying pins when they are being removed. • Lock the operator’s cab (if applicable) and install vandal
guards, if used.
PARKING
AND SECURING
In cold weather, never park the crane where the tires can
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become frozen to the ground.

! WARNING COLD WEATHER OPERATION
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Tipping Hazard! Cold weather operation requires additional caution on the

When parking
the crane and leaving it unattended follow part of the operator.
the instructions in Section 3 of this manual.
Check operating procedures in this manual for cold weather
Failure to comply with these instructions may cause death starting.
or serious injury
Don’t touch metal surfaces that could freeze you to them.

When parking on a grade, apply the parking brake and chock Clean the crane of all ice and snow.
the wheels.
Allow ample time for hydraulic oil to warm up.
Section 3 of this manual provides instructions for parking and
securing a crane when it is to be left unattended. These In freezing weather, park the crane in an area where it
are intended to allow the crane to be placed in
instructions cannot become frozen to the ground. The drive line can be
the most stable and secure position. However, Manitowoc damaged when attempting to free a frozen crane.
that certain jobsite conditions may not permit the
recognizes If applicable to your crane, frequently check all air tanks for
boom and boom extension of a crane to be fully lowered to water in freezing weather.


If applicable to your crane, always handle propane tanks approximately 7 3/4 in (see chart below). A cylinder
according to the supplier’s instructions. extended 5 feet in which the oil cools 60°F would only retract
approximately 1 1/2 in. The rate at which the oil cools
Never store flammable materials on the crane.
depends on many factors and will be more noticeable with a
If cold weather starting aids are provided on your crane, use larger difference in oil temperature verses the ambient
them. The use of aerosol spray or other types of starting temperature.
fluids containing ether/volatiles can cause explosions or fire.
Thermal contraction coupled with improper lubrication or
improper wear pad adjustments may, under certain
TEMPERATURE EFFECTS ON HOOK conditions, cause a “stick-slip” condition in the boom. This
BLOCKS “stick-slip” condition could result in the load not moving
smoothly. Proper boom lubrication and wear pad adjustment
The following information applies to Gunnebo Johnston
is important to permit the boom sections to slide freely. Slow
crane hook blocks:
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movement of the boom may be undetected by the operator
“Never use a crane block in extreme unless a load is suspended for a long period of time. To
temperatures...Sudden failure can occur. minimize the effects of thermal contraction or “Stick-slip” it is
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recommended that the telescope control lever is activated
Crane blocks shall not be heated above 180 degrees F.
periodically in the extend position to mitigate the effects of
Craneblock Working Load Limit is valid between 180
cooling oil.
degrees F and service temperature given on the
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identification tag with normal lifting precautions. If a load and the boom is allowed to remain stationary for a
period of time and the ambient temperature is cooler than the
Additional lifting precautions are required below the service
trapped oil temperature, the trapped oil in the cylinders will
temperature given on the identification tag because cold
cool. The load will lower as the telescope cylinder(s) retracts
temperture begins to affect the crane block material
allowing the boom to come in. Also, the boom angle will
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properties.
decrease as the lift cylinder(s) retracts causing an increase
Lifting above 75% of the Working Load Limit (WLL), at in radius and a decrease in load height.
temperatures between the service temperature given on the
This situation will also occur in reverse. If a crane is set up in
identification tag and -40 degrees F, must (be) done at a
the morning with cool oil and the daytime ambient
slow and steady rate to avoid stress spikes common in
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temperature heats the oil, the cylinders will extend in similar

normal hoisting dynamics.
proportions.
75% of the WLL must not be exceeded, when lifting in
Table 2-2 and Table 2-3 have been prepared to assist you in
temperatures below -40 degrees F.”
determining the approximate amount of retraction/extension
that may be expected from a hydraulic cylinder as a result of
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TEMPERATURE EFFECTS ON HYDRAULIC change in the temperature of the hydraulic oil inside the
CYLINDERS cylinder. The chart is for dry rod cylinders. If the cylinder rod
is filled with hydraulic oil, the contraction rate is somewhat
Hydraulic oil expands when heated and contracts when
greater.
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cooled. This is a natural phenomena that happens to all

liquids. The coefficient of expansion for API Group 1 NOTE: Operators and service personnel must be aware
hydraulic oil is approximately 0.00043 cubic inches per cubic that load movement, as a result of this phenomena,
inch of volume for 1°F of temperature change. Thermal can be easily mistaken as leaking cylinder seals or
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contraction will allow a cylinder to retract as the faulty holding valves. If leaking seals or faulty
hydraulic fluid which is trapped in the cylinder cools. holding valves are suspected to be the problem,
refer to Service Bulletin dealing with testing
The change in the length of a cylinder is proportional to the
telescope cylinders. (Bulletin 98-036 applies to
extended length of the cylinder and to the change in
TMS700 and bulletin G06-005A applies to RT890
temperature of the oil in the cylinder. For example, a cylinder
and RT9130.
extended 25 ft in which the oil cools 60°F would retract
Table 2-2: Boom Drift Chart (Cylinder length change in inches)

3 3
Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74
20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
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40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
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55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96
3 3
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in /in / °F) X 12 in/ft
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Table 2-3BoomDrift Chart (Cylinder length change in millimeters)

Coeff. = 0.000774 (1/ °C)

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STROKE Temperature Change (°C)
(m) 5 10 15 20 25 30 35 40 45 50 55
1.5 5.81 11.61 17.42 23.22 29.03 34.83 40.64 46.44 52.25 58.05 63.86
3 11.61 23.22 34.83 46.44 58.05 69.66 81.27 92.88 104.49 116.10 127.71
4.5 17.42 34.83 52.25 69.66 87.08 104.49 121.91 139.32 156.74 174.15 191.57
THIS116.10
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6 23.22 46.44 69.66 92.88 139.32 162.54 185.76 208.98 232.20 255.42
7.5 29.03 58.05 87.08 116.10 145.13 174.15 203.18 232.20 261.23 290.25 319.28
9 34.83 69.66 104.49 139.32 174.15 208.98 243.81 278.64 313.47 348.30 383.13
10.5 40.64 81.27 121.91 162.54 203.18 243.81 284.45 325.08 365.72 406.35 446.99
12 46.44 92.88 139.32 185.76 232.20 278.64 325.08 371.52 417.96 464.40 510.84
13.5 52.25 104.49 156.74 208.98 261.23 313.47 365.72 417.96 470.21 522.45 574.70
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15 58.05 116.10 174.15 232.20 290.25 348.30 406.35 464.40 522.45 580.50 638.55
16.5
63.86 127.71 191.57 255.42 319.28 383.13 446.99 510.84 574.70 638.55 702.41
18 69.66 139.32 208.98 278.64 348.30 417.96 487.62 557.28 626.94 696.60 766.26

Length change in mm = Stroke (m) X Temperature Change ( °C) X Coeff. (1/ °C) X 1000 mm/m
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OVERLOAD INSPECTION
This information supplements the Load Moment Indicator
(LMI) manual supplied with each Grove crane.
WARNING
When the LMI system has acknowledged an overload on
Overload Hazard!
your crane, you must carry out specified inspections on
the crane. To avoid an accident caused by overload damage to
your crane:
These inspections apply only to overloads up to 50%. For
overloads of 50% or higher, crane operation must be • Perform the inspections outlined in this
stopped immediately and Crane Care must be contacted publication for overloads up to 50%.
for corrective action.
• Stop operating the crane and contact Manitowoc
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Crane Care immediately for overloads of 50% and
higher.
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NOTE: If your crane is equipped with CraneSTAR, an
overload warning will be posted to the web site
for review by the crane owner.
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Overload warnings do NOT indicate real time
events! Warnings could be sent 24 hours (or
more) after the actual event.
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Boom Inspection

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2, 3
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Overload less than 25%

Sheaves,
1 Inspect all for damage.
Rope Guides
Collar-Wear
2 Pads, Pad Inspect for damage.
Retainers
Overload from 25% to 49%
Sheaves,
1 Inspect all for damage.
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Rope Guides
Collar-Wear
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2 Pads, Pad Inspect all for damage.
Retainers
3 Collar-welds Inspect all for damage.
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4 Pinning Areas Inspect all for cracks.
Telescopic Inspect for bent or twisted sections. Check the boom
5
Sections for straightness.
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Lift Cylinder
6 Inspect for bends or cracked welds.
Head Area
Turret-Base
7 Inspect for cracked welds.
Section
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Inspect for bent or twisted section. Check for

8 Jib Section
straightness.
9 Welds Inspect for cracks.
Inspect for cracked paint which could indicate twisted,
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10 Paint
stretched, or compressed members.
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Superstructure Inspection

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1 Lift Cylinder Inspect for leaking.
See topic in Introduction section
2 Wire Rope Inspect all for damage.
of Service Manual.
Turntable See topic in Swing section of
3 Check bolts for proper torque.
Bearing Service Manual.
1 Lift Cylinder Inspect for leaking.
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See topic in Introduction section
2 Wire Rope Inspect all for damage.
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of Service Manual.
Turntable See topic in Swing section of
Bearing Service Manual.
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4 Hoist/Drums Inspect each for damage.
5 Hoist Brakes Brakes must hold rated line pull.
Bearing Main
6 Boom Pivot Inspect for deformation, cracked welds.
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Pin
Lift Cylinder-
7 Inspect pin and welds.
Lower Mount
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8 Turret Area Inspect for deformation, cracked welds.

Mounting
Studs
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11 Paint
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Carrier Inspection

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2


Stabilizer
1 Inspect for leaking.
Cylinders
Outrigger
2 Inspect for deformation and cracked welds.
Pads
Stabilizer
1 Inspect for leaking.
Cylinders
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Outrigger
Pads
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Outrigger
Beams
Outrigger
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Boxes
6 Paint
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500E2 OPERATORS MANUAL OPERATING CONTROLS AND PROCEDURES
SECTION 3
OPERATING CONTROLS AND PROCEDURES
SECTION CONTENTS
Truck Cab Controls . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Boom length Indicator . . . . . . . . . . . . . . . . . . . . . . 3-3
Power Take-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Outrigger Status Indicator . . . . . . . . . . . . . . . . . . . 3-3
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hoist System Operation . . . . . . . . . . . . . . . . . . . . . 3-5
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . 3-2 Using Multiple Part Lines . . . . . . . . . . . . . . . . . . . . 3-5
Unattended Crane. . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 General Rules When Operating Hoist . . . . . . . . . . 3-5
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Crane Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Lifting the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Optional Hoist Burst of Speed (BOS) . . . . . . . . . . 3-6
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Swing Speed Adjustment . . . . . . . . . . . . . . . . . . . 3-2 Anti-Two Block System. . . . . . . . . . . . . . . . . . . . . . 3-6
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Outrigger Monitoring System (OMS)
Boom Telescope . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
(Optional—Standard in North America) . . . . . . . . 3-6
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Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic Capacity Alert System . . . . . . . . . . . . . . 3-7
Stabilizers Up/Down . . . . . . . . . . . . . . . . . . . . . . . 3-2
System Description . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Stabilizers Extend/Retract. . . . . . . . . . . . . . . . . . . 3-2
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
HCA Load Range Gauge. . . . . . . . . . . . . . . . . . . . 3-7
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Foot Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . 3-3 HCA System Operation . . . . . . . . . . . . . . . . . . . . . . 3-8
Pressure Sensing Switch. . . . . . . . . . . . . . . . . . . . 3-8
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydraulic Capacity Alert System (HCA) Load Jib Load Limiting Device . . . . . . . . . . . . . . . . . . . . 3-8
Range Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 System Description . . . . . . . . . . . . . . . . . . . . . . . . 3-8
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HCA Overload Light . . . . . . . . . . . . . . . . . . . . . . . 3-3 System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Anti-Two-Block/Jib Overload Light . . . . . . . . . . . . 3-3 Three Section Boom Operation . . . . . . . . . . . . . . . 3-9
Key Override Switch . . . . . . . . . . . . . . . . . . . . . . . 3-3 Anti-two-block Weight Installation . . . . . . . . . . . . 3-10
Override Button. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Installing Cable On The Hoist. . . . . . . . . . . . . . . . 3-10
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Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Wedge Socket Installation . . . . . . . . . . . . . . . . . . 3-10

Boom Angle Indicator . . . . . . . . . . . . . . . . . . . . . . 3-3
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TRUCK CAB CONTROLS power take-off may be disengaged while in any transmission
range provided that the load has first been removed from the
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Power Take-Off PTO.
Manual Shift Control Electric Shift Control
The PTO’s are engaged when the knobs on dash or floor are Full torque electric shift PTO’s are controlled by a switch. To
pulled out and disengaged when the knobs are pushed in. operate, disengage the clutch, shift to fourth or fifth gear, and
The truck gear shift lever must be in neutral and the clutch operate the switch down to engage the PTO or up to
depressed whenever the knobs are moved. disengage the PTO. Return the gear shift to neutral and
engage the clutch.
Air Shift Control
Power Shift Control
The PTO is engaged when the switch is moved to apply air to
PTO and disengaged when switch in off position. The truck If the vehicles equipped with automatic transmission, the
gear shift lever must be in neutral and clutch depressed power take-off must be engaged with the engine at idle.
when switch is moved. The transmission selector lever must Refer to transmission manufacturers instructions for special
be returned to “N” for stationary vehicle operation. The procedures.

OPERATING CONTROLS AND PROCEDURES OPERATORS MANUAL 500E2
Park Brake complete control of boom rotation, boom elevation, boom

extension, hoist, outriggers, engine foot throttle, the engine
The truck brake must be firmly set before leaving cab to emergency stop switch, and a horn switch. All control
begin operation. If the ground surface is icy or slick or is handles except the outrigger controls are positioned in the

sloped, you may be required to help immobilize the truck with same order at both control stations.
wheel chocks.

Turn
Cold Weather Operation
Operate the turn control lever to RIGHT to rotate the boom in
The following recommendations are for operating National a clockwise direction as viewed from the top of the crane.
cranes in very low (i.e., sub-zero) temperatures. Operate the turn control lever to LEFT to rotate the boom in a

Cranes should have appropriate hydraulic oil, lubricants, and counterclockwise direction as viewed from the top on the
other auxiliary items required for operation in sub-zero crane.

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temperatures. Operate individual crane functions to ensure For cranes NOT equipped with continuous rotation, a
they are sufficiently warmed prior to performing a lift. mechanical rotation stop pulls the turn control lever back to

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the center position when engaged. Boom rotation is stopped
over the front of the chassis. On rear mounted cranes NOT

Only experienced operators should operate cranes at full equipped with continuous rotation, rotate the boom over the
rated capacities between 0° F (-18° C) and -40° F (-40° C) passenger side of the chassis when stowing and unstowing

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and for derated capacities in colder temperatures to ensure to prevent immediate contact with the mechanical rotation
smooth operation. Shock loading shall be avoided. stop.

Derated capacities for each °C below -40°C Swing Speed Adjustment
rated load shown on the capacity charts 3.67
Derate the
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Located on turn motor inside frame. Turn knob in to increase
percent for each degree celsius below -40° C. maximum swing speed. Turn knob out to decrease maximum

Derated capacities for each °F below -40°F swing speed.
Derate the
rated load shown on the capacity charts 2 percent Boom
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for each degree fahrenheit below -40° F

Operate the lever to DOWN to lower the boom. Operate the
lever to UP to raise the boom.
UNATTENDED CRANE
Boom Telescope
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Operate the lever to OUT to extend the boom. Operate the

lever to IN to retract the boom.
WARNING
Tipping Hazard! Hoist
Changing weather conditions including but not limited to:
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wind, ice Operate the lever to DOWN to payout and lower the loadline.
accumulation, precipitation, flooding, lightning, Operate the lever to UP to reel in and raise the loadline.
etc. should be considered when determining the location
and configuration of a crane when it is to be left Refer to hoist system operation section for additional
information
unattended.
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Failure to comply with these instructions may cause death

or serious injury.
DANGER
The configuration in which the crane should be left while Payout loadline before extending boom. Failure to do so
unattended shall be determined by a qualified, designated will cause the loadline to break or damage the crane.
individual familiar with the job site, configuration, conditions,
and limitations.
Stabilizers Up/Down

CRANE CONTROLS Operate the lever to DOWN to lower and UP to raise.
is equipped with control stations on each side of
The crane Stabilizers Extend/Retract
the main frame. Decals on the control knobs or next to the
lever indicate
the direction to actuate the controls for the Operate the lever to extend to move beams out and to retract
various unit functions. Each station is complete and provides to move beams in.


