Manitowoc National Crane 600E-2 Operator Manual – PDF DOWNLOAD

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Manitowoc National Crane 600E-2 Operator Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc National Crane 600E-2 Operator Manual – PDF DOWNLOAD

Language : English
Pages : 100
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc National Crane 600E-2 Operator Manual – PDF DOWNLOAD

SECTION 1 13
Introduction 13
General 13
Supplemental Information 13
Safety Information 13
New Owner 13
SECTION 2 15
Safety Precautions 15
Safety Messages 15
General 15
Safety Alert Symbol 15
Signal Words 15
General 15
Accidents 15
Operator’s Information 16
Operator’s Qualifications 16
Operational Aids 17
Load Moment Indication (LMI) Systems (If Equipped) 17
Anti-Two-Blocking Device 17
Work Area Definition System (WADS) (If Equipped) 18
Crane Stability/Structural Strength 18
Load Charts 19
Work Site 19
Wind Forces 19
Lifting Operations 20
Counterweight 21
Outrigger Lift Off 21
Multiple Crane Lifts 21
Electrocution Hazard 22
Set-Up and Operation 23
Electrocution Hazard Devices 23
Electrical Contact 24
Special Operating Conditions and Equipment 24
Personnel Handling 24
Environmental Protection 25
Maintenance 25
Service and Repairs 26
Lubrication 26
Tires 27
Wire Rope 27
Sheaves 28
Batteries 29
Engine 29
Transporting the Crane 29
Travel Operation 29
Work Practices 31
Personal Considerations 31
Crane Access 31
Job Preparation 31
Working 31
Lifting 32
Hand Signals 33
Boom Extension 35
Parking and Securing 35
Shut-Down 35
Cold Weather Operation 35
Temperature Effects on Hook Blocks 36
Temperature Effects on Hydraulic Cylinders 36
Overload Inspection 37
Boom Inspection 39
Superstructure Inspection 41
Carrier Inspection 43
SECTION 3 45
Operating Controls And Procedures 45
Truck Cab Controls 45
Power Take-Off 45
Manual Shift Control 45
Air Shift Control 45
Electric Shift Control 45
Power Shift Control 45
Park Brake 45
Cold Weather Operation 45
Derated capacities for each °C below -40°C 45
Derated capacities for each °F below -40°F 45
Crane Controls 45
Turn 45
Swing Speed Adjustment 45
Boom 45
Boom Telescope 45
Hoist 46
Stabilizers Up/Down 46
Stabilizers Extend/Retract 46
Outriggers 46
Foot Throttle 46
Emergency Stop Switch 46
Horn 46
Hydraulic Capacity Alert System (HCA) Load Range Gauge 46
HCA Overload Light 46
Anti-Two-Block/Extension Overload Light 46
Key Override Switch 46
Override Button 46
Load Chart 46
Boom Angle Indicator 46
Boom Length Indicator 47
Outrigger Status Indicator (Optional—Standard in North America) 47
Hoist System Operation 49
Using Multiple Part Lines 49
General Rules When Operating Hoist 49
Lifting the Load 49
Optional Hoist Burst of Speed (BOS) 50
Anti-Two Block (A2B) System 50
Outrigger Monitoring System (OMS) (Optional—Standard in North America) 50
Hydraulic Capacity Alert System 51
System Description 51
Indicator Lights 51
HCA Load Range Gauge 51
HCA System Operation 52
Pressure Sensing Switch 52
Extension Load Limiting Device 52
System Description 52
System Operation 52
Three Section Boom Operation 53
Anti-two-block (A2B) Weight Installation 54
Installing Cable On The Hoist 54
Wedge Socket Installation 56
SECTION 4 59
Set-Up 59
Equipment Familiarization 59
Equipment Checks 59
Pre-Operation Inspection and Calibration Verification 59
Work Site Selection 60
Before Leaving the Cab 60
Proper Leveling of the Crane 60
Bubble Level Adjustment 60
Site Selection 61
Setting the Outriggers and Stabilizers 61
Lifting Over the Rear 61
Lifting Over the Front with a Front Stabilizer 61
Before Making the Lift 62
Reading and Understanding the load Charts 62
Set-Up 63
Operation 63
Definitions 64
Load Radius 64
Loaded Boom Angle 64
Working Area 64
Freely Suspended Load 64
Side Load 64
Boom Length 64
Range Diagram 64
Determining Load Capability 64
Load Determination Examples 65
Example 1 65
Example 2 65
Example 3 66
Boom Extension Operation Safety 67
Manually Extendable Boom Extension: 67
Side Folding-Swing Around Boom Extension Operation 69
Deployment Procedure 69
Stowing Procedure 70
Boom Extension Maintenance 71
Boom Extension Removal 71
Extension Jack Procedures 71
Adjustable Swing Speed Valve 72
SECTION 5 73
Lubrication Procedure and Charts 73
General 73
Environmental Protection 73
Lubricants 73
Arctic Conditions Below -18°C (0°F) 73
Chassis Grease 73
Extreme Pressure Multipurpose Gear Lubricant (EPGL) 73
Open Gear Lubricant 73
Chassis Grease Low Temp 74
Anti-wear Additives 74
Hydraulic Oil 74
Standard Hydraulic Oil 74
Above 10°F (-12°C) 74
Intermediate Hydraulic Oil 74
(-10°F to 80°F) (-23°C to 27°C) 74
Wide Range Intermediate Hydraulic Oil 74
(-30°F to 80°F) (-34°C to 27°C) 74
Arctic Hydraulic Oil 74
(-10°F and below) (-23°C and below) 74
Lubrication Points 74
Surface Protection for Cylinder Rods 74
Internal Cable Sheave Lubrication 77
The lubrication points on the sheaves are not equipped with grease fittings (zerks) and will require a grease gun adapter to accomplish the task 77
Special Tools: 77
Inner Boom Pad Lubrication 77
Side and Bottom Boom Wear Pad Lubrication 77
Hoist Gearbox Oil 78
Hoist Brake Oil 78
Hydraulic Oil Reservoir Level 79
