Manitowoc Crane 8500-1 Operator Manual 242-01 – PDF DOWNLOAD

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Manitowoc Crane 8500-1 Operator Manual 242-01 – PDF DOWNLOAD

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Manitowoc Crane 8500-1 Operator Manual 242-01 – PDF DOWNLOAD

Language : English
Pages : 822
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Crane 8500-1 Operator Manual 242-01 – PDF DOWNLOAD

IMPORTANT INFORMATION
1 SAFETY
1 1 SAFETY INFORMATION 1-1
1 2 EXPLANATION OF WARNING LABELS IN THE MACHINE 1-2
1 2 1 HANDLING OF WARNING LABELS IN THE MACHINE 1-2
1 2 2 LABEL LAYOUT 1-3
1 2 3 DETAIL OF LABEL 1-10
1 3 SAFE OPERATING PRACTICES FOR MOBILE CRANES 1-19
1 4 SAFETY AT INSPECTION AND MAINTENANCE WORK 1-43
1 5 SAFETY DURING ASSEMBLY AND DISASSEMBLY WORK 1-46
1 6 CAUTIONS IN HANDLING OIL AND PAINT 1-47
1 7 SAFETY EQUIPMENT (OPTION) 1-48
2 OPERATION
2 1 TERMINOLOGY OF MACHINE EACH PART 2-1
2 2 LOCATIONS AND TERMS OF OPERATING CONTROLS 2-4
2 2 1 HANDING LEVER AND PEDAL 2-5
2 2 2 OPERATING SWITCHES 2-14
2 2 3 VARIOUS SETTING OF MONITOR 2-42
2 2 4 ANEMOMETER INSTALLATION (OPTION) 2-51
2 2 5 AIR CONDITIONER 2-52
2 2 6 AIR CONDITIONER FOR AUTO-IDLE STOP (AIS AIR CONDITIONER)
(OPTION) 2-58
2 2 7 AM/FM RADIO 2-61
2 2 8 1WAY CALL (TRANSMITTER) 2-72
2 2 9 MONITORING CAMERA (OPTION) 2-73
2 3 CRANE OPERATION 2-76
2 3 1 ADJUSTING THE OPERATOR’S SEAT 2-76
2 3 2 GETTING ON AND OFF FROM / TO OPERATOR’S CAB 2-78
2 3 3 STARTING AND STOPPING THE ENGINE 2-79
2 3 4 EMISSION CONTROL DEVICE 2-84
2 3 5 TIER4 FINAL INDUCEMENT CONTROL 2-100
2 3 6 AUTO IDLE STOP FUNCTION 2-111
2 3 7 FUNCTION LOCK LEVER 2-114
2 3 8 TRAVELING OPERATION 2-115
2 3 9 SWINGING OPERATION 2-118
2 3 10 BOOM RAISING/LOWERING OPERATION 2-123
2 3 11 HOOK HOISTING/LOWERING OPERATION 2-127
2 4 FREE FALL OPERATION 2-136
2 5 CLAMSHELL OPERATION 2-142
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2 5 1 PREPARATION WORK 2-144
2 5 2 CLAMSHELL WORK 2-148
2 6 HANDLING OF HYDRAULIC TAGLINE (OPTION) 2-149
2 7 HANDLING OF VIBRO HAMMER 2-152
2 8 OPERATION IN WEATHER CHANGE AND SPECIAL CIRCUMSTANCE 2-155
2 8 1 CAUTION AGAINST WIND 2-155
2 8 2 CAUTION AGAINST ELECTRIC SHOCK 2-167
2 8 3 CAUTION AGAINST RADIO WAVE INTERFERENCE 2-169
2 8 4 CAUTION AGAINST LIGHTNING 2-170
2 8 5 COUNTERMEASURE AGAINST EARTHQUAKE 2-170
3 LOAD SAFETY DEVICE