Outriggers Key Override Switch

Operate the lever to up to raise the outrigger legs. Operate Turn key switch to enable or disable HCAS, jib load limiting
the lever to down to lower the outrigger legs. device, and ATB override. Some units may be equipped with
an optional manual reset valve which does not have an
Foot Throttle override key switch.
Depress the foot throttle to accelerate the truck engine Override Button
speed. Release to return to idle speed. Increasing truck
speed increases operating speed. With the override key switch in the on position, depress the
button to override the HCAS jib load limiting device and the
Emergency Stop Switch ATB system. Do not use the override to continue lifting
operations in an overload or two-blocked condition.
Operate the switch to kill the truck engine under emergency
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conditions. Switch must be reset to the “on” position to Load Chart
operate truck from cab.
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This chart shows capacities of crane at various operating
Horn areas and hoist capacities with appropriate reeving.
Operate horn button to warn fellow workers on construction Boom Angle Indicator
site of pending movement of crane.
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Located on either side of the base boom section and used to
Hydraulic Capacity Alert System (HCA) Load determine main boom angle with respect to horizontal. For
Range Gauge reference only.
Boom length Indicator 3

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Located on either side of the second boom section. The
DANGER letters on the intermediate boom lengths correspond to the
Do not use the Load Range Gauge with a jib. Refer to letters on the load chart. The length indicators are used to
“Hydraulic Capacity Alert System” for more information. define boom length and with the load chart and load radius
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are used to determine the maximum loads that may be safely

The HCA Load Range Gauge aids in determining the load lifted. Actual radius must be measured from the centerline of
condition of crane. The gauge has three colors on the dial rotation.
face: (1) Green OK, (2) Yellow Caution, and (3) Red
Overload. Outrigger Status Indicator
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HCA Overload Light The Outrigger Status Indicator is part of the Outrigger
Monitoring System and communicates to the operator the
Indicator light illuminates when HCA detects crane overload. position of the outriggers and stabilizers. The Outrigger
Boom down, extend out and hoist up functions are disabled Status Indicator is a bi-color LED located at each control
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when light illuminates. station. When power is on and the outrigger and stabilizer
beams are extended to a point at which they provide
Anti-Two-Block/Jib Overload Light maximum stability (stabilizers beams shall be fully extended
on cranes equipped with Rear Stabilizer Out and Down
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Indicator light illuminates when a two block or jib overload

conditions detected. On Jib equipped units an Audible Alert (RSOD)), the Outrigger Status Indicator illuminates constant
sounds when two-block or jib overload conditions are green, indicating a lift can be made. If power is on and one or
detected. more outrigger or stabilizer beams are not extended to a
position which provides maximum stability, the Outrigger
Status Indicator flashes red, indicating a lift should not be
made. If the Outrigger Status Indicator illuminates constant
red, there is a fault in the OMS.

20 9 11 2
8
10 4
3
2
4 5
3
5
8
6 10
9 11
12
14 7

25
1 25 6 1
7 12
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15
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24
21
16
13
22

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17

NOTE: Item 20 is located behind the
access door on the operators 18
console as shown.
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19
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23
Item Component
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14 A2B/Jib Overload Light

15 Boom Angle Indicator
16 Load Chart
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17 Swing Speed Adjustment

18 Level Indicator
Item Component
19 Front Throttle
1 HCAS Load Range Gauge Item Component
HCA-ATB Override Key
20
2 Boom Up/Down 8 O/R This Side Switch
3 Hoist 9 O/R Other Side 21 Boom Length Indicator
10 Stabilizer This Side 22 HCA-ATB Override Button
4 Telescope In/Out
5 Turn Left/Right 11 Stabilizer Other Side 23 Torsion Box

6 Emergency Stop Switch 12 Front Stabilizers 24 Fuse (10 amp)
7 Horn 13 HCAS Overload Light 25 Outrigger Status Indicator

HOIST SYSTEM OPERATION Using Multiple Part Lines

The hoist is mounted at the rear of the boom and has The hoist load rating chart on each machine provides the
capacities independent from the rest of the crane The hoist information for pull limitations on the hoist with various
can normally pull more than the crane itself can withstand. applicable part reevings. These ratings are based on
Therefore, care must be taken to insure that the load being providing the proper operating safety factor on the wire rope
lifted is within boom rating. To lift some of the heavier loads supplied with the machine. Therefore, any replacement rope
on the load chart, it will be necessary to multiple part reeve must meet the rope specification sections of this manual.
the hoist block to increase the lifting capacity of the hoist (the
speeds will be proportionately slower) and remain in the
strength limitations of the hoist and wire rope.
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7636
General Rules When Operating Hoist of the crane and hoist reeving system proceed with lifting the
load.
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1. Always payout the loadline while extending the boom.

This will maintain clearance between the boom tip and 1. Rotate, extend or move up or down until boom tips
loadline hook. directly over the load.
2. Do not rely on the ATB System to eliminate two blocking. 2. The crane is normally equipped with a rotation stop. It is
Use the system as a backup to safe operation. important that you be aware of the position of the stop
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before lifting in order to assure maximum rotation and

3. Make certain the hoist cables are not twisted or kinked prevent excessive handling of the load.
and that cables are properly seated on the drum and in
the sheaves. 3. During operations, the controls should always be
metered when beginning or terminating movement to
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4. Before lifting a load, always make certain that three full prevent sudden starting or stopping, which imposes
wraps of rope will remain on the drum at all times undue shock loads on the equipment. This is especially
throughout the lift. true when handling heavy loads. The control should be
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5. When lifting a load approaching the rated hoist load, slightly actuated to begin movement and then slowly
raise the load a few inches and return the control to increased to desired operating speed. The results
neutral to determine if the brake is working properly. obtained from metering the oil flow with the control lever
can also be aided by carefully coordinating the throttle
6. Do not drag loads in any direction with the hoist. control.
7. Never attempt to lift loads which are not loose and free, 4. Lower loadline and attach load.
such as frozen down material or poles out of ground.
5. Control load by use of a non-conductive tag line.
8. Maintain tension on the loadline at all times to prevent
the cable from becoming twisted or kinked or improperly 6. Do not leave crane unattended with the boom elevated
seated on the hoist drum or sheaves. in operating position. Always secure the boom in the
boom rest before leaving the work area.
Lifting the Load
After the vehicle and crane have been properly set up and it
has been determined the load to be lifted is within the ratings

OPTIONAL HOIST BURST OF SPEED (BOS) hoist cable and end attachments contact the underside of the
sheave case, whether by hoisting up or extending the boom
The “Burst of Speed” increases hoist line speed 50% over without paying out the hoist cable, the hoist cable can be
normal operation by diverting oil from the multi-bank control damaged by crimping or over tensioning.

valve to the hoist valve.
The anti-two-block system provided on your National Crane
The “BOS” is engaged by operating the hoist control valve can help prevent cable damage by sensing the position of
lever while pulling up on the BOS handle below the hoist the hoist cable end attachments with respect to the sheave
knob. The “BOS” feature should only be operated in a case and disabling the functions that can cause a two block
temporary manner to reduce oil heat build up, prevent truck condition.
PTO overloading, and provide independent operation of the
crane and hoist (normal hoist speed will not decrease when The anti-two-block system consists of normally open, work
crane functions are used). If the “BOS” feature is run port unloader valves in the main and hoist control valves.
When the cartridge solenoid is energized, the crane
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continuously or with an overload, damage to the crane or
truck could occur. To start the “BOS” smoothly, first pull up on functions normally, when de-energized, the oil to the boom
the BOS handle then operate the hoist lever. To stop the extend, boom down, and hoist up crane functions are
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“BOS” smoothly, return the hoist lever to its neutral position diverted to tank. These solenoids are controlled by a limit
then release switch, which is attached to the boom or jib sheave case.
the BOS handle.
. This switch is held in the closed position by a chain
suspended weight. The weight, which is looped around the

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CAUTION hoist cable, causes the contacts to remain closed until the
If the BOS feature Is run continuously or with an overload, hoist cable end attachments contact the weight and release
damage to the crane or truck could occur. the tension on the switch. At this point the contacts in the
switch open, breaking electrical continuity through the circuit
provided by the internal anti-two-block cord routed through
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Hoist Lever the boom. When this continuity is broken, the unloader
cartridges de-energize and divert the function oil to tank. An
indicator light is provided on the control console to alert the
operator when a two-block condition is detected.

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On machines equipped with an optional Load Moment

BOS Indicator (LMI) System, the anti-two-block system is integral
Handle with the LMI wiring and display. An audible, visual warning of
the two block condition is provided in the display console.

See LMI Operators Handbook for additional information.
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Normal functioning is restored by hoisting down (or retracting

boom) until the weight is once again suspended freely.
Occasionally if the hoist up and boom extend functions are
operated at maximum speed in the dump mode, the back
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pressure induced in the circuit will cause the hoist up or

boom extend functions to creep slightly (with no load on the
hook). Such a condition is not cause for alarm, as the back
pressure is not of sufficient magnitude to damage the cable
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or end connections.
Note: Maximum
Capacity with “BOS”
• One Part Line - 3000 lb (1361 kg) OUTRIGGER MONITORING SYSTEM (OMS)
•
Two Part Line - 6000 lb (2722 kg) (OPTIONAL—STANDARD IN NORTH
•
AMERICA)
Three Part Line - 9000 lb (4082 kg)
• Maximum line speed on third layer - 271 FPM The Outrigger Monitoring System (OMS) aids the operator in
(73mpm), fourth layer - 294 FPM (81 mpm) ensuring that the crane is properly setup on outriggers and
stabilizers. The OMS utilizes one sensor in each outrigger
and one proximity switch in each horizontally extending

ANTI-TWO BLOCK SYSTEM stabilizer to identify when the outriggers and stabilizer beams
are extended to a point in which they provide maximum
With untrained
or inexperienced or distracted operators, two stability.
blocking the hoist cable is a very real possibility. When the


The OMS utilizes an LED indicator to communicate to the the HCA and the Anti-Two-Block or jib load limiting systems
operator the position of the outriggers and stabilizers. The as the cause of power loss.
Outrigger Status Indicator is a bi-color LED located at each
control station. When power is on and the outrigger and
stabilizer beams are extended to a point at which they CAUTION
provide maximum stability (stabilizers beams shall be fully Do not use the override to continue lifting operations in an
extended on cranes equipped with Rear Stabilizer Out and overload or two blocked condition.
Down (RSOD)), the Outrigger Status Indicator illuminates
constant green, indicating a lift can be made. If power is on HCA Load Range Gauge
and one or more outrigger or stabilizer beams are not
extended to a position which provides maximum stability, the
Outrigger Status Indicator flashes red, indicating a lift should
not be made. If the Outrigger Status Indicator illuminates
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constant red, there is a fault in the OMS.
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HYDRAULIC CAPACITY ALERT SYSTEM
System Description
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The Hydraulic Capacity Alert System (HCA) is a hydraulically
operated, maximum capacity sensing device that will stop all
of the normal crane functions that cause overload when
maximum capacity is exceeded.
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In the event that an over capacity condition occurs, the HCA
is actuated by sensing excessive pressure in the lift cylinder.
The following systems will be inoperative:
• boom down
• extend out
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The HCA provides a load range gauge at each operator

• hoist up station. This gauge has three colors on the dial face: (1)
Green – OK, (2) Yellow – Caution, and (3) Red – Overload.
These are the functions that increase the over capacity
The gauge is plumbed directly to the lift cylinder and the
condition. This system allows for continued operation of the
indicator position can be used as an aid in determining the
hoist down, boom up and boom retract functions, the
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load condition of the crane. The lift control lever must be

functions that normally allow the operator to bring the load to
moved from boom up position to the neutral position to get
a shorter operating radius or set the load down in order to
the most accurate reading when using load range gauge.
eliminate an over capacity condition. Once the excessive
cylinder pressure has been reduced by bringing the load to a The load range gauge is provided to aid the operator when
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shorter radius or setting the load down, normal operation can operating near the rated capacity of the crane.
be resumed. This hydraulic capacity alert system uses the
NOTE: The gauge only provides accurate indication when
work port unloader solenoids in the anti-two-block system as
the lift control lever is in neutral.
the hydraulic system dump circuit.
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The gauge movement is not proportional to the load on the

The hydraulic capacity alert system has an override switch
hook. Its not unusual for the indicator to be in the red area at
a n d b ut t o n l o c a t e d o n t h e o p e r a t o r ’s c o n s o l e t h a t
less than rated load condition when operating the lift control,
momentarily overrides the hydraulic capacity alert and anti-
especially during boom down operation
two-block systems and restores power to crane functions.
.
Indicator Lights CAUTION

Two indicator lights located on the operator’s console alert Do not use the load range gauge with a jib.
the operator of function power loss and discriminate between

The load range gauge is provided to aid the operator when

operating near the rated capacity of the crane. The gauge
only provides accurate indication when the lift control lever is
in neutral. The gauge movement is not proportional to the
load on the hook. It is not unusual for the indicator to be in
the red area at less than rated load condition when operating

the lift control, especially during boom down operation.

JIB LOAD LIMITING DEVICE
System Description
The jib load limiting device is an electro-mechanically
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operated, maximum capacity sensing device that stops all
normal crane functions that cause overload when maximum

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capacity of the jib is exceeded. In the event that an over
capacity condition occurs, the jib load limiting device is

HCA SYSTEM OPERATION actuated by sensing excessive force on a load cell which
causes the boom down, extend out, and hoist up functions to
Once an over-capacity conditions reached, the HCA will not
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become inoperative. These are the functions that increase
allow the operator to move the load to a greater radius. the over capacity condition. On jibs with a manually
extendable section, a configuration switch operated by the
Pressure Sensing Switch extension retaining pin distinguishes between an extended
When trip pressure is reached, the pressure sensing switch jib and a retracted jib. This system allows for continued
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breaks electrical continuity to the work port unloader operation of the hoist down, boom up, and boom retract
solenoid in the main control valve.When power is removed functions, the functions that normally allow the operator to
from this solenoid, the unloader valves allow the oil flowing to bring the load to a shorter operating radius or set the load
hoist up, telescope out and boom down to flow to tank. This down in order to eliminate an over capacity condition. Once
the excessive force on the load cell has been reduced by
path to tank will prevent further operation of these functions.
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When the overload condition is corrected by hoisting down, bringing the load to a shorter radius or setting the load down,
the boom, or raising the boom, the pressure
retracting normal operation can be resumed. This system uses the
sensing switch allows the work port unloader solenoids to be work port unloader solenoid in the anti-two-block system as
powered thereby allowing the crane to function normally. the hydraulic system dump circuit.
The jib load limiting system has an override switch and
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During the operation at near capacity loads, care must be

taken to operate the controls smoothly or the system may be button located on the operator’s console that momentarily
shocked into the dump mode prematurely. overrides the hydraulic capacity alert, the jib load limiting
device, and the anti-two-block system and restores power to
Caution should be exercised when operating near 80° of crane functions. Two indicator lights located on the
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boom elevation. If the boom lift cylinder is fully extended and operator’s console alert the operator of function power loss

pressurized above trip pressure, the system solenoid will and discriminate between the hydraulic capacity alert and
deactivate and the boom will remain locked at 80°. To correct the anti-two-block or jib load limiting systems as the cause of

this condition, momentarily actuate the override switch and power loss. In the event of a two-block or jib overload
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boom down approximately 5°. Some units may be equipped condition, an audible alarm will sound in addition to the

with a Manual Reset Valve Option that can be used to unlock lighting of the indicator light.
the unit from 80°. See Controls and Hydraulics Section for
additional description of this system. Do not use the override to continue lifting operations in an
overload or two blocked condition.
The override system consists of a key switch and a
momentary push button switch.The key switch provides System Operation
power to the momentary push button switch located on the
console.To The jib load limiting device will operate as stated in the
momentarily override, activate key switch and System Description Section. Once an over-capacity
depress push button on console. This will activate the work
port unloader solenoid and return power to hoist up, condition is reached, the system will not allow the operator to
telescope out, and boom down functions.The override switch move the load to a greater radius. The truck may have to be
is not to be used during normal use of the crane or as an aid repositioned closer to the load in order to set the load at the
in using the crane in an overload or anti-two blocked desired location.
condition.


