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OPERATOR`S MANUAL 1 2 3 4 5 6

1. R67 R60 R61 ii R58 R59 a r l 27 Nog 8 17 19 29 33 33 l l 160 Jib A 24250128 6 R61 R63 R58 Bee a 3 26 ax 30 Nog 8 l 170 Jib N 24250128 11 R R61 R63 R58 7 7 P 27 28 8 17 19 2 3 33 33 RTI 180 Jib 24250123 R 32 R61 R63 R58 Ben va t e 221 Z 8 17 19 33 33 33 x l l 190 Jib 2425023 R 32 32 32 R61 R63 R58 RES 2 gt 27 28 28 17 19 99 33 33 33 1 1 l 200 Jib lt _ 24 25 or 23 11 4 of 22 ec 10 S gt o o m g lt NOISIA3H R67 R61 R63 R58 562 28 7 28 7 Pa zx E 5 R t 30 28 28 17 19 31 33 33 33 210 TAVANI 32 2 R61 R63 R58 Ru 28 28 z 28 4 5 _ SEC 1 1 lt er 0 28 3 8 17 19 99 3 33 33 33 4 _ 220 Jib i 24250r23 1 R6 R63 R58 169 32 32 28 32 32 zi PNE
2. ag 5 R61 R63 R58 R59 22 R6 R63 R58 fey 28 MEE NER CEN x 2 lt 2 E y 28 28 8 27 30 28 8 17 19 33 33 17 19 29 31 150 Jib lt 100 Jib 24250123 67 11 5 24250128 R67 H 5 R61 R63 R58 R59 28 32 R61 R63 R58 R59 MR ME TEE z S 27 30 98 28 8 30 28 17 19 29 31 33 17 19 d 140 90 Jib 24250128 24250123 5 5 R61 R63 R58 R59 R60 28 M LR R61 R63 R58 R59 X lt X PU IE E l gt 30 28 28 8 27 8 130 Jib lt I 80 Jib 11 24 25 or 23 R67 L 6 24 25 or 23 R67 11 28 32 R R61 R63 R58 R59 R61 R63 Re lt 27 28 17 19 29 33 70 Jib 7 24250r23 R67 11 11 R67 gt n 24 25 or 23 l R61 R63 R58 R59 28 8 gt 17 19 33 Z 10 5 Recommended 44 Luffing Jib Assembly 24 25 or 2 11 Note See Table on page 22 For Alternate combinations 5 or 23 5 5 Us o lt ONI S3NVHO9 90MOLINVIN MANITOWOC CRANES INC
3. s SETUP AND INSTALLATION See NOTE 5 Bolt Clamp 7 4 203 Tighten each side equally to provide equal gap See NOTE 1 for torque value 44 LOWER JIB POINT LOWER JIB ce POINT SHEAVES D 4 201 m 52 51 53 Location of Guide Sheaves with Lead Line NOTE 1 Going to Point Sheave Indicated Drum 1 Lead Line NOTE 2 Routed to Dimension B Sheave NOTE 3 S9 0 62 in 16 mm NOTE2 S8 2 06 in 52 mm NOTE 3 NOTE 4 S7 4 75 in 121 mm NOTE NOTE 5 S6 10 44 in 265 mm NOTE 3 Drum 3 Lead Line Routed to Dimension A Sheave S4 10 69 in 272 mm NOTES 3 amp 4 3 5 00 127 mm NOTE 3 S2 2 06 in 52 mm NOTE 3 1 0 62 16 2 Position clamps hand tight against sheave bearing Before torquing bolts check that sheave turns freely Torque bolts lubricated with S A E 20 oil to 120 ft Ib 163 Nm This location requires sheave bearing to be snug against jib top side plate as shown at Dimension B This location Dimension A requires two clamps as shown at Position guide sheave at this location for whip line operation over upper jib point Use two clamps Install rope retaining pin in this hole Lock Washer FIGURE 4 48 Published 06 20 08 Control
4. o o o o o o o o kai hal ad A kadi hal kad Hal Lai D kadi hal kad hal Lad Lad kadi hai kad aai Lai LA kad ka o o o o o o o o gt gt kad La kad kad kai kad ka kedi baii ONI S3NVHO9 90MOLINVIN MODEL 18000 LUFFING JIB RIGGING 44 Luffing Jib on 55 79A Boom with 100 Mast DESCRIPTION OF PART 78292 PIN 137502 WASHER 160720 PIN 172298 PIN 172960 LUFFING JIB LOWER POINT ROLLER ASSEMBLY 174211 LUFFING JIB UPPER POINT ROLLER ASSEMBLY 178905 TIMBER 179840 STRAP 179862 COLLAR 179863 PIN 179915 TOP 30 Boom Jib 9 14 m see O 