3 1 ARRANGEMENT OF EQUIPMENTS 3-3
3 2 TYPES AND FUNCTIONS OF EQUIPMENT 3-6
3 3 CONNECTING PROCEDURE OF WIRING 3-12
3 3 1 CRANE ATTACHMENT 3-13
3 4 FUNCTION OF MONITOR 3-20
3 5 OPERATING PROCEDURE OF MONITOR 3-21
3 5 1 SETTING OF CRANE CONFIGURATION 3-26
3 5 2 SELECTION OF MAIN/AUXILIARY HOOK SELECTION 3-35
3 5 3 SETTING OF WORK AREA LIMIT VALUE 3-36
3 6 SWING LIMITATION DEVICE (OPTION) 3-41
3 7 LOAD HISTORY (DATA LOGGER) 3-53
3 8 FUNCTION OF GROUND INCLINE INDICATOR (OPTION) 3-54
3 9 WARNING AND AUTO-STOP 3-56
3 9 1 CONTENT OF WARNING AND AUTO-STOP 3-56
3 9 2 CONTENT OF AUTO-STOP 3-57
3 9 3 RELEASING AUTO-STOP 3-58
3 10 INSPECTION 3-64
3 10 1 INSPECTION PROCEDURE WHEN ERECTING THE BOOM AFTER THE
ATTACHMENT ASSEMBLY WORK IS COMPLETED 3-64
3 10 2 INSPECTION AFTER ERECTING ATTACHMENT 3-66
3 11 CAUTIONS IN HANDLING LOAD SAFETY DEVICE 3-68
3 12 ERROR CODE DISPLAY AND MESSAGE 3-69
3 13 WARNING CODE LIST AND CONDITION, ACTION 3-82
3 14 CHECKING PROCEDURE OF LOAD SAFETY DEVICE 3-88
4 ASSEMBLY/DISASSEMBLY OF MAIN MACHINERY
4 1 SWING AND TRAVEL STABILITY 4-1
4 2 HANDLING THE REMOTE CONTROL SWITCH BOX 4-4
4 3 ASSEMBLING OF BASE MACHINE 4-8
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4 3 1 CAB STEP EXTENSION 4-10
4 3 2 UNLOADING BASE MACHINE FROM TRAILER 4-12
4 3 3 EXTENDING THE CRAWLER 4-13
4 3 4 INSTALLING OF LADDER FOR MACHINERY GUARD 4-20
4 3 5 RAISING GANTRY 4-21
4 3 6 INSTALLING THE BOOM TIP 4-26
4 3 7 INSTALLATION OF THE BASE GUY LINE 4-28
4 3 8 FRONT DRUM WIRE ROPE REEVING 4-30
4 3 9 CARBODY WEIGHT INSTALLATION (USING SELF REMOVAL DEVICE) 4-35
4 3 10 ASSEMBLING THE COUNTERWEIGHTS (USING SELF REMOVAL
DEVICE) 4-50
4 3 11 MOUNTING THE ASSEMBLED COUNTERWEIGHT TO BASE MACHINE
(USING SELF REMOVAL DEVICE) 4-58
4 4 DISASSEMBLY OF BASE MACHINE 4-67
4 4 1 REMOVE THE COUNTERWEIGHTS FROM THE MACHINE (USING
SELF REMOVAL DEVICE) 4-69
4 4 2 DISASSEMBLY OF THE COUNTERWEIGHT 4-78
4 4 3 CARBODY WEIGHT REMOVAL (USING SELF REMOVAL DEVICE) 4-83
4 4 4 WINDING UP THE FRONT DRUM WIRE ROPE 4-97
4 4 5 REMOVING THE BOOM GUY LINE 4-99
4 4 6 DISASSEMBLING THE BOOM TIP 4-101
4 4 7 LOWERING THE GANTRY 4-103
4 4 8 REMOVAL OF LADDER FOR MACHINERY GUARD 4-108
4 4 9 RETRACTING THE CRAWLERS 4-109
4 4 10 BASE MACHINERY LOADING ONTO TRAILER 4-115
4 4 11 STORE AND REMOVAL OF CAB STEP 4-118
4 5 TRANSPORTATION 4-120
4 6 INSTALLATION/REMOVAL OF BOOM BASE 4-121