When trip force is reached, the jib load limiting device breaks These systems do not prevent structural or stability
electrical continuity to the work port unloader solenoid in the overloads to the crane or hoist caused by:
main control valve. When power is removed from this
1. Freely swinging loads or operating in an out-of-level
solenoid, the unloader valves allow the oil flowing to hoist up,
condition which will result in excessive side loading.
telescope out and boom down to flow to tank. This path to
tank will prevent further operation of these functions. When 2. Side loading due to pulling sideways on the boom with
the overload condition is corrected by hoisting down, boom rotation or load hoist. Load must always be
retracting the boom, or raising the boom, the jib load limiting directly under boom tip.
device allows the work port unloader solenoid to be powered
3. Sudden load movements from erratic operation of the
thereby allowing the crane to function normally.
crane functions which will result in excessive shock
During operation at near capacity loads, care must be taken loading.
to operate the controls smoothly or the system may be
4. Improper loadline reeving for loads larger than single
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shocked into the dump mode prematurely.
line pull capacity.
The override system consists of a key switch and a
5. Extending the boom without first paying out the loadline
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momentary push button switch. The key switch provides
which can result in deadheading (two blocking) the
power to the momentary push button switch located on the
loadline against the boom tip.
console. To momentarily override, activate key switch and
depress push button on console. This will activate the work 6. Loads with lift cylinder fully retracted.
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port unloader solenoid and return power to hoist up,
telescope out, and boom down functions. The override 7. Excessive induced loading during auger system
switch is not to be used during normal use of the crane or as operation.
an aid in using the crane in an overload or two-blocked 8. Operation without outriggers and stabilizers fully
condition. deployed or inadequate footing for the outriggers and
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stabilizers.
CAUTION THREE SECTION BOOM OPERATION

The HCA and the Jib Load Limiting Device are intended to A rod-fed, double-acting cylinder, attached to the 1st and 2nd
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be used as only aids to prevent overload conditions. Do boom sections, supports and propels the 2nd boom section.
not use the Hydraulic Capacity Alert System and the Jib
Load Limiting Device as substitutes for safe operating The extend cables attach to the base end of the 1st boom
practices as out lined in this manual. section, are reeved around sheaves attached to the cylinder,
and attach to the base end of the 3rd boom section providing
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Do not expect the Hydraulic Capacity Alert System and the

support and extension of the 3rd boom section.
Jib Load Limiting Device to detect all possible overload
conditions.
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THREE SECTION BOOM

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2
1 7 6 4
5
Item Component Item Component 3
1. Base 5 2nd Section

2 Extend Cable 6 Retract Cable
3 Tip 7 1st Section
4 3rd Section

The retract cables attach to the tip end of the 1 st boom 3. Insert the cable through the slot and position around the

section and are reeved around sheaves attached to the 2nd
anchor wedge (1) Figure 3-1.
boom section. They are attached to the base end of the 3rd NOTE: The end of the cable should be even with the
bottom of the slot for the anchor wedge.
boom section providing retraction of the 3rd boom section.
This type of boom operation ensures that the 2 nd and 3rd 2 2

section booms extend and retract equally. Proper service

and maintenance is required to insure smooth and proper
operation

Anti-two-block Weight Installation
the hoist cable from slipping out of the ant-two-
To prevent
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block weight, rig the weight as shown below.
3
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Upper Link
Chain Length
16 inches (40 cm) Do
not shorten the chain.
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7312
FIGURE 3-1
Hoist
Lower Link
Cable 4. Position the anchor wedge in the drum slot; pull firmly on
The anti-two-block chain must be the free end (2) of the cable to secure the wedge.
installed between the slot in the
NOTE: If the wedge does not seat securely in the slot,
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weight and the hoist cable.

carefully tap (3) the top of the wedge with a mallet.

Slot

Anti-two-block Weight
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7196
INSTALLING CABLE ON THE HOIST 5. Slowly rotate the drum, ensuring the first layer of cable is
evenly wound onto the drum.
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6. Install the remainder of the cable, as applicable.

CAUTION
If cable is wound from the storage drum, the reel should WEDGE SOCKET INSTALLATION

be rotated in the same direction as the hoist.
1. Properly match socket, wedge and clip to wire rope size.
The cable should preferably be straightened before The wire rope must pass through the “go” hole in the
NOTE:
wedge. It must not pass through the “no go” hole in the
installation on the hoist drum.
wedge.
Install

cable
on the hoist drum in accordance with the
2. Align live end of rope, with center line of pin.
following procedure.
3. Secure dead end section of rope.
1. Position the cable over the boom nose sheave and route
to the hoist drum. 4. Tighten nuts on clip to recommended torque. (See
Table)
2. Position the hoist drum with the cable anchor slot on top.


5. Do not attach dead end to live end or install wedge .

backwards. Wedge Socket
6. Use a hammer to seat Wedge and Rope as deep into Live
socket as possible before applying first load. End Dead
Dead Live End is
End
End Entering
Wrong Side
20 x Cable Dia
Minimum
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RIGHT WRONG
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Terminator Wedge Socket
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Torque Value Table

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Cable Size (inches) 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4
Torque ft/lbs 45 65 65 95 95 130 225 225 225 360
Torque values shown are based upon clean dry threads free of lubrication.
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THIS PAGE BLANK
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500E2 OPERATORS MANUAL SET-UP
SECTION 4
SET-UP
SECTION CONTENTS
Equipment Familiarization . . . . . . . . . . . . . . . . . . . 4-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Equipment Checks . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Determining Load Capability . . . . . . . . . . . . . . . . . 4-6
Pre-Operation Inspection and Calibration Load Determination Examples. . . . . . . . . . . . . . . . 4-6
Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Jib Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Work Site Selection . . . . . . . . . . . . . . . . . . . . . . . 4-2
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Before Leaving the Cab . . . . . . . . . . . . . . . . . . . . 4-2 Side Folding-Swing Around Jib Operation . . . . . 4-10
Deployment Procedure . . . . . . . . . . . . . . . . . . . . 4-10
Lifting Over the Rear. . . . . . . . . . . . . . . . . . . . . . . 4-2
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Lifting Over the Front with a Front Stabilizer. . . . . 4-3 Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Before Making the Lift . . . . . . . . . . . . . . . . . . . . . . 4-3 Jib Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Jib Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Reading and understanding the load Charts . . . . 4-3
Jib Jack Procedures . . . . . . . . . . . . . . . . . . . . . . 4-12
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Set-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
ce Adjustable Swing Speed Valve . . . . . . . . . . . . . . 4-12
EQUIPMENT FAMILIARIZATION • Check the loadline cable for kinks, broken strands or
other damage in accordance with instructions in the
All members of the crew should become familiar with the Lubrication and Maintenance Sections.
location and operation of controls, the correct operating
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procedure, the maximum lifting capacities, and the safety • Check to see that the hydraulic hoses and fittings are in
precautions applicable to the unit before operating. This good condition and show no signs of leaking. The hoses
crane is a complex piece of equipment and can be should be free from cuts and abrasions and there should
overloaded in many ways. Carefully follow the operating be no evidence of binding. Any damage or leakage
procedures outlined below and in the instructional pages of should be repaired immediately.
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the load rating chart at the operator’s station. • Check HCA, anti-two-block system and jib load limiting
device for proper operation.
Equipment Checks
NOTE: Consult truck manufacturer’s manual for vehicle
Perform the following checks prior to placing the unit in checks.
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operation:
• Inspect for any unusual conditions such as pools of Pre-Operation Inspection and Calibration
hydraulic fluid or lubricating oil under the chassis, any Verification
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outrigger which may have crept down or up and any

1. Check the electrical wiring connecting the various parts
signs of damage or improper maintenance.
of the system for physical damage.
• Check that the tires are inflated to the proper pressure.
2. Check the anti-two-block switches and weights for free
• Check the level of the hydraulic reservoir. movement.
• Check the operation of the “stop” and horn circuits.
• Check for missing and loose bolts, pins, and ring
retainers DANGER
The following tests shall be performed with care to
• Check for damaged structural members and welds. prevent damage to the machine or injury to personnel.
• Check all rope guides and cable keepers. Proper functioning of the system requires successful
completion of these tests before operating the machine..
• Check all sheaves for free turning.

SET-UP OPERATORS MANUAL 500E2
If the operator cannot see the load handling device Its best to select a location on the site such that most of the

approaching the boom nose, he shall have an assistant lifting can be done over the outrigger support or rear of the
(signal person) watch the load handling device. The truck.
operator shall be prepared to stop the machine immediately
should the anti-two-block system not function properly as Before Leaving the Cab
indicated by lighting the red warning light, sounding the
1. Position the truck so that the outriggers can be extended
audible alarm (jib-equipped cranes) and locking the crane
without encountering obstructions. Set the truck park
movements, hoist up, telescope out and boom down.
brake securely and turn front wheels into the curb.
Check the anti-two-block alarm light and the audible alarm Wheel chocks may be required under certain conditions.
(jib-equipped
cranes) by performing one of the following
2. With the gear shift in neutral, depress clutch (if equipped
tests:
with a manual transmission), and engage the power
•
By manually lifting the weight attached to the anti-two- takeoff by pulling out the shifting knob.
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block switches. When the weight is lifted, the audible
3. Bring the hydraulic system up to operating temperature
alarm
(jib-equipped cranes) should sound, the anti-two- (oil reservoir warm to the touch) by allowing the system
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block alarm light should light.
to operate by actuating the outrigger retract switch with
• raise the main boom load handling device to
Slowly all outriggers fully retracted.
create a potential two-block condition. When the load
handling
device lifts the weight, the audible alarm (jib-
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equipped cranes) should sound, the anti-two-block
alarm DANGER
light should light and the motion of the load To prevent the crane from tipping over.
handling device should be stopped. Lower the load
handling device slightly to eliminate this condition. • Make sure crane is level.

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• Slowly extend (telescope) the boom to create a potential • Do not operate the boom until all outriggers are
two-block
condition. When the load handling device lifts extended and set providing firm support.
the weight, the audible alarm (jib-equipped cranes)
• Make sure the tires are clear of ground.
should sound, the anti-two-block alarm light should light

and the boom telescope out function should be stopped.
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If operating on sloping ground provide blocks. When lifting is

Lower the load handling device slightly to eliminate this
to be done on soft terrain or hot asphalt, support the
condition.
outrigger and stabilizer pads with bearing pads. Some
concrete and asphalt surfaces are relatively thin and cannot
CAUTION support outrigger or stabilizer loading. Concrete can break
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If the light and audible alarm (jib-equipped cranes) do not through and cause instability.

function as described and the crane movements are not Variation in chassis, outrigger, and mounting configurations
stopped, the system is not working properly. The will cause outrigger foot loading to differ on each crane,

malfunction shall be corrected before operating the crane. however, outrigger foot loads can be as high as 40,000 lbs
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(18,145 kg) when outriggers are at full span (131 psi

• If the crane is equipped with a boom extension (jib) that
(0.9 MPa) on standard outrigger pads). Support surface
is deployed and rigged for work, repeat the test
bearing capacities vary by a large amount from 833 psi
procedure
for the boom extension (jib) anti-two-block
(5.7 MPa) on bed rock down to 14 psi (0.1 MPa) on soft clay.
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switch.
Loose sand or soft asphalt will support even less load. It is
imperative that the operator take proper precautions to
Work Site Selection
insure the outrigger foot has adequate cribbing for existing

Always seek the best possible work site when parking the soil conditions.
crane. An ideal parking location at a job site is firm, level, dry
If specific outrigger foot loading is required for an individual
ground or pavement located in close proximity to the work

station. Avoid uneven, rocky or muddy terrain, steep grades
crane, contact National Crane with actual chassis weights
and crane details.
or locations with unnecessary overhead obstructions.
Location should be selected such that outriggers can be fully Lifting Over the Rear
extended and leg comes down on firm level surface.
care must be taken when in the vicinity of
Particular Before conducting any boom operations, extend both
overhead power lines so that proper clearance conditions outriggers until the chassis weights removed from the
can be maintained. Do not select a location at which the wheels. Level the crane from side-to-side. A level indicator is

boom could not come within minimum recommended provided at either control station. Then extend and lower the
distance of the power lines at full extension. stabilizers to level the crane front-to-back. Again refer to the


level indicator to insure that the crane is properly leveled.

