Manitowoc 8500-1 Installation and user guide

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©2013 Manitowoc
Published 08-16-13, Control # 208-03
Manitowoc
SERVICE/MAINTENANCE MANUAL
This manual has been prepared for and is considered part of -
8500-1/8500E-1
Model Number
8500Ref
Serial Number
This Manual is Divided into the following Sections:
SAFETY SECTION
SECTION 1 REFERENCE MATERIALS
SECTION 2 TEST PROCEDURES
SECTION 3 GENERAL
SECTION 4 POWER TRAIN
SECTION 5 HYDRAULIC SYSTEM
SECTION 6 HOIST SYSTEM
SECTION 7 BOOM HOIST SYSTEM
SECTION 8 SWING SYSTEM
SECTION 9 PROPEL SYSTEM
SECTION 10 ELECTRICAL SYSTEM
SECTION 11 AIR CONDITIONER
SECTION 12 TROUBLESHOOTING
NOTICE
The serial number of the crane is the only method Manitowoc has of providing you with
correct parts and service information.
Always furnish serial number of crane and its attachments when ordering parts
or discussing service problems with your Manitowoc distributor or the factory.
To prevent death or serious injury:
• Avoid unsafe operation and maintenance.
Crane and attachments must be operated and maintained by trained
and experienced personnel. Manitowoc is not responsible for qualifying
these personnel.
• Do not operate or work on crane or attachments without first reading
and understanding instructions contained in Operator Information
Manual and Service Manual supplied with crane and applicable
attachments.
• Store Operator Information Manual and Service Manual in operator’s
cab.
If Operator Information Manual or Service Manual is missing from cab,
contact your Manitowoc distributor for a new one.

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TABLE OF CONTENTS
Published 08-16-13, Control #208-03 1 8500-1/8500E-1
SAFETY
1. REFERENCE MATERIALS
1.1 8500-1 SPECIFICATION..........................................................................................1-3
1.1.1 CRANE OUTER DIMENSION...........................................................................1-3
1.1.2 CRANE SPECIFICATION, PERFORMANCE....................................................1-4
1.1.3 CRANE WORKING RANGES ...........................................................................1-5
1.2 8500-1 DIMENSION, WEIGHT OF EACH COMPONENT.......................................1-8
1.2.1 MAIN MACHINERY...........................................................................................1-8
1.2.2 COUNTERWEIGHT...........................................................................................1-9
1.2.3 ATTACHMENT..................................................................................................1-11
1.3 8500-1 SWING AND PROPEL STABILITY..............................................................1-14
1.4 8500-1 PROPEL ALLOWABLE SLOPE ANGLE......................................................1-16
1.4.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION.....1-16
1.5 8500E-1 SPECIFICATION .......................................................................................1-22
1.5.1 CRANE OUTER DIMENSION...........................................................................1-22
1.5.2 CRANE SPECIFICATION, PERFORMANCE....................................................1-24
1.5.3 CRANE WORKING RANGES ...........................................................................1-25
1.6 8500E-1 DIMENSION, WEIGHT OF EACH COMPONENT.....................................1-28
1.6.1 MAIN MACHINERY...........................................................................................1-28
1.6.2 COUNTERWEIGHT...........................................................................................1-29
1.6.3 COUNTERWEIGHT WITH SELF-REMOVABLE DEVICE (OPTION) ...............1-30
1.6.4 ATTACHMENT..................................................................................................1-31
1.7 8500E-1 SWING AND PROPEL STABILITY............................................................1-35
1.8 8500E-1 PROPEL ALLOWABLE SLOPE ANGLE ...................................................1-37
1.8.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION.....1-37
1.9 ENGINE MAIN SPECIFICATION.............................................................................1-43
2. MAINTENANCE STANDARDS TEST PROCEDURES
2.1 MAINTENANCE STANDARD...................................................................................2-3
2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE ............................................2-3
2.1.2 PROPEL DEVICE..............................................................................................2-11
2.2 PERFORMANCE STANDARD AND TEST PROCEDURE......................................2-19
2.2.1 OPERATING SPEED ........................................................................................2-20
2.2.2 POINT AND METHOD OF MEASURING PRESSURE.....................................2-21
2.2.3 SLEWING RING................................................................................................2-26
3. GENERAL WORK STANDARD
3.1 TIGHTENING TORQUE OF CAP SCREWS AND NUTS ........................................3-3