4 6 1 BOOM BASE INSTALLATION 4-121
4 6 2 BACKSTOP INSTALLATION 4-123
4 6 3 UPPER SPREADER INSTALLATION 4-124
4 6 4 REEVING BOOM HOIST WIRE ROPE 4-125
4 6 5 INSTALLATION OF BOOM HOIST WIRE ROPE TO THE DRUM 4-127
4 6 6 WINDING UP OF BOOM HOIST WIRE ROPE TO THE DRUM 4-128
4 6 7 UPPER SPREADER REMOVAL 4-130
4 6 8 BACKSTOP REMOVAL 4-131
4 6 9 REMOVAL OF BOOM BASE 4-132
4 7 CARBODY WEIGHT INSTALLATION (WHEN USING ASSIST CRANE) 4-134
4 7 1 CARBODY WEIGHT INSTALLATION 4-134
4 7 2 CARBODY WEIGHT REMOVAL 4-138
4 8 SELF REMOVAL CYLINDER (OPTION) INSTALLATION/REMOVAL 4-141
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4 9 SELF REMOVAL CYLINDER (OPTION) TAKEOUT/STORAGE 4-145
4 9 1 TAKEOUT OF CYLINDER 4-145
4 9 2 STORAGE OF CYLINDER 4-149
4 10 CRAWLER INSTALLATION/REMOVAL (USING SELF REMOVAL CYLINDER
[OPTION]) 4-152
4 10 1 INSTALLATION OF CRAWLER 4-152
4 10 2 REMOVAL OF CRAWLER 4-169
4 11 CARBODY WEIGHT INSTALLATION/REMOVAL (USING SELF REMOVAL
CYLINDER [OPTION]) 4-182
4 11 1 CARBODY WEIGHT INSTALLATION 4-182
4 11 2 CARBODY WEIGHT REMOVAL 4-192
5 ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT
5 1 ASSEMBLING THE ATTACHMENT 5-5
5 1 1 ARRANGEMENT OF BOOM/JIB/GUY LINE 5-6
5 1 2 BOOM AND GUY LINE ARRANGEMENT 5-8
5 1 3 HANDLING OF SPREADER GUIDE 5-15
5 1 4 INSTALLING THE BOOM 5-18
5 1 5 CAUTION FOR CANTILEVER 5-28
5 1 6 FRONT DRUM WIRE ROPE REEVING 5-29
5 1 7 INSTALLING THE AUXILIARY SHEAVE 5-34
5 1 8 REAR DRUM WIRE ROPE REEVING TO AUXILIARY SHEAVE 5-35
5 1 9 ASSEMBLING THE FIXED JIB 5-38
5 1 10 REAR DRUM WIRE ROPE REEVING TO THE FIXED JIB 5-41
5 1 11 FUNCTION CHECK OF EACH LIMIT SWITCH 5-44
5 2 ERECTING THE ATTACHMENT 5-45
5 2 1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT 5-45
5 2 2 ERECTING THE ATTACHMENT 5-46
5 2 3 CONFIRMATION BEFORE LOWERING THE ATTACHMENT 5-49
5 2 4 LOWERING THE ATTACHMENT 5-50
5 3 DISASSEMBLING THE ATTACHMENT 5-51
5 3 1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING 5-52
5 3 2 WINDING UP THE FRONT/REAR DRUM WIRE ROPES 5-54
5 3 3 DISASSEMBLING THE JIB 5-56
5 3 4 REMOVING THE AUXILIARY SHEAVE 5-59
5 3 5 DISASSEMBLING THE BOOM 5-60
5 4 CAUTION WHEN TRANSPORTING BOOM 5-65
6 WIRE ROPE
6 1 HANDLING OF WIRE ROPE 6-1
6 1 1 SPECIFICATION OF WIRE ROPE 6-2
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6 1 2 WIRE ROPE LENGTH 6-5
6 1 3 CAUTIONS IN HANDLING WIRE ROPE 6-7