539 179959 PIN 195197 SHAFT 195198 PLATE Keeper 195204 SHAFT 195208 PIN 195209 JIB STOP ASSEMBLY 195666 PIN A00228 SUPPORT Jib Strut A02735 SIGN Boom A04331 LUFFING JIB HOIST ASSEMBLY A05312 ROLLER ASSEMBLY see Note 1 JIB BUTT MOD 1 PI 23 171230 JIB BUTT MOD 2 PIECE 24 171283 1 BUTT 44 Boom Lower Section 40 see Note 2 see O 539 25 171284 1 BUTT 44 Boom Upper Section 40 see O 539 TER FRAME 79 BOOM 26 A07488 ADAPTER FRAME ASSEMBLY R1 171825 PLATE Keeper 3 4 thick R2 194986 PIN Keeper 5 di
5. 2 2 18 Personnel Handling 2 20 Pedestal barge Mounted 2 21 Pedestal Mounted Crane 2 21 Definition nr pd o edo dede on dre tree deme rd 2 21 Examples ae vd EE uides iude are ay Ere 2 21 Barge Mounted 2 22 Definition es Tess urua p rediere 2 22 ert Erde dee 2 22 pte Published 06 20 08 Control 033 07 2 i i 2 ii 18000 LUFFING JIB OPERATOR S MANUAL Capacity Charts 2 P Peru E ns 2 23 Shock Eoaditg ue coe erp UE nde aa 2 23 Definition reo det rer P rero ege as rand rine E grand dear da ane d 2 23 Operation On 2 24 General 5 eet a pa u qaya 2 24 Definitions dro rre rds gro rune gite TU wind 2 24 Crane 2 24 Transporting Crane on Barge 2 24 Safety and Information 0 2 25 Maintaining SIGNS 1 2 5 S mers teh dub tado ead pus pasur
6. Counterweight 28 total each Rear catwalk with railings Total upperworks counterweight COUNTERWEIGHT LOWER Counterweight tray each Counterweight each 6 total front 3rear Stairway each Total lowerworks counterweight 30 ft 9 1 m LIVE MAST 30 ft 9 1 m mast with straps MACHINE OPTIONS Drum assembly whip line without Upperworks jacking Swing drive assemblies each Rotating bed alignment pendants each LOWERWORKS OPTIONS Carbody pedestals with pads each MAST NO 56 20 ft 6 1 m mast butt with boom hoist drum with and guide sheave 20 ft 6 1 m mast top with sheaves wire rope guide and straps 40 ft 12 2 insert with straps 20 ft 6 1 insert with straps 1 6 Published 06 20 08 Control 033 07 Weight Pounds Kilograms
7. 18 485 8 384 40 ft 12 2 m insert with equalizer rails 19 185 8 702 40 ft 12 2 m insert medium 13 685 6 207 40 ft 12 2 m insert with sheaves 19 640 8 908 28 ft 2 11 16 in 8 6 m basic strap each 755 342 20 ft 6 1 m strap with connector links each 610 276 40 12 2 m strap with connector links each 1 120 508 Links attached to equalizer each set with 110 49 Equalizer with pins 3 675 1 666 Boom stop each tube 1 795 814 Drum 1 or 2 assembly load hoist without rope 9 970 4 522 LUFFING JIB NO 44 40 12 2 butt 8 605 3 903 12 ft 3 7 m lower but 4 430 2 009 28 8 5 upper butt 5 305 2 406 30 ft 9 1 m top with straps upper and lower point 14 090 6 391 10 ft 3 0 m insert 44 1 890 857 20 ft 6 1 m insert 44 3 215 1458 40 12 2 insert No 44
8. 4 22 Raising Boom and 44 Luffing 4 26 Lowering Boom and 44 Luffing 4 30 Removing 44 Luffing 4 33 Removing Jib 4 34 Luffing Jib Rigging 79 4 35 General uya 22x ee E e due 4 35 Assist Crane 4 35 Index ii Published 06 20 08 Control 033 07 Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL Preparing Crane Boom and 4 38 Installing 79A Luffing 2 4 42 Raising Boom and 79 Luffing 4 57 Lowering Boom and 479A Luffing 4 62 Removing 79A 1 4 64 Wire Rope 1 4 74 Wire Rope 4 74 Removing Wire Rope from Shipping 4 74 Seizing and Cutting Wire 4 74 Anchoring Wire Rope to 4 75 Win