Always keep the load as close to the ground as possible.
180°
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Check to ensure that the jib, if so equipped, is stowed
correctly on the first section boom.
Lifting Over the Front with a Front Stabilizer
Before Making the Lift
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1. Check all controls for proper operation by operating
each system through one complete cycle. This is
particularly important after the unit has been serviced or
360° repaired. If any abnormal operations are detected,
correct the condition before continuing.
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2. During all operations, the controls should be metered

when beginning or terminating a movement to prevent
sudden starting or stopping which imposes undue shock
loads on the equipment. This metering can be
performed by metering the control lever and the foot
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throttle.
READING AND UNDERSTANDING THE

LOAD CHARTS
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A front stabilizer is required when loads are to be lifted over

the front of the vehicle. Before conducting any boom The structures and components of your unit are designed to
operations, extend both outriggers until the chassis weight is provide satisfactory service if the unit is not loaded in excess
removed from the wheels. Level the crane side-to-side using of the maximum rated loads specified on the load chart.
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the level indicator located at either control station as a Overloading can create serious potential safety hazards and
reference. Then extend and lower the rear stabilizers to level can also shorten the service life of your unit. It is important
the crane front-to-back. Again refer to the level indicator to that you know the weight and radius of any load that you are
insure that the crane is properly leveled. After the crane is attempting to handle. This should be done by use of a
leveled side-to-side and front-to-back, extend the front dynamometer and tape measure or by contacting your
stabilizer leg(s) until firm contact is made with the ground. supervisor.
Always keep the load as close to the ground as possible. Overloading a crane can cause Block
many types of failure depending on +
the configuration and working Sling
position of the crane, such as +
DANGER structural damage to almost any part Load
Do not operate outriggers unless they are visible to either Total Rated
of the crane, hoist or cable failure
the operator or a designated signal person to avoid Load
and tipping the unit over.
crushing injury

The load chart shows the maximum rated loads including • The correct loaded radius must be measured and not

load (weight being lifted), load handling equipment such as exceeded during any point of the lifting operation.
slings, buckets, and downhaul weight that can be handled by
• The placards located at the operators platform for the
the crane and the hoist. The weight of the load handling purpose of informing the operator when a load can or
equipment and boom attachments must be deducted from
cannot be handled.
the maximum load rating shown on the load chart to

determine the payload which can be lifted. Additional • Load ratings cannot be interpolated between load points
reduction may be necessary to make allowance for such shown on the chart in the boom areas.
the effects of freely swinging loads, wind, ground
factors as
• When boom length or radius or both are between points
conditions, out-of-level conditions and operating speeds.
listed on load chart, the smallest load shown at either the
The ratings shown on the outrigger full span load chart are next larger radius or boom length shall be used.
maximum loads and are based on:
• Capacities of the jib cannot be interpolated between
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- the structural integrity of the crane in shaded areas, angles nor at reduced lengths because the strength of
the stability of the crane in non shaded areas. the jib and its attachment point to the boom does not
-
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increase when the boom is shortened.
The stability or non shaded areas represent a stability tipping
NOTE: Rated loads shown on the load chart pertain to this
factor of 85% (Note: For New York City approved units, the
machine as originally manufactured and equipped.
stability or non shaded areas represent a stability tipping
factor of 75%) when:
Modifications to the machine or use of equipment
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that is not factory specified or approved can be
1. All outriggers
are extended with positive contact on firm, hazardous. Refer to capacity deduction chart for
level surface, the tires are free of the ground and the weights which must be deducted from rated loads
machines level within 1. when accessories are attached to boom or

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loadline.
2. The proper amount of counterweight has been installed,
if required.
Set-Up
3. The unit is mounted in accordance with factory
1. Inspect vehicle and crane including crane operation

instructions on a vehicle with proper specifications.
prior to use each day.
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4. The weight of load handling devices is considered as a

part of the load being lifted.
2. Load ratings shown on the chart are maximum allowable
loads with the crane mounted on a factory approved
5. The correct loadline reevings used for the load to be truck and all outriggers set on a firm level surface so the
lifted. crane is level; ensure the Outrigger Status Indicator
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illuminates green before making a lift. This crane is not

6.
Adverse environmental conditions such as wind are not
rated for use without outriggers.
present.
3. Depending on the nature of the supporting surface,
7. The operator controls the loads smoothly.
structural supports under the outrigger floats may be
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8. Tires are inflated to the proper pressure. necessary to spread the load to a larger bearing surface.
9. The load to be handled does not exceed the maximum 4. Always level the crane with the level indicator located at

capacity at the boom length and loaded radius. the operator stations located on either side of the crane
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frame.
10. The loads are lifted in the proper area around the truck.

A stability test should have been performed on this crane Operation
and can be
repeated by referring to the Installation Section of 1. Operation of this equipment in excess of maximum load
the Service Manual. rating and disregard of instructions is hazardous. Always

All capacities are given in direct relationship to the boom refer to the load chart for load and area limits before
length and loaded radius at which the loads being handled. operating the crane. Rated loads at rated radius shall
not be exceeded. Over loading this crane may cause
• are measured from the centerline of rotation to
All radii structural collapse or instability. Do not rely on the HCA
the loadline with the load suspended. system or the jib load limiting device to weigh the load
•
All variances of loads and radii of operation are shown and control limiting boom angle and radius. Use these
on the load chart mounted on the main frame. system as a backup to safe operation.
• Boom angle should be used as reference only to aid in 2. Use the angle indicator as a reference only. When lifting
determining radius. maximum loads, measure radius.


3. Rated loads do not exceed 85% of the tipping load as 15. Do not allow personnel to ride on hook, hook block, load
determined by SAE Crane Stability Test Code J765a or any device attached to the loadline. Use only National
when mounted on a factory recommended truck Crane approved baskets.
NOTE: For New York City approved units, rated load do 16. Operate controls slowly and smoothly to avoid damage
not exceed 75% of the tipping load as determined to crane or personnel.
by SAE Crane Stability Test Code J765a when
17. Boom must be in carrying rack and outriggers fully
mounted on a factory recommended truck.
retracted for travel.
4. Structural limited ratings on the load chart are shaded.
18. Do not operate crane within 10 feet (3.05m) of live power
Stability limited loads are not shaded. Machine will not
lines.
always tip before structural damage occurs.
5. Rated loads include the weight of the hook block, slings, Definitions
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other lifting devices and boom accessories. Their
weights must be subtracted from the listed rated load to Load Radius
determine the net load that can be lifted.
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Horizontal distance from the centerline of rotation before
6. Rated loads are based on loading to the center of the vertical load line or block with
freely suspended loads. load applied.
Block
Always position the boom +
Loaded Boom Angle
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tip directly over the load Sling
before lifting. No attempt + Loaded boom angle is the angle between the first section
shall be made to push Load boom and the horizontal, after lifting the rated load at the
Total Rated
down with the boom or Load
rated radius. The boom angle before loading should be
move the load sideways in greater to account for deflections. The loaded boom angle
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any direction by pulling or combined with the boom length give only an approximation
dragging the load. of the operating radius.
7. The user shall operate at reduced ratings to allow for Working Area
adverse job conditions such as soft or uneven ground,
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high winds or erratic operation which produce swinging Area measured in a circular arc above the center line of
(side) loads, experience of personnel, two machine lifts, rotation as shown on the Working Area diagram. If no decal
or other hazardous conditions for safe operation. is present the work areas 360°.
8. When boom length or radius or both are between points

listed on load chart, the smallest load shown at either the
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next larger radius or boom length shall be used. Full Capacity

Work Area
9. Do not exceed jib capacities at any reduced boom
length. If Jib is between angle ratings on load chart, the
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smallest load shall be used.

10. Its safe to attempt to telescope or retract any load listed
if rating is not exceeded. Capacities at retracted boom
length cannot be telescoped without exceeding ratings.
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11. Always pay out loadline before extending boom to avoid

damaging loadline or crane structure.
12. Loads lifted must be within safe hoist capacity as well as
safe crane capacity. Multiple part rope reeving must be
Freely Suspended Load
used on loads exceeding hoist single part rated pull. Jibs
are rated for single part use only. Load hanging free with no direct external force applied
except by the loadline.
13. Do not operate the boom over personnel or allow them
to walk or stand beneath the boom or load. Side Load
14. Do not allow personnel on truck bed or crane frame area Horizontal side force applied to the lifted load either on the
when operating crane. ground or in the air.

Boom Length 4. Refer to crane load chart.

Length of the boom, from boom pivot pin to wire rope on last Starting point: Assuming the boom is fully retracted [27 ft'
main boom section. A decal on either side of the boom (8.23 m) boom length], the capacity at a 10 ft (3.04 m) radius

shows when certain boom lengths are reached. The letters is 18,900 lbs (8,573kg).
on the intermediate boom lengths correspond to the letters
chart. In order to get the load on the roof, the load must be:
on the load
• hoisted from the ground
Range Diagram
• swung around the rear of the truck (dead spot in rotation
Corresponds to the pictorial in the load chart. The chart is over the cab)
shows the operating radius and height of the unloaded boom
tip at all boom lengths and angles. The chart should be used • boom extended to 62 ft (18.90 m) extension
as a guide to position unloaded loadline and to determine • load hoisted to a height that will clear the top of the
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approximate height to which the load can be lifted. building
• boom rotated to the point load is to be placed
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DETERMINING LOAD CAPABILITY
• boom tip lowered to 40 ft (12.19 m) radius
The following procedure is a typical method which must be
used to determine the crane’s ability to handle a load. The • load lowered to building roof.

crane is equipped with a standard hoist:
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Ending Point: The load rating at the ending point is 3950 lbs
1. Determine the weight of the load and load handling (1792 kg). The boom will be at 62 ft (18.90m) extension and

equipment. the loaded radius is 40 ft (12.19 m).
2. Determine the radius from center line of crane rotation to • The crane has enough capacity at each end of the lift to

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position of load. allow the lift to be made.
3. Determine
the radius from centerline of crane rotation to • Refer to hoist load chart. Crane is reeved for single part
center of point where load is being moved to. line.
4. to load chart for crane and determine that load and
Refer • Allowable load for single part lines 7700 lbs (3492 kg)
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radius of lifting are within capacity of crane. well above the 2480 lbs (1124 kg) to be lifted.
5.

Refer to load chart to determine correct hoist reeving. • Operator should now proceed to lift the load as smoothly
as possible

Load Determination Examples .
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The following examples are for illustrative purposes only.

CAUTION
The load chart ratings, component weights and dimensional This load could not be lifted if the jib were being used on
data may not be the same as the actual unit. Always use this machine as maximum capacity of the 23 ft (7 m) jib at

actual information from the crane and job site when planning 40 ft (12.19 m) radius would only be 1800 lbs (816 kg) at
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a lift. 65°. The capacities remain the same even with the boom
retracted.
Example 1
The hoist in this example can lift 7700 lbs (3492 kg) while
A load is to be lifted from the ground and weighs 2300 lbs the boom is only able to withstand 3950 lbs (1792 kg) at
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(1043 kg) at a radius of 10 ft (3.04 m). The load will be placed 40 ft (12.19 m) radius. Therefore, one could easily
of a building at a radius of 40 ft (12.19 m) and a
on the roof damage the crane by attempting to pull until the hoist
height of 40 ft (12.19 m) above the ground on the opposite stops with a heavier load.
side of the
truck.
1. Determine the load. Example 2
Assume a load of 9000 lbs (4082 kg) at 10 ft (3.04 m) radius
Load = 2300 lb (1043 kg) on the ground beside the truck to be picked up, swung over
1 Part Load Block = 150 lb (68 kg) and placed on the truck bed at an 8 ft (2.43 m) radius from
the crane. Crane is reeved for single part.
Sling = 30 lb (14 kg)
Total Load = 2480 lb (1125 kg)
1. Weight of load and load handling equipment.
2. Starting Load = 9000 lb (4082 kg)

Radius =10 ft (3.04 m)
3. Ending Radius = 40 ft (12.19 m) 1 Part Load Block = 150 lb (68 kg)


Sling = 50 lb (22 kg) 2. Starting Radius Given = 30 ft (9.14 m)
Total Load = 9200 lb (4173 kg) 3. Ending Radius Given = 40 ft (12.19 m)
2. Starting Radius = 10 ft (3.04 m) 4. Refer to Crane load chart.
3. Ending Radius = 8 ft (2.43 m) To reach the load on the roof, the jib must be utilized to clear
the roof with the load.
4. Refer to crane load chart.
The crane capacity at the 10 ft (3.04 m) radius is 18,900 lbs CAUTION
(8,573 kg). At the 8 ft (2.43 m) radius, the capacity is
19,750 lbs (8,960 kg). Do not attempt to deploy the jib until reading and
understanding jib operation information found later in this
The crane capacity is adequate. section of the manual.
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5. Refer to hoist load chart.
Both the retracted 23' jib length and extended 41' jib length
The capacity of a 1 part line is 7700 lbs (3492 kg), which is have the necessary capacity at a 30' (9.14 m) radius. Only
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less than load to be lifted. the retracted 23' jib has the capacity at the 40' (12.19 m)
radius to accomplish the task.
NOTE: Crane must be reeved for 2 part to lift the 9,000 lbs Starting Point: With the 23 ft (7 m) jib deployed and the boom
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(4082 kg) load. fully extended, the capacity is 2,450 lbs (1111 kg) at a 30 ft
(9.14 m) radius and boom angle of 72.1.
Two part hoist capacity is 15,400 lbs (6985 kg)
Ending Point: With the main boom still fully extended, the
After reeving for 2 part line the new Step 1 calculation is the capacity is 1,800 lbs (816 kg) at a radius of 40 ft (12.19 m)
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weight of load and load handling equipment. and boom angle of 65.4.
Load = 9000 lb (4082 kg) NOTE: The capacity of the jib remains the same even with
the main boom retracted. Operate with jib by radius
1 Part Load Block = 200 lb (90.7 kg) when main boom is fully extended and operate with
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Sling = 50 lb (22 kg) jib by boom angle when main boom is not fully
extended. Do not exceed rated jib capacities at any
Total Load = 9250 lb (4195 kg)
reduced boom lengths.
Example 3 5. Refer to hoist load chart.
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A load of 1500 lbs (680 kg) is to be lifted from the roof of a The capacity of a 1 part lines 7700 lbs (3492 kg) which is well
building at a radius of 30 ft (9.14 m) and a height of 80 ft above the 1,680 lbs (762 kg) to be lifted.
(24.38 m) and placed on the ground on the other side of the NOTE: The HCA Load Range Gauge does not provide
truck at a radius of 40 ft (12.19 m). accurate indication of overload conditions when
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1. Weight of load and load handling equipment. operating with a jib deployed. The HCA will not
prevent the crane from being operated in an
Load = 1500 lb (680 kg) overload condition. The Jib is equipped with a jib
load limiting device which will prevent the jib from
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1 Part Load Block = 150 lb (68 kg) being operated in an overload condition.
Sling = 30 lb (14 kg) The operator should proceed to lift the load as smoothly as
Total Load = 1680 lb (762 kg) possible.

JIB OPERATION SAFETY 9. Area where jib swings around must be clear of
obstructions and power lines when stowing and
1. The anti-two-block switch weight and cord must be unstowing jib.
attached to the jib when deployed.
10. Use safety glasses when necessary.
2. Do not lift load with the boom tip when the Jib is pinned
on the
boom tip. 11. Do not extend/retract boom unless boom is horizontal
when stow pin A and jib swing pin B are removed during
3. Operate with jib by radius when main boom is fully stowing or unstowing procedures.

extended. If necessary, increase boom angle to maintain
loaded radius. 12. Always put spring clips in pins to ensure that they will
stay in place.
When radius is between points listed on load chart, the
load shown at the next longer radius shall be used. 13. When the jib is stowed, the boom can not be fully
retracted if a boom tip attachment option is installed.
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4. Operate with jib by boom angle when main boom is not
fully extended. Do not exceed rated jib capacities at any

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reduced boom lengths.
CAUTION
When angle is between points listed on load chart, the
load shown at next lower boom angle shall be used. • Boom tip attachment can contact jib in stowed
position when boom is fully retracted.
Jib is stowed correctly.
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5. Ensure
• Contact can cause damage to boom extension
a. Removal of swing around pins, C, without proper system and jib stow system.
installation of stow pin A and jib swing pin B, may
• Boom must be left extended 0.5 ft (0.2 m) to prevent
allow jib to fall off.
contact.
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b. Extending boom with jib stowed and failure to
• Boom attachment must be removed for retracted
remove swing pins, C, will damage unit upon boom lifting operations.
extension.
6. Only attempt to swing jib to working or stowed position Manually Extendable Jib:
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when boom is horizontal, stow pin A and jib swing pin B,

1. Extension retaining pin, E, must always be installed
are removed
and swing pins, C, are in place. Jib could
when operating.
swing uncontrollably if boom is not horizontal.
2. All swing around (stow and unstowing) operations shall
7. shall be fully set up according to proper set-up
Crane
be done with jib retracted and pinned.
procedures outlined previously when stowing or
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unstowing
jib. 3. The extendable section may slide out of 1st section jib to
the mechanical stop when pin E is removed. Keep
8. Operate boom and turn functions very slowly and
personnel clear of area.

carefully when using jib since jibs can increase boom
length by 50%.
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A Stop Pin B Jib Swing Pin C1 Jib Deployment

C2 Jib Deployment D Stow Loop F Load Line Attachment Point
Jib in Stow Position
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JIb in Operating position
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A Stow C2 Jib Deployment

B Jib Swing D Stow Loop
C Swing Around E Extension
Retaining
C1 Jib Deployment F Load Line
Attachment
Point

SIDE FOLDING-SWING AROUND JIB 15. Route loadline over jib sheave and install keeper. Install

OPERATION line block to end of loadline.
16. Remove anti-two-block weight/chain assembly from

Deployment Procedure boom tip switch and install on jib tip switch. Be certain to
use keeper provided with switch.
1. Using boom telescope function, fully retract boom.