6 1 4 WINDING WIRE ROPE TO THE DRUM 6-8
6 1 5 CORRECTING METHOD OF ENTANGLED WIRE ROPE 6-12
6 1 6 ROPE SOCKET INSTALLATION 6-14
6 1 7 REPLACEMENT STANDARDS FOR WIRE ROPE 6-15
7 MAINTENANCE
7 1 INSPECTION INTERVAL 7-9
7 1 1 TABLE OF INSPECTION POINTS 7-9
7 1 2 TABLE OF OIL, GREASE AND WATER SUPPLY POINTS 7-11
7 2 INSPECTION 7-13
7 2 1 INSPECTION OF UPPER MACHINERY 7-13
7 2 2 INSPECTION OF LOWER MACHINERY 7-20
7 2 3 INSPECTION OF ATTACHMENT 7-22
7 2 4 INSPECTION METHOD OF EACH POINT 7-24
7 3 INSPECTION AND OIL/GREASE AND WATER SUPPLY 7-54
7 3 1 INSPECTION, OIL/GREASE AND WATER SUPPLY POINTS OF UPPER
MACHINERY 7-56
7 3 2 LOWER LUBRICATION 7-60
7 3 3 ATTACHMENT LUBRICATION 7-62
7 3 4 INSPECTION, GREASING (WATER SUPPLY) ON EACH POINT 7-64
7 4 REPLACEMENT AND CLEANING/WASHING FILTER ELEMENT AND
STRAINER 7-86
7 4 1 REPLACEMENT, CLEANING, WASHING POINTS OF FILTER ELEMENT
AND STRAINER 7-86
7 4 2 REPLACEMENT, CLEANING, WASHING METHODS OF FILTER
ELEMENT AND STRAINER 7-88
7 5 BATTERY INSPECTION 7-108
7 6 LOCATION AND USE OF FUSE 7-114
7 7 OPERATION UNDER SEVERE CONDITIONS 7-116
7 8 HANDLING OF DIESEL PARTICULATE FILTER 7-121
7 9 MACHINE STORAGE 7-124
7 10 TIGHTENING TORQUE VALUES 7-125
7 11 PERIODICAL REPLACING SECURITY PARTS 7-130
7 12 ADJUSTMENT 7-132
7 12 1 ADJUSTMENT OF FRONT, REAR, THIRD (OPTION) DRUM LOCKS 7-132
7 12 2 ADJUSTMENT OF BOOM DRUM LOCK 7-133
7 12 3 CRAWLER SHOES ADJUSTMENT 7-134
7 13 CONSUMABLE PARTS LIST 7-135
7 14 MEASURES REQUIRED FOR FRONT, REAR WINCH MONITORING 7-143
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7 14 1 THEORETICAL SERVICE LIFE 7-143
7 14 2 USED PROPORTION OF THEORETICAL SERVICE LIFE 7-144
7 14 3 DETERMINING OF THE RESIDUAL THEORETICAL SERVICE LIFE 7-148
8 REFERENCE MATERIALS
8 1 SPECIFICATION 8-1
8 1 1 CRANE OUTSIDE DIMENSION 8-2
8 1 2 CRANE SPECIFICATION, PERFORMANCE 8-3
8 1 3 CRANE WORKING RANGES 8-5
8 2 DIMENSION, WEIGHT OF EACH COMPONENT 8-8
8 2 1 BASE MACHINE 8-8
8 2 2 COUNTERWEIGHT 8-10
8 2 3 ATTACHMENT 8-11
8 3 CLAMSHELL RATED LOADS (OPTION) 8-13
8 4 SWING AND TRAVEL STABILITY 8-16
8 5 TRAVEL ALLOWABLE SLOPE ANGLE 8-19
8 5 1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION 8-19
8 6 LOW GANTRY POSITION 8-25
8 7 SAFETY DEVICE LIST (OPTION) 8-26
9 DIAGRAM
9 1 HYDRAULIC DIAGRAM 9-1
9 2 ELECTRIC SCHEMATIC 9-5

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