9. 3 8 Wind Conditions 2c nne eedem dme re eem a 3 8 44 Luffing Jib on 55 79A Boom with 100 foot 30 5 m 3 9 Operation Permitted 3 9 Operation Not Permitted 3 9 79A Luffing Jib on 55 or 55 Boom without MAX ER Attachment 3 10 Operation Permitted 3 10 Operation Not Permitted 3 10 79A Luffing Jib on 55 or 455A Boom with MAX ER Attachment 3 11 Operation Permitted 3 11 Operation Not Permitted 3 11 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL OPERATION SECTION 3 OPERATION STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30 5 2007 USE WHIPLINE Auxiliary Hoist Tap elbow with one hand then use regular signals HOIST With forearm vertical LOWER With arm extended USE MAIN HOIST Tap fist on forefinger pointing up move downward forefinger pointing head then use regular signals hand in small horizontal circle down move hand in small horizontal circles MOVE SLOWLY Use one hand to give any motion signal and RAISE BOOM Arm extended LOWER BOOM Arm e
10. 1 890 857 Jib hinge pins link assembly each 340 154 29 8 8 8 strut butt 5 325 2415 21ft 64 m struttop 4 625 2 097 1ft5in 0 4 spreader link withpins 690 312 1 ft 10 in 0 6 link with pins each 225 102 1 ft10in 0 6 link each 135 61 1 ft 7 in 0 5 m spreader link with pins each 535 242 Adjustable link with pins each 585 265 7 ft 4 in 2 2 backstay strap each 275 124 30 ft 9 1 m backstay strap with links each 865 392 20 ft 6 1 backstay strap with links each 610 276 40 ft 12 2 m backstay strap with links each 1 120 508 10 ft 3 0 m backstay strap with links each 355 161 1 ft 11 1 2 in 0 6 m backstay link pins each set 115 52 LUFFING JIB NO 79A 20 ft 6 1 79 10 315 4678 30 ft 9 1 top with double straps upper heavy duty and lower point and wire rope guide 27 835 12 625 20 ft 6 1 m insert 79 with double straps 7 835 3 55
11. 70 SS I 1IAA jer hee M peo1 104 1uBI9AA 8 JO uoneoo GZL H eZ 81uzi Joy Assy woog i SOL 702 791 1 ur peo 1 194 i 8j luono iq 22 9PIS A4M9IA __ 40 221 02 Buyunoy Je9N w JO uj ueg epejdeoey peo1 epoejdeoeM do woog V6L 901 woog uo pedoo eg PNN 9 way JO 1 65 J N OSULIL peo7 Julod 19407 LL _ ejejdeoey LV LV woog jutog ejoejdeoey epis uo pua ye1 OL 19614 1901 UM 018201 YOUMS apis 1uBr4 uo peaa 01 0 8201 YOUMS REVISION 13 of 20 gt m z Q lt MANITOWOC CRANES INC 186 185 184 172 Dead End Right Side Load Link 9 Wired 70K 12 ft Lg 173 175 mne Mi Lower Point Multi Part Line Switch Location With Lower Point Reeving Left To Right Dead End On Right Side Or M
12. 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION THIS PAGE BLANK mm Published 06 20 08 Control 033 07 4 5 SETUP AND INSTALLATION Jib Stops in Operating Position Roller Jib Stop Support P Boom Stop Jib both sides t TR ig S 18000 LUFFING JIB OPERATOR S MANUAL Pins in Upper Holes for Operation Pins in Lower Holes for Shipping and for Handling Jib Stop Assembly Support this End of Jib Stops 50 Ib 23 kg Before Removing Pins from Lower Holes Shaft with Keeper Plate 4 101 Jib