17. Disconnect twist lock quick coupler on anti-two-block
2. Using lift function, lower boom to allow for easier access
cord going to boom anti-two-block switch and attach to
to jib deployment pins C1 and C2.
quick coupler on jib anti-two-block wire on rear of jib
NOTE: When lowering the boom below horizontal, two between the upper and lower jib ears.
persons may be required. With the telescope
18. Install jib swing pin B and spring clip into jib ears.
control in neutral, the boom can creep out when
below horizontal. 19. For manually extendable jibs, pull extension retention
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pin E, and extend second section out by pulling on
3. Install pins C1 in upper and lower jib ears. Install retainer
clips. These pins will be used as a pivot point to sheave case. The second section jib, as it extends, will
spring
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hit a mechanical stop that allows for extension pin E
swing jib into the deployed position.
installation. Install pin E and spring clip.

4. Locate the stowed position of pins C2. If the pins are in
jib attachment holes or boom sheave case jib holes, STOWING PROCEDURE
pins from storage location.
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remove
5. Remove
jib swing Pin B from top ear of jib.
6. Remove stow Pin A from ramp/side stow bracket

assembly on jib and stow in Stow Loop D and install
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spring clip.
7. tag line to sheave case end of jib.
Attach
8. Using lift function, raise boom to a horizontal position.

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9. Using telescope function, slowly extend boom

approximately one foot. This procedure will pull the jib
out of the stow bracket.

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DANGER
Use Caution during this step. The Jib is free to swing
the boom upon boom extension.
away from
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10. Using
tag line, swing jib into deployed position.
11. Remove cable keeper pins from boom sheave case and

jib. Remove hook block. Pivot jib slightly to allow for
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loadline to be removed from boom sheave case.

Remove loadline from boom sheave case and place in
an area to minimize possible damage.
12. Pivot jib into place, visually aligning the upper C2 pin
holes. Install upper C2 pin and spring clip. A slight 1. Using lift function, lower boom so that jib tip is close to
hammer
strike may be necessary to install pins. Always the ground.
use proper eye protection during this step.
NOTE: When lowering the boom below horizontal, two
13. Using jib jack, (Refer to Jib Jack Procedures in this persons may be required. With the telescope
chapter) position jib so that lower C2 pin holes are in control in neutral, the boom can creep out when
alignment
and install lower C2 pin and spring clip. below horizontal.
14. Using hoist function, un-spool enough loadline to reeve 2. For manually extendable jibs, pull extension retention
over jib sheave case. Keep slight tension on
loadline pin and fully retract extendable 2nd section jib into the 1st
loadline to avoid bird caging of loadline on hoist drum. section. Retraction of 2nd section may be facilitated by


attaching loadline wedge socket to attachment point F 15. Remove pins C1 from upper and lower jib ears. A slight
on the jib sheave case. Slowly activate the hoist up hammer strike may be necessary to remove pins.
function until the 2nd sections fully retracted Always use proper eye protection during this step.
3. Reinstall extension retention pin through the 1st and 2nd 16. Reinstall loadline over boom sheave case.
section jib assembly and install spring clip.
4. Remove loadline from jib sheave case. Place loadline in
area to avoid possible damage from stow procedure. DANGER
5. Disconnect twist lock anti-two-block wire connector at Visually check all pin positions to assure Jib is fully
rear of 1st section jib. Connect twist lock connector to retracted into side stow brackets, jib stow attachments
anti-two-block switch connector on boom tip. Move anti- secure, and all pins and spring clips are in their proper
two-block weight assembly to boom tip switch. locations. Failure to properly secure the jib during stowing
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and erecting may allow the jib to fall. Serious personal
6. Attach tag line to sheave case end of jib. injury or death could result.
7. Remove spring clips from pins C2 on both upper and
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lower jib ears.
8. Remove pins C2 from upper and lower jib ears. Do not
remove C1 pins at this time. C1 pins will be used as a WARNING
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pivot point to swing jib into stow position. A slight Always have at least one, if not both of the following in
hammer strike may be necessary to remove pins. place at all times:
Always use proper eye protection during this step.
• Side stow bracket completely engaged into stow
Utilization of the jib jack at this time will aid in pin hole
hook with stow pin A properly in place.
alignment to facilitate pin removal.
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• Both pins C1 in upper and lower jib holes properly in
9. Using lift function, raise boom to a horizontal position.
place through mating holes on boom tip
10. Using extend function, extend boom approximately 1
foot. Jib Maintenance
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11. Using tag line attached to jib sheave case, slowly swing 1. Lubricate sheave pin on jib with grease gun containing
jib into stow position (parallel with 1st section boom). chassis grease weekly.
Pins C1 are the jib pivot points during this operation.
2. Check for free rotation of jib sheave daily when using jib.
3. Lubricate jib sheave case pivot pin with grease gun
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containing chassis grease monthly.

CAUTION
Use caution when swinging jib to avoid unnecessary Jib Removal
impact with 1st section boom
Should jib removal from the boom become necessary,
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12. Install jib swing pin B with spring clip through jib ear and proceed as follows
boom sheave case holes. This pin will keep the jib
assembly in line (parallel) with the 1st section boom. Pin
B does not retain the jib in its stowed position on the 1st
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section boom. CAUTION

Jib Weights
13. Using boom telescope function, slowly retract boom.
The ramp/side stow bracket assembly on the side of the The 41 ft (12.49 m) jib weights 960 lbs (435 kg) at 129 in.
1st section jib will engage the hook on the side of the 1st (328 cm) when retracted from mounting pin holes.
section boom, first lifting the jib and then engaging the jib
side stow bracket and the boom hook completely upon 1. Unstow and swing jib into position on the boom tip
full retraction of the boom. according to Steps 1 - 10 in the preceding jib deployment
section.
14. Install stow pin A with spring clip into the ramp/side stow
bracket assembly on the jib. Complete engagement of 2. Support and raise the jib at its balance point and remove
stow brackets and proper installation of pin A is critical the two swing around pins. Jib is now free of boom.
for a secure jib stow attachment.
3. To install, proceed in reverse order of removal.

Jib Jack Procedures When Jib is stowed on side of crane, always leave ram and
handle sleeve pushed all the way down to reduce exposure
The Jib Pin alignment device (Jib Jack) is an aid for installing to rusting.
the fourth or “last” jib pin when setting up a jib. This device

has been designed to line up the bottom jib pin hole on the
ADJUSTABLE SWING SPEED VALVE
left side of the crane the hole in the boom ear.

The jib pin alignment device consists of a hydraulic jack This crane is equipped with an adjustable swing speed
mounted horizontally on the underside of the jib. A handle for valve. This valve allows the operator to limit the maximum
the jack is provided and is installed above the jack on the swing speed of the machine to suit operator preference or
side of the jib. varying applications.

Prior to using the Jib Jack, complete Steps 1 to 12 in the An adjustment dials located on the swing holding valve
“Side Folding-Swing
Around Deployment Procedure”. mounted on the swing motor inside the crane frame. The
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valve has an adjustment screw with a lock collar. Loosen the
1. Remove jack handle and using the flattened end, close
lock collar when adjusting the speed, then tighten the lock
jack release valve by turning the handle clockwise until it
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collar to maintain swing speed limit setting. The adjustment
is firmly closed.
dial allows the maximum swing speed to be reduced as
2. the round end of the handle into the handle sleeve
Insert required.
and pump jack until ram contacts boom sheave case.

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3. Continue to pump slowly until jib pin holes exactly
aligned with hole in boom ear. At this time the final jib pin

can be easily tapped into position.
If hole
alignment is “over shot” due to jacking too far, the
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jack can simply be relieved and the process repeated.
To relieve the jack, use the flattened end of jack handle

to slowly turn relief valve counter clockwise no more
than one full turn.

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4. After all jib pins are installed, relieve jack.

alignment device is also useful when removing
The jib pin
the “fourth” pin. Use the jib jack to relieve jib weight induced
pressure on the “fourth” pin and it will be much easier to
remove.
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Once the jib has been erected or stowed, it is important that

the jack handle be properly placed back on its stowage
that the cotter key be properly placed in the
hooks and
stowage hook to retain the handle on the hook.
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CAUTION
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Avoid “shock loads” created by quickly opening and

closing the release while jack is under load. This may
result in overloading of the hydraulic circuit and possible
damage to the jack.

500E2 OPERATORS MANUAL LUBRICATION PROCEDURE AND CHARTS
SECTION 5
LUBRICATION PROCEDURE AND CHARTS
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Wide Range Intermediate Hydraulic Oil. . . . . . . . . 5-2
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Arctic Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Arctic Conditions Below -18°C (0°F). . . . . . . . . . . 5-1 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Chassis Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Surface Protection for Cylinder Rods . . . . . . . . . . 5-3
Extreme Pressure Multipurpose Gear Lubricant Internal Cable Sheave Lubrication. . . . . . . . . . . . . 5-5
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(EPGL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Inner Boom Pad Lubrication . . . . . . . . . . . . . . . . . 5-5
Open Gear Lubricant . . . . . . . . . . . . . . . . . . . . . . 5-2 Side and Bottom Boom Wear Pad Lubrication . . . 5-5
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Chassis Grease Low Temp. . . . . . . . . . . . . . . . . . 5-2 Hoist Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Anti-wear Additives . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Hoist Brake Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Hydraulic OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Oil Reservoir Level. . . . . . . . . . . . . . . . . 5-7
Standard Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . 5-2
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Intermediate Hydraulic Oil. . . . . . . . . . . . . . . . . . . 5-2 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . 5-7
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GENERAL results. However, certain fluids, such as halogenated
hydrocarbons, nitro hydrocarbons, and phosphate ester
Following a designated lubrication procedure is important to hydraulic fluids, might not be compatible with hydraulic
ensure a maximum crane life. The procedures and system seals and wear bands. If you are in doubt about the
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lubrication charts in this section include information on the suitability of a specific fluid, check with your authorized
types of lubricants used, the location of the lubrication points, Manitowoc distributor or Manitowoc Crane Care.
the frequency of lubrication, and other information. This
NOTE: All fluids and lubricants may be purchased by
section does not include lubrication requirements for the
contacting the Manitowoc Crane Care Parts
truck chassis. Refer to truck service manual for this
Department.
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information.
Regardless of temperature and oil viscosity, always use
The service intervals specified are for normal operation
suitable start-up procedures to ensure adequate lubrication
where moderate temperature, humidity, and atmospheric
during system warm-up.
conditions prevail. In areas of extreme conditions, the
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service periods and lubrication specifications should be

Chassis Grease.
altered to meet existing conditions. For information on
extreme condition lubrication, contact your local National Lubricating grease of proper consistency is to be applied
Crane Distributor or Manitowoc Crane Care. periodically at relatively frequent intervals with grease guns
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through grease fittings. Minimum apparent viscosity of 300

Lubricants SUS (Saybolt Universal Seconds) at 100° F (38° C) is
Specific recommendations of brand and grade of lubricants
are not made here due to regional availability, operating
recommended.
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Extreme Pressure Multipurpose Gear
conditions, and the continual development of improved
products. Where questions arise, contact your National Lubricant (EPGL)
Crane Distributor or Manitowoc Crane Care. This gear lubricant is compounded to achieve high load
carrying capacity and meet the requirements of either API-
Arctic Conditions Below -18°C (0°F) GL-5 or MIL-L-2105C. Unless otherwise specified,
In general, petroleum based fluids developed especially for SAE 80W-90 viscosity may be used for year round service.
low temperature service may be used with satisfactory Low temperature usage is restricted as follows:

LUBRICATION PROCEDURE AND CHARTS OPERATORS MANUAL 500E2
Intermediate Hydraulic Oil

SAE Viscosity Minimum Ambient Temperature
Number F (C) (-10°F to 80°F) (-23°C to 27°C)
75W -40 (-40) For colder operating environments, the standard fluid may be
80W -15 (-26) replaced with a Low Service Temperature Multi Viscosity
Hydraulic Oil with High Viscosity index 175+.
85 +10 (-12)
90 +20 (-7) Wide Range Intermediate Hydraulic Oil.
140 +40 (+5) (-30°F to 80°F) (-34°C to 27°C)

250 +50 (+10) For even colder operating conditions, the standard fluid may
be replaced with a petroleum based fluid developed
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Open Gear Lubricant especially for colder environments.
This is a special high-graphite adhesive lubricant that helps
Arctic Hydraulic Oil.
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to eliminate fretting corrosion, is water resistant, and forms a
dry lubrication
film which does not attract dust. Lubricant (-10°F and below) (-23°C and below)
meets NLGI Class 1-2 specifications.
In general, petroleum based fluids developed especially for
Grease Low Temp
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Chassis low temperature service may be used with satisfactory
results. However, certain fluids, such as halogenated
This special
grease for low temperature remains plastic at - hydrocarbons, nitro hydrocabons and phosphate ester
60°F (-51°C) with melting point of 280°F (138°C). The hydraulic fluids might not be compatible with hydraulic
grease is a heavy duty extreme pressure type lubricant system seals and wear bands. Arctic hydraulic oil is not

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(Lubricate Low Temp or equal). recommended for service in ambient temperatures above
32°F (0°C).
Anti-wear Additives
If you are in doubt about the suitability of a specific fluid,
Excessive wear in the system may cause a loss in volumetric check with your authorized National Crane distributor or
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efficiency, and may cause shutdowns for maintenance. An Manitowoc Crane Care.
efficient anti-wear oil protects the components against

rusting, resists oxidation and helps prevent wear. NOTE: All fluids and lubricants may be purchased by
contacting the Manitowoc Crane Care Parts

Hydraulic OIL Department.
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Oil in a hydraulic system serves as the power transmission

LUBRICATION POINTS
medium, system lubricant and coolant. Selection of the
proper oil is essential to ensure satisfactory system A regular frequency of lubrication must be established based

performance and life. The most important factors in selecting on component operating time. The most efficient method of
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an oil for hydraulic service are viscosity and anti-wear keeping track of lube requirements is to maintain a job log of
additives. crane usage.
All oil levels are to be checked with the crane parked on a

CAUTION level surface in transport position, and while the oil is cold,
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Operation of the crane with incorrect hydraulic oil in sub unless otherwise specified. On plug type check points, the oil

freezing temperature (below 32°F, 0°C) can cause levels are to be at the bottom edge of the fill port.
damage to the extend cylinder. Over lubrication of non-sealed fittings will not harm the

fittings or components, but under lubrication shortens
Standard Hydraulic Oil lifetime.