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3.1.1 STANDARD TIGHTENING TORQUE ............................................................... 3-3
3.1.2 TIGHTENING TORQUE OF HYDRAULIC FITTINGS.......................................3-6
3.2 STANDARD PARTS.................................................................................................3-8
3.2.1 BOLT.................................................................................................................3-8
3.2.2 O-RING..............................................................................................................3-9
3.2.3 BACK-UP RING.................................................................................................3-10
3.2.4 BITE TYPE FITTING.........................................................................................3-11
3.3 CONVERSION TABLE.............................................................................................3-13
3.3.1 UNIT CONVERSION.........................................................................................3-13
3.3.2 MILLIMETER : INCH CONVERSION TABLE....................................................3-14
3.3.3 METER AND FOOT CONVERSION TABLE.....................................................3-16
3.3.4 GRADE CONVERSION TABLE........................................................................3-17
3.3.5 UNIT WEIGHT TABLE ......................................................................................3-17
3.3.6 SYSTEM INTERNATIONAL (SI) UNIT CONVERSION TABLE ........................3-18
4. POWER TRAIN
4.1 INTRODUCTION......................................................................................................4-3
4.2 ENGINE....................................................................................................................4-6
4.2.1 INTRODUCTION...............................................................................................4-6
4.2.2 REMOVAL.........................................................................................................4-6
4.2.3 REPAIR AND MAINTENANCE .........................................................................4-9
4.2.4 INSTALLATION.................................................................................................4-9
4.3 PUMP DRIVE ASSEMBLY.......................................................................................4-12
4.3.1 INTRODUCTION...............................................................................................4-12
4.3.2 REMOVAL.........................................................................................................4-13
4.3.3 DISASSEMBLING THE POWER DIVIDER.......................................................4-16
4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER...........................................4-18
4.3.5 ASSEMBLING THE POWER DIVIDER.............................................................4-19
4.3.6 RE-INSTALLATION...........................................................................................4-20
5. HYDRAULIC SYSTEM
5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS ..............................................5-3
5.2 HYDRAULIC CIRCUITS AND COMPONENTS .......................................................5-9
5.2.1 COMPONENT SPECIFICATIONS.................................................................... 5-9
5.2.2 LAYOUT OF HYDRAULIC COMPONENTS......................................................5-13
5.3 HYDRAULIC SYSTEM.............................................................................................5-27
5.3.1 PREFACE..........................................................................................................5-27
5.3.2 OUTLINE...........................................................................................................5-27
5.3.3 OIL FLOW FROM No.1 AND No.2 PUMPS......................................................5-28

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5.3.4 OIL FLOW FROM No.3 PUMP..........................................................................5-30
5.3.5 OIL FLOW FROM No.4 AND No.5 PUMPS
(FRONT, REAR DRUM BRAKE COOLING) .....................................................5-32
5.3.6 OIL FLOW FROM No.6 PUMP..........................................................................5-34
5.3.7 OIL FLOW FROM No.7 PUMP..........................................................................5-38
5.4 VALVE......................................................................................................................5-46
6. HOIST SYSTEM
6.1 APPARATUS AND LOCATION OF COMPONENTS...............................................6-3
6.2 ADJUSTMENT OF DRUM LOCK.............................................................................6-5
6.3 WINCH .....................................................................................................................6-6
6.3.1 WINCH INSTALLATION....................................................................................6-6
6.3.2 WINCH ASSEMBLY..........................................................................................6-8
6.3.3 REDUCTION UNIT ASSEMBLY........................................................................6-10
6.4 BRAKE PEDAL.........................................................................................................6-12
6.4.1 ASSEMBLY DRAWING.....................................................................................6-12
6.4.2 ADJUSTING THE BRAKE PEDAL....................................................................6-14
6.5 BLEEDING AIR FROM BRAKE CIRCUIT................................................................6-15
6.6 CONSTRUCTION AND FUNCTION ........................................................................6-17
6.6.1 HYDRAULIC SCHEMATIC................................................................................6-17
6.6.2 LIFTING A LOAD...............................................................................................6-20
6.6.3 HOLDING A RAISED LOAD..............................................................................6-24
6.6.4 LOWERING A LOAD (POWER LOWERING) ...................................................6-28
6.6.5 FREE FALL OPERATION .................................................................................6-32
7. BOOM HOIST SYSTEM
7.1 APPARATUS AND LOCATION OF COMPONENTS...............................................7-3
7.2 BOOM HOIST WINCH INSTALLATION...................................................................7-5
7.3 BOOM DRUM LOCK................................................................................................7-6
7.3.1 ASSEMBLY DRAWING.....................................................................................7-6
7.3.2 ADJUSTING THE BOOM DRUM LOCK............................................................7-7
7.4 REDUCTION UNIT...................................................................................................7-8
7.5 CONSTRUCTION AND FUNCTION ........................................................................7-11
7.5.1 HYDRAULIC SCHEMATIC................................................................................7-11
7.5.2 RAISING THE BOOM........................................................................................7-12
7.5.3 NEUTRAL (HOLDING BOOM)..........................................................................7-14
7.5.4 LOWERING BOOM...........................................................................................7-16