Wire Rope Lubrication 79
SECTION 6 81
Maintenance Checklist 81
Crane Inspection And Maintenance 81
Inspection 81
Daily Inspections 81
Weekly Inspections 82
Monthly Inspections 82
Periodic Annual Inspection 82
Special Boom Inspection 82
Stability 82
Hoist Cable Inspection and Maintenance 83
Keeping Records 83
Environmental Conditions 83
Dynamic Shock Loads 83
Precautions and Recommendations During Inspection 83
Inspection 83
Daily Inspections 84
Monthly Inspections 84
Periodic Inspections 84
Wire Rope Replacement 84
Care of Wire Rope 85
Rope Construction 85
Crane Adjustments and Repairs 85
Extension Jack Service and Maintenance 86
Adding Oil 86
Changing Oil 86
Lubrication 86
Rust Prevention 86
Oil Cooler Service & Maintenance (Optional) 86
Extension Load Limiting Device 86
Single Character Display 86
Hydraulic System Trouble Diagnosis 87
Extension Jack Troubleshooting 90
Tire Load And Inflation Table 91
Specifications 94
Hydraulic Pump 94
Hydraulic System 94
Reservoir 94
HCA 94
Hoist Speed and Pull 94
Crane Operating Speeds 95
CTRL571-00_Warm-up_Procedures–Supplement pdf 0
Crane Warm-up Procedures 3
Engine 3
Transmission 3
Hoist 3
Swing Drive and Turntable Bearing 3
Axles 4
Hydraulic Oil System 4
CTRL641-00_Boom Cable Tensioning-Supplement pdf 0
General 0
Cable Tensioning 0
Tensioning Setup Procedure 0
1 Mark the front of each section with a chalk line as indicated in Figure 1 0
2 Extend and retract boom several times to establish working state of cables 0
3 Extend boom so scribed lines are exposed by approximately 12 inches 0
4 Measure the extension gaps between each boom section and scribed line and note values 0
5 Retract boom so that the scribed lines are exposed by approximately 6 inches 0
6 Measure the retraction gaps between each boom section and scribed line and note values 0
7 Extend and retract the boom a few times and then repeat measuring the extension gaps 0
8 Adjust all corresponding cables according to Cable Tightening Sequence instructions 0
Figure 1 0
Cable Tension Sequence 0
Five section boom with two stage cylinder 0
1 321 retract cables 0
2 123 extend (synchronizing) cables 0
3 234 extend cables 0
4 432 retract cables 0
5 345 extend cables 0
6 543 retract cables 0
Four section boom with two stage cylinder 0
1 321 retract cables 0
2 123 extend (synchronizing) cables 0
3 234 extend cables 0
4 432 retract cables 0
Four section boom with one stage cylinder 0
1 123 extend cables 0
2 321 retract cables 0
3 234 extend cables 0
4 432 retract cables 0
Three section boom with one stage cylinder 0
1 123 extend cables 0
2 321 retract cables 0
5 – Section Boom w/ 2 Stage Cylinder Cable Positioning 0
Figure 2 0
Cable Tightening Sequence 5 Section Boom with Two Stage Extend Cylinder 0
321 and 123 cable balancing 0
Extension 0
1 Measure the extension gaps between the first and second section and the second and third section 0
2 Tighten 321 retract cable located at the front bottom of the base section the difference in the extension gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the extension gaps 0
4 Tightening until the extension gap between the first and second section and the extension gap between the second and the third are equal 0
Retraction 0
1 Measure the retraction gaps between the first and second section and the second and third section 0
2 Tighten the 123 synchronizing cable located at the back of the base section the difference in the retraction gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the retraction gaps 0
4 Tightening until the retraction gap between the first and second section and the retraction gap between the second and the third are equal 0
234 and 432 cable balancing 0
Extension 0
1 Measure the extension gaps between the third and fourth section and the second and third section 0
2 Tighten the 234 extend cable located at the back top of the second section the difference in the extension gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the extension gaps 0
4 Tightening until the extension gap between the third and fourth section is equal to the extension gap between the second and third section 0
Retraction 0
1 Measure the retraction gaps between the second and third section and the third and fourth section 0
2 Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the retraction gaps 0
4 Tightening until the retraction gap between the third and fourth section is equal to the retraction gap between the second and third section 0
345 and 543 cable balancing 0
Extension 0
1 Measure the extension gaps between the fourth and fifth section and the third and fourth section 0
2 Tighten the 345 extend cable located at the back top of the third section the difference in the extension gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the extension gaps 0
4 Tightening until the extension gap between the fifth and fourth section is equal to the extension gap between the fourth and third section 0
Retraction 0
1 Measure the retraction gaps between the fourth and fifth section and the third and fourth section 0
2 Tighten the 543 retract cable located at the front bottom of the third section the difference in the retraction gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the retraction gaps 0