Above 10°F (-12°C) Worn grease fittings that do not hold a grease gun, or those
that have a stuck check ball, must be replaced.
fill standard hydraulic oil is SAE grade 10W-20
The factory
Hydraulic Oil. This fluid is acceptable for operating When wear pads or rotation bearings are lubricated, cycle
temperatures above -12°C (10°F). the components and lubricate again to ensure complete

lubrication of the entire wear area.

operated daily, exposed rod surfaces will corrode. Some

cylinders will have rods exposed even when completely
CAUTION
retracted. Assume all cylinders have exposed rods, as
Lubrication intervals (page 5-2) are to be used only as a corrosion on the end of the rod can ruin the cylinder.
guide. Actual intervals should be formulated by the
operator to correspond accordingly to conditions such as It is recommended that all exposed cylinder rods be
continuous duty cycles and/or hazardous environments. protected using Boeshield® T-9 Premium Metal Protectant.
Manitowoc CraneCARE has Boeshield T-9 Premium Metal
Surface Protection for Cylinder Rods Protectant available in 12 oz. cans that can be ordered
through the Parts Department.
Steel cylinder rods include a thin layer of chrome plating on
their surfaces to protect them from corroding. However, NOTE: Cylinder operation and inclement weather will
chrome plating inherently has cracks in its structure which r e m o v e t h e B o e s h i e l d p r o t e c ta n t . I n s p e c t
machines once a week and reapply Boeshield to
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can allow moisture to corrode the underlying steel. At typical
ambient temperatures, hydraulic oil is too thick to penetrate unprotected rods.
these cracks. Normal machine operating temperatures will The following describe the lubrication points and gives the
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allow hydraulic oil to warm sufficiently to penetrate these lube type, lube interval, lube amount, and application of
cracks and if machines are operated daily, protect the rods. each. Each lubrication point is numbered, and this number
Machines that are stored, transported, or used in a corrosive corresponds to the index number shown on the Lubrication
environment (high moisture, rain, snow, or coastline Chart. Lube description and symbols are found in tables
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conditions) need to have the exposed rods protected more below.
frequently by applying a protectant. Unless the machine is
Symbol Description Manitowoc Lube Specification

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EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2. A6-829-003477
EP-3MG Extreme Pressure Moly Grease A6-829-015304
GL-5 Extended Service Interval Gear Lubricant - SAE Grade 80W-90 A6-829-012964
AFC - 50/50 50/50 Blended Fully Formulated Antifreeze/Coolant, SAE J1941, ASTM D6210 A6-829-101130
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HYDO Hydraulic Oil - Must meet ISO 4406 cleanliness level 17/14 A6-829-006444
EO-15W/40 Engine Oil - SAE 15W-40, API Service Classification CI-4 or better A6-829-003483
EP-OGL Open Gear Lubricant, CEPLATTYN 300 Spray, NLGI Grade 1-2 A6-829-102971
AGMA EP-4 Extreme Pressure Gear Lubricant. A6-829-100213
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WRL Wire Rope Lubricant A6-829-015236

LTG Low Temperature Grease, NLGI Grade 1 A6-829-225828
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13

18

Oil Fill/Breather

4
Oil Drain
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12
14

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5
18 16

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19 4
10a 20
10b

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7
23
19
20
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11

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2 3
15
9a
9b 22
1
NOTE: Torque diffuser to
51 lb-ft (69 Nm). Openings
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must face bottom of tank.

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Recommended
Item Application Procedure Frequency
Lubricant
1
Hydraulic oil reservoir HYDO Check fill change Weekly, semi-annually, as required
After first 40 hrs. as indicated by
2 Oil filter, magnetic plug, hydraulic oil reservoir Change or clean
gauge thereafter.
3 Breather, hydraulic oil reservoir Clean Monthly
4 pins: boom (3 plcs), jib (1 pl)
Sheave EP-MPG Grease gun Weekly
5 Wire rope (loadline) EP-OGL Brush or spray Semi-Annually
6 Boom pivot pin EP-MPG Grease gun Monthly

7 Lift cylinder pins - 2 ea. EP-MPG Grease gun Monthly
8 Swing bearing (turret) (not shown) EP-MPG Grease gun Weekly
9a drive U-Joint 2 ea.
Pump EP-MPG Grease gun Monthly
Remove pump and apply to
9b Pump spline shaft (direct mount) EP-MPG Semi-Annually
shaft or grease gun
10a Hoist gearbox. SAE 90 EP Change/check and fill Every 1000 hours or 6 months


Recommended
Item Application Procedure Frequency
Lubricant
10b Hoist brake HYDO Change/check and fill Every 1000 hours or 6 months
11 Control linkage EO-15W/40 Oil Can As Required
12 Swing drive gearbox GL-5 Change After 100 operating hours
13 Swing gear teeth EP-OGL Spray Can Monthly
14 Boom extension LTG Brush, roller or grease gun Monthly or as required
15 Outrigger beams, bottom, sides LTG Brush or roller Monthly or as required
Any time boom is disassembled or
16 Extension cables (not shown) WRL Spray or brush
5 years
17 Boom Wear Pads (not shown) EP-MPG Brush or roller Monthly or as required
18 Swing Motor Pinion Bearing EP-MPG Grease gun Sparingly every 50 hours
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19 Extend Sheaves EP-3MG Grease gun Weekly
Retract Sheaves: Extend the boom until the
20 retract sheave grease holes are visible through EP-3MG Grease gun Weekly
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the access holes along side of boom.
21 Diffuser strainer, Hydraulic oil reservoir Clean Semi-Annually with oil change
22 Magnetic plug, hydraulic oil reservoir Clean At oil filter service interval
23 Continuous rotation swivel (optional) EP-MPG Grease gun Monthly
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Internal Cable Sheave Lubrication 1. Extend boom until grease access hole (Item 19 on the
Lubrication Points diagram) becomes visible on side of
2nd section.
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DANGER 2. Check alignment between the 2nd section access hole
Do not, under any circumstances, work at an elevated and the 3rd section access holes. When these holes
height without using proper fall protection as required by become aligned, the end of the extend cable sheave pin
local, state or federal regulations is visible and accessible for lubrication.
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3. This boom position also aligns the access holes at the

The lubrication points on the sheaves are not equipped with
grease fittings (zerks) and will require a grease gun adapter rear of the 1st section for lubrication of the retract
to accomplish the task. sheaves.
Special Tools: Inner Boom Pad Lubrication

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Nozzle or needle grease gun fitting: 1. With the boom fully retracted, apply grease to the wear
• 0.25 inch (6.35 mm) diameter nozzle grease gun tip pads on the top of second boom section with a small
(National P/N 955047). paint brush or a grease gun.
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• Contact the Manitowoc Crane Care to obtain this tip. 2. Extend boom to position the wear pad access holes
directly above the wear pads on the third boom section,
• Observation through the sheave case for the extend apply grease to the pads using the brush or gun.
sheaves and the hoist mount for retract
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3. Extend boom to position the wear pad access holes

NOTE 1: To determine the amount of grease required, directly above the wear pads on the fourth boom section,
visually inspect the sheaves. From the front of apply grease to the pads using the brush or gun.
the boom, look back through the sheave case at
the extend sheaves. From the back of the boom, 4. After grease is applied to all wear pads raise the boom to 5
look up through the hoist mount at the retract the maximum angle and slowly extend the boom to full
sheaves. A small amount of grease extrusion extension and slowly retract completely.
around the pin is adequate. 5. Repeat steps 1-4 three times to ensure the boom is fully
The extend sheaves are located on the boom tip end of the lubricated.
extend cylinder, and the retract sheaves are located on the
Side and Bottom Boom Wear Pad
inside rear of the 2nd section. Lubrication is as follows:
Lubrication
1. Fully extend and set the outriggers.
2. Lower the boom to horizontal.

3. Fully extend the boom and apply grease to the side and 5. Extend and retract the boom several times until the
of the 2nd and 3rd sections with a brush.
bottom grease is evenly spread.
4. Raise the boom to about 75° and retract the boom 6. Repeat steps 1-3 as necessary to ensure the boom is
fully lubricated.
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Hoist Gearbox
Oil
Gearbox Oil Fill
To check the hoist gearbox oil level, remove the oil
plug in the center of the hoist. The oil should be
inspection
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level with the bottom of the inspection hole.

rotate the hoist until the plug is level with the oil fill
To add oil,
hole. Add SAE 90 EP gear lube until the oil is level with the
bottom of the fill hole.
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NOTE: Hoist gear and brake lubricants are satisfactory for

operation in temperatures from -10°F to +110°F (-
23°C to 43°C). For operation outside this range,
contact Manitowoc Crane Care for
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recommendations.

Gearbox Vent

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Gearbox Oil Drain

Hoist Brake Oil
To check the hoist brake oil, remove the vent/fill plug and
visually inspect the level. The fluid should be level with the
bottom of the vent/fill hole. If more fluid is needed, use
National Crane hydraulic oil.
.

! DANGER
Do not use EP type gear lubes in the brake section. This
may prevent proper operation and cause the load to fall
resulting in serious injury or death.

Hydraulic Oil Level
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Brake Vent/Fill Plug
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Sight Gauge
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Brake Drain Plug
WIRE ROPE LUBRICATION

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A wire rope cannot be lubricated sufficiently during
manufacture to last it’s entire life. Therefore, new lubricant
must be added throughout the life of a rope to replace factory
HYDRAULIC OIL RESERVOIR LEVEL lubricant which is used or lost. It is important that lubricant
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applied as part of a maintenance program shall be

The hydraulic oil reservoir has a sight gauge located on the compatible with the original lubricant, and to this end, the
side of the reservoir. This sight gauge has a decal beside it rope manufacturer should be consulted. Lubricant applied
that indicates a "full" level and an "low oil" level. The oil shall be of the type which does not hinder visual inspection.
required to bring it from the "low" line to the "full" line is 5 Those sections of rope which are located over sheaves or
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gallons. Do not fill the reservoir above the "full" line. The oil otherwise hidden during inspection and maintenance
level should be checked with the crane parked on a level procedures require special attention when lubricating rope.
surface in the transport condition (all cylinders retracted and The object of rope lubrication is to reduce internal friction and
boom stowed) and the oil cold. to prevent corrosion.
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During fabrication, ropes receive lubrication; the kind and

amount depends on the rope’s size, type, and anticipated
use. This in-process treatment will provide the finished rope
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with ample protection for a reasonable time if it is stored

under proper conditions. But, when the rope is put into
service, the initial lubrication may be less than needed for the
full useful life of the rope. Because of this possibility, periodic
applications of a suitable rope lubricant are necessary.
5
The following are important characteristics of a good wire
rope lubricant:
1. It should be free from acids and alkalis.
2. It should have sufficient adhesive strength to remain on
the ropes.

3. It should be of a viscosity capable of penetrating the • dripping

interstices between wires and strands.
• pouring
4. It should not be soluble in the medium surrounding it • swabbing
under the actual operating conditions (i.e. Water).
• painting
5. It should
have a high film strength.
• pressure spray
6. It should resist oxidation.
Whenever possible, the lubricant should be applied at the
Before applying lubrication, accumulations of dirt or other top of a bend in the rope, because at that point the strands
abrasive material should be removed from the rope. are spread by bending and are more easily penetrated.
Cleaning can be accomplished by using a stiff wire brush and There should be no load on the rope while it is being
solvent, compressed air, or live steam. Immediately after the lubricated. It should be noted, the service life of wire rope will
wire rope is cleaned, it should be lubricated. Many
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be directly proportional to the effectiveness of the method
techniques may be used to include: used and amount of lubricant reaching the working parts of
• bath the rope.
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500E2 OPERATORS MANUAL MAINTENANCE CHECKLIST
SECTION 6
MAINTENANCE CHECKLIST
SECTION CONTENTS
Crane Inspection And Maintenance . . . . . . . . . . . 6-1 Jib Jack Service and Maintenance . . . . . . . . . . . . 6-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Daily Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Weekly Inspections . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Monthly Inspections . . . . . . . . . . . . . . . . . . . . . . . 6-2 Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
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Periodic/Annual Inspection . . . . . . . . . . . . . . . . . . 6-3 Oil Cooler Service and Maintenance (Optional) . . 6-7
Special Boom Inspection . . . . . . . . . . . . . . . . . . . 6-3 Jib Load Limiting Device . . . . . . . . . . . . . . . . . . . . 6-7
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Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Single Character Display . . . . . . . . . . . . . . . . . . . . 6-7
Hoist Cable Inspection and Maintenance. . . . . . . 6-3 Hydraulic System Trouble Diagnosis . . . . . . . . . . 6-8
Keeping Records . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Jib Jack Troubleshooting . . . . . . . . . . . . . . . . . . . 6-11
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Environmental Conditions . . . . . . . . . . . . . . . . . . . 6-4 Tire Load And Inflation Table. . . . . . . . . . . . . . . . 6-12
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . 6-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Precautions and Recommendations During
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
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Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Wire Rope Replacement. . . . . . . . . . . . . . . . . . . . 6-5
HCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Care of Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Hoist Speed and Pull . . . . . . . . . . . . . . . . . . . . . . 6-15
Rope Construction . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Crane Operating Speeds . . . . . . . . . . . . . . . . . . . 6-16
Crane Adjustments and Repairs . . . . . . . . . . . . . . 6-6
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CRANE INSPECTION AND MAINTENANCE The inspections are separated into the following frequency
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classifications:
A regular schedule of inspection and maintenance is
essential to keep your unit in peak operating efficiency. • Daily inspections -These items should be visually
Operators or service personnel responsible for the care of inspected each day by the operator prior to using
the unit must be completely familiar with the type and the unit.
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frequency of inspections and maintenance operations. The • Weekly inspections -These items should be visually
following pages outline the inspections and maintenance inspected weekly by the operator.
required to keep the crane in proper operating condition.
• Monthly inspections -These inspections are to be
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Refer to the Service Manual for complete instructions on performed monthly by the personnel responsible for
preforming maintenance on this crane. maintenance and service of the crane.
• Periodic inspections -This inspection is a thorough
Inspection
inspection conducted at least every three months
The following pages list inspections which are to be and includes all items listed under Daily, Weekly,
conducted on your unit to help assure its operating properly and Monthly inspection in addition to those items
and safely. Check all items listed at the frequency listed and listed under periodic inspection. Federal Laws
make necessary repairs prior to operating. Refer to the through OSHA and ANSI B30.5 require that dated
Service Manual when installing missing or loose fasteners. and signed records of these periodic inspections be
Should a defect be found, a determination must be made as kept. A crane inspection log book is available from
to whether the deficiency is a safety hazard or though not yet National Crane to assist you in keeping records.
a safety hazard, needs to be monitored in the monthly
inspections.
6
MAINTENANCE CHECKLIST OPERATORS MANUAL 500E2
21. All fasteners retaining loadline centering block are in

place and tight.
! WARNING
22. All safety covers for proper installation.

If any defect determined during the inspection is a safety
hazard the machine must be removed from service and 23. Boom lift and outrigger holding valves for proper
corrected.
the defect operation.
24. Hoist brake for proper operation at hoist capacity load.
25. Control and drive mechanisms for excessive wear and/
Daily Inspections or contamination from lubricants, water or other foreign
matter.
Check the following items:
1. oil level.
Engine Weekly Inspections
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2. Hydraulic oil level. Check the following items:

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3. Radiator coolant level. 1. Battery water level.
4. parts or damage to structures or welds.
Loose 2. Tire pressure.
5. Operation of lights, safety equipment and gauges. 3. Lubrication of points required by Lubrication Chart.

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6. Condition of tires and suspension. 4. Boom lift and outrigger holding valves for proper

7. Condition of loadline and end attachment for corrosion, operation.
severe kinking, crushing, cutting, or slippage of cable 5. Torque mounting bolts during first month of operation of
or wedge socket.
clamps machine and then during periodic inspections thereafter
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8. Loose parts or damage to loadline centering blocks. (see page 6-15 for Torque Values).
6. Hoist brake for proper operation at hoist capacity load.
9. Position of loadline with guides and on sheaves.
10. Free turning of sheaves. 7. Torque boom wear pad retaining bolts during first month
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of operation, then monthly thereafter.

11. Lubrication of points required by Lubrication Chart.
8. Check to see that crane Owner's Manual is with the unit.
12. Evidence of oil leak from hoses, gearboxes or swivel. If the manual is missing, obtain serial number of unit and
order manual immediately.
13. Hand and foot controls for malfunction or incorrect
adjustment.
er

Monthly Inspections
14. Truck parking brake operation.
Check the following items:
15. Boom proportioning to insure that all boom sections 1. All cylinders and valves for improper operation or signs
extend and retract equally.
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of leaks.

16. All securing hardware such as cotter pins, snap rings,
2. Lubrication of points required by Lubrication Chart.
hairpins, pin keepers and capscrews for proper

installations. 3. Load hook for cracks or having more than 15 percent
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normal throat opening or 10 degree twist.