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8. SWING SYSTEM
8.1 APPARATUS AND LOCATION OF COMPONENTS...............................................8-3
8.2 CONSTRUCTION AND FUNCTION........................................................................8-4
8.2.1 HYDRAULIC SCHEMATIC................................................................................8-4
8.2.2 SWING ..............................................................................................................8-6
8.2.3 STOPPING........................................................................................................8-8
8.3 SWING REDUCTION UNIT .....................................................................................8-11
8.4 SWING BEARING....................................................................................................8-14
8.5 SWING LOCK ..........................................................................................................8-16
9. PROPEL SYSTEM
9.1 APPARATUS AND LOCATION OF COMPONENTS...............................................9-3
9.2 PROPEL REDUCTION UNIT...................................................................................9-4
9.2.1 MOTOR AND REDUCTION UNIT.....................................................................9-6
9.3 ADJUSTMENT.........................................................................................................9-10
9.4 CONSTRUCTION AND FUNCTION........................................................................9-11
9.4.1 HYDRAULIC SCHEMATIC................................................................................ 9-11
9.4.2 PROPELLING (RIGHT SIDE FORWARD)........................................................9-12
9.4.3 STOPPING........................................................................................................9-14
10. ELECTRIC SYSTEM
10.1 ELECTRICAL.........................................................................................................10-3
10.1.1 ELECTRICAL WIRING SCHEMATIC..............................................................10-3
10.1.2 CONNECTOR LAYOUT..................................................................................10-21
10.1.3 LOCATION AND USE OF FUSE.....................................................................10-155
10.1.4 WIPER CONTROL RELAY (2479R1366) ....................................................... 10-161
10.1.5 PRESSURE SWITCH (FOR PROPEL MOTION DETECT)............................10-162
10.1.6 PRESSURE SWITCH (FOOT BRAKE)...........................................................10-163
10.1.7 PRESSURE SENSOR.....................................................................................10-164
10.1.8 INCLINATION SENSOR..................................................................................10-168
10.1.9 BUZZER UNIT.................................................................................................10-169
10.1.10 RELAY BOX ..................................................................................................10-171
10.1.11 RELAY BOX ..................................................................................................10-182
10.1.12LOAD CELL (CRANE).....................................................................................10-186
10.1.13ANGLE SENSOR............................................................................................ 10-187
10.1.14TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE. 10-188
10.1.15 HOW TO CHECK THE FAILURE CONTENTS..............................................10-189
10.1.16CHECKING OF DIAGNOSIS LAMP FUNCTION............................................10-195
10.1.17ENGINE ECU.................................................................................................. 10-196

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10.2 LOAD SAFETY DEVICE ........................................................................................10-198
10.2.1 CONFIGURATION OF SCREENS..................................................................10-199
10.2.2 SYSTEM DAIGRAM........................................................................................10-200
10.2.3 MONITOR INDICATION..................................................................................10-201
10.2.4 DETAIL OF MOMENT LIMITER CONNECTOR..............................................10-207
10.2.5 SHIFTING TO MAINTENANCE SCREEN.......................................................10-220
10.2.6 INPUT, OUTPUT SIGNAL...............................................................................10-222
10.2.7 ML FUNCTION SETTING................................................................................10-231
10.2.8 DATA COPY, FORMAT...................................................................................10-235
10.2.9 LANGUAGE, UNIT SETTING..........................................................................10-241
10.2.10ML ADJUSTMENT (NORMAL)........................................................................10-242
10.2.11ML ADJUSTMENT (TEMPORARY) ................................................................10-270
10.2.12OPERATION PROGRESS..............................................................................10-271
10.2.13VERSION INFORMATION ..............................................................................10-273
10.2.14FAILURE HISTORY.........................................................................................10-274
10.2.15ADJUSTMENT DATA......................................................................................10-278
10.2.16DOWNLOAD ML PROGRAM..........................................................................10-286
10.2.17DOWNLOAD OF MONITOR PROGRAM........................................................10-288
10.3 MAIN CONTROLLER.............................................................................................10-294
10.3.1 ARRANGEMENT OF MAIN CONTROLLER...................................................10-294
10.3.2 COMPOSITION OF SYSTEM .........................................................................10-295
10.3.3 FUNCTION OF MAIN CONTROLLER.............................................................10-296
10.3.4 MAIN CONTROLLER 1, 2 (HARDWARE).......................................................10-336
10.3.5 SPECIFICATIONS OF MAIN CONTROLLER OUTPUT .................................10-337
10.3.6 ARRANGEMENT OF MAIN CONTROLLER CONNECTOR PIN....................10-345
10.3.7 ADJUSTMENT OF MAIN CONTROLLER.......................................................10-361
10.3.8 CONTROLLER MALFUNCTION EMERGENCY MEASURES........................10-365
11. AIR CONDITIONER
11.1 AIR CONDITIONER ...............................................................................................11-3
11.2 PARTS ILLUSTRATION.........................................................................................11-11
11.3 DISASSEMBLY AND ASSEMBLY OF THE UNIT..................................................11-14
11.3.1 REMOVAL OF THE BLOWER UNIT...............................................................11-14
11.3.2 REPLACING THE BLOWER MOTOR.............................................................11-15
11.3.3 REPLACING THE BLOWER CONTROLLER..................................................11-15
11.3.4 REMOVAL OF THE HEATER CORE..............................................................11-15
11.3.5 REMOVAL OF THE AIR-CON UNIT CASE-FRONT AND- REAR ..................11-16
11.3.6 REPLACING THE EVAPORATOR AND EXPANSION VALVE.......................11-17
11.3.7 INSTALLATION OF EVAPORATOR SENSOR...............................................11-17