4 Tightening until the retraction gap between the fifth and fourth section is equal to the retraction gap between the fourth and third section 0
4- Section Boom w/ 2 Stage Cylinder Cable Positioning 0
Figure 3 0
Cable Tightening Sequence 4 Section Boom with Two Stage Extend Cylinder 0
321 and 123 cable balancing 0
Extension 0
1 Measure the extension gaps between the first and second section and the second and third section 0
2 Tighten 321 retract cable located at the front bottom of the base section the difference in the extension gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the extension gaps 0
4 Tightening until the extension gap between the first and second section and the extension gap between the second and the third are equal 0
Retraction 0
1 Measure the retraction gaps between the first and second section and the second and third section 0
2 Tighten the 123 synchronizing cable located at the back of the base section the difference in the retraction gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the retraction gaps 0
4 Tightening until the retraction gap between the first and second section and the retraction gap between the second and the third are equal 0
234 and 432 cable balancing 0
Extension 0
1 Measure the extension gaps between the third and fourth section and the second and third section 0
2 Tighten the 234 extend cable located at the back top of the second section the difference in the extension gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the extension gaps 0
4 Tightening until the extension gap between the third and fourth section is equal to the extension gap between the second and third section 0
Retraction 0
1 Measure the retraction gaps between the second and third section and the third and fourth section 0
2 Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the retraction gaps 0
4 Tightening until the retraction gap between the third and fourth section is equal to the retraction gap between the second and third section 0
4- Section Boom w/ 1 Stage Cylinder Cable Positioning 0
Figure 4 0
Cable Tightening Sequence 4 Section Boom with (1) Stage Extend Cylinder 0
321 and 123 cable balancing 0
Extension 0
1 Measure the extension gaps between the first and second section and the second and third section 0
2 Tighten 123 extend cable located at the back top of the base section the difference in the extension gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the extension gaps 0
4 Tightening until the extension gap between the first and second section and the extension gap between the second and the third are equal 0
Retraction 0
1 Measure the retraction gaps between the first and second section and the second and third section 0
2 Tighten the 321 retract cable located at the front bottom of the base section the difference in the retraction gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the retraction gaps 0
4 Tightening until the retraction gap between the first and second section and the retraction gap between the second and the third are equal 0
234 and 432 cable balancing 0
Extension 0
1 Measure the extension gaps between the third and fourth section and the second and third section 0
2 Tighten the 234 extend cable located at the back top of the second section the difference in the extension gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the extension gaps 0
4 Tightening until the extension gap between the third and fourth section is equal to the extension gap between the second and third section 0
Retraction 0
1 Measure the retraction gaps between the second and third section and the third and fourth section 0
2 Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the retraction gaps 0
4 Tightening until the retraction gap between the third and fourth section is equal to the retraction gap between the second and third section 0
3- Section Boom w/ 1 Stage Cylinder Cable Positioning 0
Figure 5 0
Cable Tightening Sequence 3 Section Boom with (1) Stage Extend Cylinder 0
321 and 123 cable balancing 0
Extension 0
1 Measure the extension gaps between the first and second section and the second and third section 0
2 Tighten 123 extend cable located at the back top of the base section the difference in the extension gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the extension gaps 0
4 Tightening until the extension gap between the first and second section and the extension gap between the second and the third are equal 0
Retraction 0
1 Measure the retraction gaps between the first and second section and the second and third section 0
2 Tighten the 321 retract cable located at the front bottom of the base section the difference in the retraction gap measurements 0
3 Extend and retract the boom a few times and then repeat measuring the retraction gaps 0
4 Tightening until the retraction gap between the first and second section and the retraction gap between the second and the third are equal 0
Figure 6 0
Cable Retention 0
TORQUE VALUES for Second Nut: 0

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