17. Proper condition and operation of overload and anti-two-
block operator aid systems to include switch, weight and 4. All structural members (boom, sub-base, turret and
chain at boom tip (and jib tip if equipped), power cords, outriggers) for bends, cracks or broken members.
alarms and indicator lights on console. Cycle
audible
slowly to check for proper operation. 5. All welds for breaks or cracks.

18. Presence and proper operation of load hook safety 6. All pins for proper installation.
latch. 7. All control, safety and capacity placards for readability
19.
Hooks and latches for excessive wear, cracks or and secure attachment.
damage from heat or chemicals. 8. Torque of cable clip bolts above wedge socket at end of
loadline should be 95 lb-ft.
20. All drain holes at rear of first section boom are clear of all
obstructions. 9. All boom wear pad retaining bolts.


10. Boom extension cables for proper tension or evidence of Special Boom Inspection
abnormal wear.
If the boom has not been disassembled and inspected in the
11. Sheaves and cable drums for wear and cracks. last five years or 3,000 hours of use, the boom is to be
12. Unspool loadline and check according to rope completely torn down to allow a thorough inspection of the
maintenance procedure. extend and retract cables, sheaves, and pins.
Periodic/Annual Inspection Stability

Check the following items: Stability of unit throughout working area. Check stability
procedure in Installation Section of the Service Manual
1. All items listed under daily, weekly and monthly annually or when any changes made to crane or truck.
inspections.
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2. Loose bolts and fasteners in all areas. Torque pin HOIST CABLE INSPECTION AND
retainer bolts. MAINTENANCE
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3. All pins, bearings, shafts, and gears for wear cracks or
distortion to include all pivot, outriggers and sheave
pins, and bearings. ! WARNING
Worn or Damaged Equipment Hazard!
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4. Boom angle and boom length indicator for accuracy over
full range. Never use a worn or damaged wire rope. Death or serious
injury could result from using worn or damaged wire rope.
5. Hydraulic systems for proper operating pressure.
6. Outrigger pads for excessive wear or cracks. Wire rope should be inspected frequently/daily and
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periodically/yearly in accordance with the following
7. Cylinders for:
information excerpted from a National Consensus Standard
a. Damaged rods as referenced by Federal Government Agencies.
Recommended inspection intervals may vary from machine
b. Dented barrels
t o m a ch i ne an d m a y v ar y b as e d on e n vi r o n m en ta l
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c. Drift from oil leaking by piston conditions, frequency of lifts, and exposure to shock loads.
The inspection time intervals may also be predetermined by
d. Leaks at rod seals, welds, or holding valves state and local regulatory agencies.
8. PTO drive line system for proper alignment, lubrication NOTE: Wire rope may be purchased through Manitowoc
and tightness. Crane Care.
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9. Hydraulic hose and tubing for evidence of damage such Any deterioration observed in the wire rope should be noted
as blistering, crushing or abrasion. in the equipment inspection log and an assessment
10. Top and bottom wear pads for excessive wear. concerning wire rope replacement should be made by a
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qualified person.
11. Inspect all electrical wires and connections for worn, cut
or deteriorated insulation and bare wire. Replace or Keeping Records
repair wires as required.
A signed and dated report of the wire rope’s condition at
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12. Extend and retract cables, sheaves, pins and bearings each periodic inspection must be kept on file at all times. The
for wear or abrasion. report must cover all inspection points listed in this section.
13. Main frame and stabilizer mount bolts for proper torque The information in the records can then be used to establish
(see Torque Chart). data which can be used to determine when a wire rope
should be replaced.
14. Rotation bearing and gearbox mounting bolts for proper
torque (see Torque Chart). It is recommended that the wire rope inspection program
include reports on the examination of wire rope removed
15. Missing or unreadable warning labels. from service. This information can be used to establish a
16. Missing or unusable/unsafe condition of steps, ladders, relationship between visual inspection and the rope’s actual
handrails, guards or seat. internal condition at the time of removal from service.
6
Environmental Conditions period of a month or more must be given a thorough

inspection before it is placed in service. These inspections
The life expectancy of wire rope may vary due to the degree should cover all types of deterioration including:
of environmental hostility and other conditions to which these
• Distortion such as kinking, crushing, un-stranding, bird
mechanical devices are subjected. Variation in temperature,
continuous excessive moisture levels, exposure to corrosive caging, main strand displacement or core protrusion.
chemicals or vapors or subjecting the wire rope to abrasive
• Loss of cable diameter in a short cable length or
material may shorten normal wire rope life. Frequent/ unevenness of outer strands indicates the cable needs
periodic inspections and maintenance of wire rope is to be replaced.
recommended for preventing premature wear and to insure
long-term satisfactory performance. • Significant corrosion.
NOTE: Refer to Wire Rope Lubrication, page 5-7 for wire • Broken or cut strands.
rope lubrication requirements.
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• Number, distribution and type of visible broken wires.
Dynamic
Shock Loads • Core failure in rotation resistant ropes.
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Subjecting wire rope to abnormal loads beyond the • Prior electrical contact with a power line or other electric
limit will shorten the wire rope life expectancy.
endurance arc damage.
Examples of this type of loading are listed below. • Significantly corroded, cracked, bent, or worn end

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• High velocity movement, for example; hoisting or connections.
swinging of a load followed by abrupt stops. Only inspect the outer surface of a cable. Never attempt to

• Suspending loads while traveling over irregular surfaces open the cable.
such as railroad tracks, potholes, and rough terrain. Pay particular attention to areas of the rope where wear and
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• Lifting a load that is beyond the rated capacity of the other damage is likely to occur:
lifting mechanism, such as overloading. • Pick-up Points: Sections of wire rope that are repeatedly
stressed during each lift, such as those sections in
Precautions
and Recommendations During contact with sheaves.
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Inspection
• End Attachments: The point where a fitting is attached to
use safety glasses for eye protection.
• Always the wire rope or the point where the wire rope is attached
• Wear protective clothing, gloves, and safety shoes as to the hoist drum.
appropriate. • Abuse Points: The point where the wire rope is
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subjected to abnormal scuffing and scraping.

• Measure the rope’s diameter across crowns of the
strands when determining if rope has become damaged, Daily Inspections
refer to Figure 6-1.
All cable in continuous service must be inspected at the
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beginning of each work day. Inspect the eye end and length
of cable that is used in daily operation. The end should be
inspected for abrasion, corrosion, broken wires, and loose or
broken servings. Inspect the remainder of the cable length
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used for daily operations for points showing kinks, sharp

bends, or any other evidences of damage or excessive wear.
Monthly Inspections

Inspect the eye end and length of cable normally used in
1 daily operations. Examine the rest of the cable for kinked,

crushed or otherwise damaged points.
Periodic Inspections
A925
FIGURE 6-1 Wire rope should be inspected periodically/annually, or at a

shorter time interval, if necessitated by environmental or
Inspection other adverse conditions, and shall cover the entire length of
All hoist cable in service needs to be inspected on a daily,
the wire rope. Periodic inspection should include all previous
items listed under Inspection, plus the following:
monthly, and quarterly basis. Cable which has been idle for a


• Inspect for severely corroded or broken wires at end

connections.
• Inspect wire rope in areas subjected to rapid
deterioration such as:
- Sections in contact with saddles, equalizer sheaves,
or other sheaves where wire rope travel is limited.
- Sections of wire rope at or near terminal ends where • Kinking, crushing, bird caging, or any other damage
corroded or broken wires may protrude. resulting in distortion of the rope structure.
• Inspect boom nose sheaves, hook block sheaves, boom • Evidence of heat damage.
extension/extension sheaves, auxiliary boom nose
• Reductions from nominal diameter of more than:
sheaves, and hoist drums for wear. Damaged sheaves
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or hoist drums can accelerate wear and cause rapid - 0.0156 in (.4 mm) for rope diameters to 0.313 in (8
deterioration of the wire rope. mm)
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Inspect the eye end of the cable for greater wear than the - 0.031 (.8 mm) for rope diameters 0.375 in (9.5 mm)
rest of the cable. If the cable is in good condition, reverse the to 0.50 in (12.7 mm)
cable on the drum so that the wear is equalized along the
total length of the cable. - 0.047 in (1.2 mm) for rope diameters 0.561 in (14.3
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mm) to 0.75 in (19.1 mm)
Wire Rope Replacement - 0.063 (1.6 mm) for rope diameters 0.875 in (22.2
It is difficult to determine the exact time for replacement of mm) to 1.125 in (28.6 mm).
wire rope (hoist cable) since many variable factors are • One outer wire broken at its point of contact with the core
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involved. Proper determination of the condition of a rope of the rope which has worked its way out of, and
depends upon the judgment of an experienced person. The protrudes or loops out from the rope structure.
following reasons are sufficient for consideration of rope
replacement: Care of Wire Rope
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• Six randomly distributed broken wires in one rope lay or Handle wire rope with care to prevent damage to the
three broken wires in one strand in one lay. The rope is individual wires which affect the overall strength and
unsafe for further use if there are either three broken performance of the rope. Do not allow the formation of kinks,
wires in one strand (Breaks 2, 3, 4) or a total of six because this displaces the strands of wire from their original
broken wires in all strands in any one lay. position and relation to each other causing severe bending
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and unequal tensions in the strands. This distortion and wire

displacement cannot be corrected even under high tension
and a permanent weak point remains in the rope. Displaced
or raised wires indicate a previous kink, but does not show
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the damaged condition of the inner rope wires.

Never pull wire rope over a non-rotating support such as a
1 2 5 6
spindle bar, a pin, or an inoperative sheave. This practice
3 4
causes severe abrasion to the outer strand wires. A properly
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• In rotation resistant ropes: two randomly distributed operating sheave or snatch block is essential to safety and
broken wires in six rope diameters or four randomly long service life of the rope.
distributed broken wires in 30 rope diameters
Do not use worn sheaves or sheaves with flat grooves
• Wear of one-third the original diameter of outside because they do not provide sufficient support to prevent the
individual wires. Worn rope, usually indicated by flat distortion and flattening of the rope. Sheaves with nicked or
spots on the outer wires is unsafe for further use when broken flanges can cut or otherwise damage the rope.
less than two-thirds the thickness of the outer wire
remains. An even distribution of rope coils over the hoist drum is
essential to smooth operation. This prevents the rope from
• Necking down of the rope indicates core failure. cutting down through or crushing other coils on the drum
resulting in damage to and difficulty in unwinding the rope.
.
6
Rope Construction 7. Load block lowered to ground or otherwise secured

against dropping.
Standard 8. Relieve hydraulic oil pressure from all hydraulic circuits
before loosening or removing hydraulic components.
9/16 in. (14.3mm) Dia. Wire Rope:
Rotation Resistant After adjustments and repairs have been made, the crane
shall not be returned to service until all guards have been
18X25 Nominal Breaking Strength:
reinstalled, trapped air removed from hydraulic system if
19.25 Tons (17,463 kg) required, safety devices reactivated, and maintenance
Optional equipment and all warning tags removed.

9/16 in. (14.3mm) Dia. Wire Rope: Any hazardous conditions disclosed by the inspection
requirements listed above shall be corrected before
6X25 General Purpose
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operation of the crane is resumed. Adjustments and repairs
6X25 Nominal Breaking Strength: shall be done only by designated personnel who are properly
trained. Use only parts supplied by your National Crane
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16.8 tons (15,241 kg)
Distributor or Manitowoc Crane Care to repair the crane.
replacement is required for crane extension
If wire rope
system, replacement ropes must be obtained through the JIB JACK SERVICE AND MAINTENANCE
Manitowoc Crane Care. Extension ropes are pre-stretched
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and have special connections for proper operation Important: Use only a good grade hydraulic jack oil,
transmission oil, or turbine oil. Avoid mixing types of oil. Do
replacement is required for crane loadline, care
If wire rope not use brake fluid, alcohol, glycerin, detergent motor oil, or
should be taken in selecting a wire rope suitable for crane dirty oil. Improper fluid can cause serious internal damage to
use. Wire rope strength requirements are shown on the
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the jack rendering it inoperative.
crane load chart to match the hoist option selected when the
crane was purchased. Rope construction required is optional Adding Oil
with 6 x 25 and Dyform being the most common lifting ropes.
High strength, rotation resistant is preferred and furnished 1. With saddle fully lowered and piston depressed, set jack
in upright level position and remove oil filler plug.
standard by National Crane. This rope eliminates single part
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line load spin. It also eliminates load block spin up when 2. Fill until oil is level with filler plug hole.
multi-part reeving is used which results in prolonged rope
life. Changing Oil

CRANE ADJUSTMENTS AND REPAIRS 1. For best performance and longest life, replace the
er
complete oil supply at least once a year.

Before adjustments and repairs are started on a crane, the
following precautions shall be taken as applicable: 2. To drain the oil, remove the filler plug.

1. A warning tag should be placed in a conspicuous place 3. Lay the jack on its side and drain the oil into a suitable
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at the drain pan. The oil will run slowly because air must enter
controls stating that the machine requires as oil drains out.
adjustment or repair before it can be operated.
2. The crane should be placed where it will cause the least 4. Keep dirt and foreign matter out of the system.
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interference with other equipment or operations in the 5. Replace with proper oil as described above.
area.
3. All controls at the off position and all operating features
Lubrication

secured from inadvertent motion by brakes or other Add proper lubrication oil to all pivoting sections every three
means. months.
4.
All methods used to start the truck's engine rendered
inoperative.
Rust Prevention
5.

Power plant stopped or disconnected at take-off. Check ram every three months for any sign of rust or
corrosion. Clean as needed and wipe with an oil saturated
6. Boom lowered to the ground or otherwise secured cloth.
against dropping.
NOTE: When not in use, always leave the saddle and ram
all the way down.

OIL COOLER SERVICE AND MAINTENANCE • error codes

(OPTIONAL) • current angle reading.
The heat exchanger must be kept clean to allow for efficient On power-up, the unit first displays startup codes. The
operation of the cooler system. Frequent washing of the startup code can consist of up to four digits, but will usually
heat exchanger core will eliminate oil film, road dirt and other be only the single digit "2". Each number will be displayed for
foreign object buildup on the heat exchanger fins which only 0.5 sec. The codes are:
reduces cooling efficiency.
1. The eprom is being initialized. This should only happen
Frequent inspection and tightening of hose clamp line t h e f i r s t t i m e t h e u n i t i s p o w e r e d o n a ft e r i t i s
connections will eliminate the possibility of end connection programmed.
failure due to back pressure from cold startup.
2. The unit is checking for the combination of numbers that
If cooler system fails to provide adequate performance, erase the previously stored table number in the
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reduced air or oil flow through the heat exchanger is the EEPROM. This will be displayed when the unit is
probable cause. The cooling fan should be inspected for powered on and the switches are not set with this
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proper operation (see Specifications). Any obstructions to air combination of numbers.
flow should be corrected (cooler too close to other truck
components, foreign matter in heat exchanger fins, etc.) All 3. This is displayed only before a new table number is
hy d r a u l i c l i n es s ho u l d b e p er i od i c a ll y c he c k ed f or stored in EEPROM. The 2 will be displayed first.
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obstructions, hose kinks or other flow restrictions. 4. The switches are set up with the combination of
numbers to erase the table number. On the next power
JIB LOAD LIMITING DEVICE on, the table number will be read in and stored to
EEPROM.
This system is designed to provide load limiting capability for
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jibs. This is accomplished with the use of an angle sensor, a After the startup codes, the table number will be displayed in
load cell force sensor, a microprocessor, and enough the form of 3 digits. The first digit will always be a zero. The
memory to store 30 table sets containing the maximum force digits will each be displayed for about 1 second.
for a given jib head angle and given crane configuration. The After the table number is displayed, the display will begin to
system will compare the measured force to the table and will sequence through the following information. After reaching
en
provide lockout when the table value is exceeded. The the end of the sequence, the display will start again at the
system should be checked for proper operation during initial current load reading.
crane start up and quarterly thereafter.
• Current load reading (lb): 4 digits, decimal point ON
Single Character Display • Current limit value (lb): 4 digits, decimal point flashing
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The electronics box of the jib load limiting device is equipped

• Error codes (only if an error exists):
with a single character display that provides the following
information: - 4 digits, first and last digits are blanks.
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• startup codes - 0-invalid table number,

• table number selected - 1-load readings higher than the limit.
• current load reading • Current angle reading: 4 digits, decimal point OFF,
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displays in tenths of degrees.