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11.3.8 REPLACING THE MOTOR ACTUATOR ........................................................11-18
11.4 FAULT DETECTION FROM THE CONTROL PANEL INDICATION ..................... 11-19
11.4.1 GENERAL .......................................................................................................11-19
11.4.2 FAULT IN THE INPUT AND OUTPUT CIRCUIT OF
THE MOTOR ACTUATOR..............................................................................11-19
11.4.3 FAULT IN THE THERMISTOR SENSOR CIRCUIT........................................11-19
11.5 BASIC SYSTEM OF HVAC....................................................................................11-20
11.6 RECHARGING OF THE COOLANT ......................................................................11-25
11.6.1 CAUTION AT WORK.......................................................................................11-25
11.6.2 WORK PROCEDURE ..................................................................................... 11-27
11.6.3 RECHARGING PROCEDURE........................................................................11-29
11.7 ELECTRIC WIRING DIAGRAM .............................................................................11-35
12. TROUBLESHOOTING
12.1 TROUBLESHOOTING........................................................................................... 12-3

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SAFETY

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SAFETY
8500-1/8500E-1 0-2 Published 08-16-13, Control #208-03

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SAFETY
Published 08-16-13, Control #208-03 0-3 8500-1/8500E-1
SAFETY INFORMATION
Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Suf-
ficient care should be taken to avoid these accidents.
Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of per-
sonnel.
Thus, precautionary measures, or notes, written in this manual should be read and understood by personnel before
starting each task.
Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority.
Messages of safety are indicated with caution marks. The safety information contained in this manual is intended
only general safety information.
Messages of safety appear in this manual and on the machine. All messages of safety are identified by the words
"DANGER", "WARNING" and "CAUTION". These words mean the following:
It is very difficult for us to forecast every danger that may occur during operation. However, safety can be ensured
by operating this machine according to methods recommended by Manitowoc. While operating machine, be sure to
perform work with great care, so as to not damage the machine, or let accidents occur.
Please continue studying this manual until proper operation is completely understood.
Indicates an imminently hazardous situation which, if not avoided, will result in loss of life or se-
rious injuries.
Indicates a potentially hazardous situation which, if not avoided, could result in loss of life or se-
rious injuries.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injuries. It may also be used to alert against possible damage to the machine and its compo-
nents.
Supplementary explanation.

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SAFETY
8500-1/8500E-1 0-4 Published 08-16-13, Control #208-03
EXPLANATION OF WARNING LABELS IN THE MACHINE
Since the warning labels are installed in the machine and indicated with the three stages in the same way as the
warning description, confirm the positions and contents of all warning labels first.
Put them to the practical use to secure safety when operating, checking and performing maintenance.
HANDLING OF WARNING LABELS IN THE MACHINE
1. When the warning label is damaged or stained, order it to the designated service shop.
2. Do not remove the warning labels.
3. When the surface of the warning label is soiled and difficult to be seen, wipe it cleanly.

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SAFETY
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LABEL LAYOUT
* Numbers in the drawings correspond with those in the label explanation detail after P.0-14.
2
5
11 8
10
9
3
1
4
6 (8500E-1)

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6
32 (8500E-1)
31

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17
26
24
23
6
20
21

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17
24
20
6

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27
22
21
7

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15 (8500-1 w/ J08E-UV) 16 (8500-1 w/ J08E-VM)
15 (8500E-1)
12
12
19
25
21

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14
18
20
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20 20