• current limit value
6
HYDRAULIC SYSTEM TROUBLE possible cause and possible solution. These are not all

DIAGNOSIS inclusive but are designed to help isolate the problem and
should be checked before calling the factory Service
The following
chart lists malfunctions which may occur Department
during equipment operation, followed immediately by

Condition Possible Cause Possible Solution
Pull up emergency stop switch.
Emergency stop switch on crane control
Truck engine will not start Check all other normal motor vehicle
console depressed.
systems as outlined by normal practice.
Insure overload system is working properly
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Overload system inoperative. and Anti-Two-Block/Overload solenoid is
powered.

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Load too heavy. Check load chart.
PTO not engaged. Engage PTO.
Low hydraulic fluid supply. Check and fill as required.
No response
to control
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Suction line blocked. Drain tank and hose and remove blockage.
Broken hydraulic pressure line. Replace as required.
Defective hydraulic pump. See Pump Service Manual.

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Incorrect relief valve setting Adjust relief.
Relief valve sticking. Clean relief.
Check PTO ratio, pump size and engine
Pump not operating at proper speed.
speed for proper oil flow.
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Low hydraulic fluid supply. Check and fill as required.

Relief valve sticking. Remove and clean.
Relief setting too low. Readjust to proper setting.
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Worn pump, motor or cylinder. Replace bad part.

Plugged filter. Change filter.

Poor hydraulic system performance Valve spools not fully open. Adjust linkage so valve has full throw.
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Boom holding valves out of adjustment. Adjust or clean as required.

Reduce engine speed, slow cycle time to
Oil temperature too high.
cool oil or add oil cooler option.

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Hydraulic oil too cold or dirty. Warm oil or use less viscous oil.
Line restricted. Check lines; clean and repair as necessary.
Internal control valve crack. Replace valve.

Load too heavy. Check load chart and reduce load.


Loose turntable bearing. Torque bearing mounting bolts.
Loose swing gearbox mounting bolts. Tighten bolts.
Replace worn parts or adjust gearbox
Worn gears or bearing.
spacing.
Operator control of lever too erratic. Operate controls smoothly.
Motor counterbalance valves dirty or not Clean or replace counterbalance valves not
Swing moves erratic or sloppily set properly. set at 600 psi.
(Standard system)
Replace worn brake parts or shim brake to
proper torque.
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Brake not holding properly.
Replace worn brake parts or shim brake to
proper torque
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Brake releasing at wrong time or Bleed air from brake with bleed screw on
erratically. side of brake.
Adjust or clean brake for proper release.
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Swing speed adjustment set too low.
Adjust valve on turn motor.
Turn circuit relief valves sticking. Clean and check circuit pressure.
Turntable bearing drag. Lubricate thoroughly as rotating boom.
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Swing will not turn (Standard Check for 200 + PSI brake pilot pressure.
System) Brake not releasing properly. Clean pilot line or adjust motor
counterbalance valves.
Adjust or clean brake for proper release.
Swing speed adjustment set too low.
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Adjust valve on turn motor.

Adjust foot throttle or check for too high PTO
Excessive pump speed.
ratio.
Low oil temperature. Allow unit to warm up.
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Low hydraulic oil supply. Check and fill.
Excessive pump noise during Suction line kinked, collapsed or blocked. Clear blockage.
operation Warm oil or use oil more applicable to
Hydraulic oil too thick.
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environment.
Relief valve chattering. Dirt in relief valve or damaged relief.
Hydraulic tubing vibration. Check for loose tubing.
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Tank breather plugged. Clean breather.

Not getting oil to cylinders. Clean and replace as required.
Worn or damaged piston seals. Replace as required.
Cylinders drift Air in hydraulic oil. Cycle operate crane cylinder to remove air.
Loose holding valve. Tighten valve.
Dirt in holding or check valve. Clean valve.
6

Check load and change to applicable
Load too heavy.
multipart reeving.

Relief valve setting too low. Check and adjust if required.
Motor worn excessively. Replace motor.
Hoist will not lift or hold load
Counterbalance valve defective or
leaking.
Clean and replace as necessary.
Anti-two-block system defective. Repair anti-two-block system.

Brake worn out. Repair or replace brake.

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Gearbox grease low. Check and fill as required.
Hoist gearbox heats
Duty cycle too high. Reduce cycle time or speed of hoist.

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Boom sections need lubrication. Grease boom.
Re-shim as described in boom assembly
Wear pads not shimmed correctly.
section.
Boom chatters during extension/

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retraction or doesn't proportion Worn wear pads. Replace pads.
properly
Extension cables out of adjustment. Readjust cables and tension properly.
Disassemble and inspect and replace
Extend or retract cables broken.
cables.
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Proportioning cables not attached. Reconnect, replace and/or adjust cables.

Anti-two-block system shut down. Lower hook, and extend load.
Boom will not extend
Check anti-two-block system; repair if
Defective anti-two-block system
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defective.
Carefully check the integrity of all circuits
external to the electronics box, from the jib
Loose or incorrect wiring.
tip to the console. Compare to electrical
schematic.
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Carefully check the integrity of all circuits

external to the electronics box, from the jib
Loose or incorrect wiring.
tip to the console. Compare to electrical
schematic.
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System is in a state of constant cut-

out Check fuse at crane console. Replace if
necessary. Remove electronics box from jib,
Blown fuse.
remove electronics from housing, and check
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2A fuse on board. Replace if necessary.

ATB switch open. Ensure that ATB switch is closed.
Follow procedure in system installation
No table selected. section to select the correct table for the
application.



To set the zero point, remove all force from
the load cell. Remove the electronics from
the housing. Set the switch position 8 to ON.
Power the system. Do not turn off power
until both the zero point and the gain have
System is in a state of constant cut-
Load cell not calibrated. been set. To set the zero point, press the
out (continued)
button on the board. To set the gain, set
switch position 8 to OFF. Set the switch to
the correct code that matches the load cell
gain. This code can be found on the tag that
accompanies the load cell. Press the button.
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Check to see which table is selected using
the single character display. If the wrong
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Wrong table selected. table is selected, select the proper table
using the procedure in the system
installation section.
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Ensure that the electronics box is tightly
mounted to the jib. Zero the angle sensor
Single sensor not zeroed.
using the procedure in the system
installation section.
Configuration switch must be closed when
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System cuts out too early or too late Configuration switch stuck open or closed the jib is Retracted and open when the jib is
(two section jibs only). extended. Adjust or replace switch As
necessary.
Ensure that pivot pin is free, well lubricated,
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and allows the jib head to pivot freely.

Pivot pin not free to move.
Inspect and replace bearings in jib head
assembly as required.
Foreign object stuck between jib head Remove any foreign objects which interfere
assembly and jib. The only contacts with jib head assembly operation.
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between the jib head assembly and the

jib are to be the load cell and the pivot pin.
Jib Jack Troubleshooting
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No oil in system Add oil to reservoir tank through oil filler hole
Will not lift load
Release valve not closed Turn handle clockwise tightly
Will lift load only part way Oil level low Add oil to reservoir tank through oil filler hole
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The following valve or valves leaking

• Suction valve
Replace jack
Will lift load but will not hold • Delivery valve
• Release valve
Packings worn or damaged Replace jack
Release valve stuck, probably dirt or Transfer load then replace dirty oil, flush oil
Jack will not lower
foreign matter reservoir with kerosene
Dirty oil Change hydraulic oil
Poor lifting
Air in hydraulic system Purge air from system
Oil seal for pump unit worn in out or
Poor pumping action
damaged
Replace jack
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Tire Load And Inflation Table NOTE: The values in the tables below are as published by
the Tire and Rim Association 2005. Your vehicle
Definite tire inflation pressures are established for each tire may be equipped with other tire sized or the same
size depending upon the load imposed on the tires. For size tires rated differently. Always check the tire

greater stability, riding comfort and prolonged tire life, tires sidewalls to verify the maximum capacity and
should be inflated for the loads carried. The “Load and inflation. Inflation pressure and loading must not
inflation Table" shown below indicates the proper inflation exceed the values shown on the wheel or rim.
pressure.

Tire and Load Inflation Tables

Letters in parenthesis denote the load range for which the bold face loads are a maximum.
International load index numbers are shown after the load range. The load range letters and
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corresponding ply rating are shown below.
D = 8 ply • E = 10 ply • F = 12 ply • G = 14 ply
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H = 16 ply • J = 18 ply • L = 20 ply • M = 22 ply • N = 24 ply

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Radial Ply Metric Tires for Trucks, Busses, and Trailers Used in Normal Highway Service
Radial Ply Tires Mounted on 15° Drop Center Rims
Tire and Rim Association Standard

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Metric Wide Base Tires for Trucks, Busses, and Trailers Used in Normal Highway Service
Tires Used as Singles Mounted on 15° Drop Center Rims

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Radial Ply Tires for Trucks, Busses, and Trailers Used in Normal Highway Service
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SPECIFICATIONS
Hydraulic Pump
Displacements:
Section P1 ..................................................................... 34 GPM (128.7 LPM) at 2400 RPM
Section P2 .................................................................... 18 GPM (68.1 LPM) at 2400 RPM
Section P3 ..................................................................... 10 GPM (37.8 LPM) at 2400 RPM
Hydraulic System
Requirements:
Boom and Outrigger System ......................................... 18 GPM (68 LPM), 3900 psi +100/-000 (26.89 MPa)
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Boom Extend ................................................................ 18 GPM (68 LPM), 2800 psi +50/50 (19.31 MPa)
Boom Retract ................................................................ 18 GPM (68 LPM), 2900 psi +100/-000 (20.00 MPa)
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Hoist System ................................................................. 30 GPM (128 LPM), 3300 psi +100/-000 (22.75 MPa)
Turn ............................................................................... 10 GPM (38 LPM), 2350 psi +100/-000 (16.20 MPa)
Reservoir
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Capacity ........................................................................ 66 Gallons (250 L)
Filtration ........................................................................ 10 Micron Return
Flow rates listed are at free flow condition (approx. 100 psi/ 1 MPa)
HCA
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Load charts are based on 2650 psi (18.27 MPa) Constant Pressure (2800 psi (19.31 MPa) Trip Pressure on HCA)
Hoist System Wire Rope ............................................... Standard 325 ft (99 m) of 9/16 “(14.3 mm) diameter,
Rotation Resistant Nominal Breaking Strength ............. 38,500 lb (17,463 kg) 325 ft (99 m) of 9/16 “(14.3 mm)
diameter
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Rotation Resistant Nominal Breaking Strength ............. 38,500 lb (17,463 kg)

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Hoist Speed and Pull

Hoist Pull Hoist Speed BOS Hoist Speed Rope Capacity
Layer
lbs (kg) fpm (mpm) fpm (mpm) ft (m)
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1 10,380 (4708) 157 (48) 222 (68) 64 19

2 9,360 (4246) 175 (53) 246 (75) 136 41
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3 8,520 (3865) 192 (59) 271 (83) 215 65

4 7,820 (3547) 209 (64) 294 (90) 301 91
5 7,230 (3279) 257 (69) 318 (97) 394 120
NOTE: All ratings based on 34 GPM at 3300 psi (128.7 LPM at 22.75 MPa)
Burst of Speed maximum pull = 3000 lb (1361 kg)
6
Crane Operating Speeds

Rotation 375°......................................................................... 15 ± 5 sec (1.8 ± 0.2 rpm) Swing speed based on and
adjustment knob in closed position.
Boom up -10° to 80° .............................................................. 25 ± 5 sec
Boom Down 80° to -10° ......................................................... 20 sec ± 5 sec
Boom Extend/Retract Three Section 27 - 71 ft
Extend .......................................................................... 53 ± 6 sec, 50 fpm (15.2 mpm)

Retract .......................................................................... 50 ± 6 sec, 53 fpm (16.1 mpm)
Boom Extend/Retract Three Section 23 - 60 ft

Extend .......................................................................... 44 ± 6 sec, 49 fpm (14.9 mpm)
Retract .......................................................................... 42 ± 6 sec, 51 fpm (15.6 mpm)
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500E2 OPERATORS MANUAL
ALPHABETICAL INDEX
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Adjustable Swing Speed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Anti-Two Block System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Crane Adjustments and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Crane Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Crane Inspection And Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Determining Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
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Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Equipment Familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
HCA System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
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Hoist Cable Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Hoist System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
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Hydraulic System Trouble Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Installing Cable On The Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
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Jib Load Limiting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Jib Load Limiting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Jib Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Lubrication Procedure and Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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Maintenance Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Oil Cooler Service and Maintenance (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Operating Controls And Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operator’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
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Operator’s Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Optional Hoist Burst of Speed (BOS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Outrigger Monitoring System (OMS) (Optional—Standard in North America). . . . . . . . . 3-6
Overload Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Parking and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
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Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Reading and understanding the load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
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Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Side Folding-Swing Around Jib Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Transporting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Truck Cab Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Unattended Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Wedge Socket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
National Crane Published 10-20-2011 Control # 111-05 APL-1

OPERATORS MANUAL 500E2
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APL-2 Published 10-20-2011 Control # 111-05

National Crane 500E2 Operators Manual

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OPERATOR MANUAL

An untrained operator subjects himself and others to death or

responsible for qualifying personnel.

to adequately warm the crane prior to cold weather

Engine RPM for at least one complete revolution in one

Warm-up Procedures for All Temperature Ranges:

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

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

serious injury. Do not operate this crane unless:

• You read, understand, and follow the safety and operating

other reproductive harm. Wash hands after handling.

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

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

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

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

National Crane 1-1

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

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

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

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

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

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

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

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

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

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

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

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

National Crane 1-3

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

Information in this manual does not replace federal, state or

Constant improvement and engineering progress makes it Safety Information

National Crane and our Dealer Network want to ensure your

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

500E2 Series Major Components

Item Component Item Component

Should this crane become involved in a property damage accident,

If accident involves personal injury notify your local distributor and

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

Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . 2-10 Temperature Effects on Hydraulic Cylinders . . . 2-23

Special Operating Conditions and Equipment . . 2-11 Superstructure Inspection . . . . . . . . . . . . . . . . . . 2-28

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

NOTE: Emphasizes operation or maintenance 1565 East Buchanan Trail

GENERAL Phone: 888-777-3378 (888-PSR.DEPT)

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

Controls and design may vary from crane to crane; therefore,

National Crane Published 10-20-2011 Control # 111-05 2-3

Caution must be used when lowering the boom, extending

2-4 Published 10-20-2011 Control # 111-05

STRENGTH mid-extend position (vertical strip, if applicable), the

Use adequate cribbing under outrigger floats to distribute

National Crane Published 10-20-2011 Control # 111-05 2-5

kept below the capacity shown on the applicable Load Chart.

2-6 Published 10-20-2011 Control # 111-05

(hook block, boom extension, etc.) must be considered part

adequate cribbing may be required to obtain a larger bearing

National Crane Published 10-20-2011 Control # 111-05 2-7

Counterweight • Maintain communication between all parties throughout

2-8 Published 10-20-2011 Control # 111-05