Stop Boom Butt Lugs Wire Rope Guide Rigging Winch inside Jib Strut Published 06 20 08 Control 4 033 07 4 102 44 Jib Butt Luffing Jib Luffing Jib Wire Rope Wire Rope Guide Guide a Jib Strut Rest Pins with Cotter Pins FIGURE 4 5 Q anitowoc Crane Care 18000 LUFFING JIB OPERATOR S MANUAL LUFFING JIB RIGGING GUIDE 44 General The following installation raising lowering and removal instructions apply to the 44 luffing jib mounted on a 55 79A Assist Crane Requirements Either the Model 18000 or an assist crane can be used to install and remove the jib If the Model 18000 is used it must be in the setup configuration same as when installing counterweights and crawler or assembling boom s
13. Suig 6v 65 E JS ues M 66 epis 7 19 6 JeNeosuelJ dol air jeu dif Ajquessy GS AOZ PAMA luloq woog 7 3 yur peo P TN Q mecum yur peo1 JO 7 apis GOL dol 1 JO 1 SION IN 1 SPON 70 SK epis 05 T Jean 89 Jejouo2 epis 29 183 Z Julod qif 190 aul JO Sued OL 40 e 9 P z Way sy YMS puy 6 yur peo11O uone o ssv Jamo7 woog 394 V6 uoog julod dif 907 6 sued eio 10 Z 681 6 way peo1 jO uoneoo1 poN Z dol woog 410 SS piousjos jeots ug dois q r 1994 SCEMEF IM 501 do 1 pedoo7 eg 1snIN 0 JO Hed uires REVISION 9 of 20 gt m z Q lt MANITOWOC CRANES INC 62 62 58 58 51 57 _ l 50 1 59 viii 9ftlg 55 1 lI H 59 59 49 Single Part Line View 4 Upper Boom Point 170419 Ref Dead End On Upper Boom Point 26 44 9 Load Link Wired 70K Luffing Jib Angle Min Ref 12ftLg 27 See Note 8 View P P Location Of Load Link Item 9
14. OPERATOR S MANUAL This manual has been prepared for and is considered part of 18000 Luffing Jib Model Number 18005910 Luffing Jib Serial Number This Manual is divided into the following sections SECTION 1 INTRODUCTION SECTION 2 SAFETY INFORMATION SECTION 3 OPERATING CONTROLS AND PROCEDURES SECTION 4 SET UP AND INSTALLATION SECTION 5 LUBRICATION SECTION 6 MAINTENANCE NOTICE The serial number of the crane and applicable attachments i e luffing jib MAX ER is the only method your distributor or the factory has of providing you with correct parts and service information The serial number is located on a crane identification decal attached to the operator s cab and each attachment Refer to the Nameplate and Decal Assembly Drawing in Operator s Manual for the exact location of the crane identification decal Always furnish serial number of crane and its attachments when ordering parts or discussing service problems with your distributor or the factory WARNING To prevent death or serious injury e 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
15. Qe 4 105 View A Lower 2 Jib Hinge Pin A Boom Point with Keeper Plate 6 in 152 mm Blocking Here so Blocking Distance from Center typical of Jib Hinge Pin to Ground is 54 ft 1 4 m View E Jib Sections View D Upper Pin with Snap Pins Installed 4 106 X Removable Horizontal Pin with Cotter Pins adm Lower Pin with Snap Pins Not Installed FIGURE 4 6 4 8 Published 06 20 08 Control 033 07 C an t E Crane Care 18000 LUFFING JIB OPERATOR S MANUAL Install Jib Butt See Figure 4 6 for following procedure 1 Lift jib butt adapter frame into position at end of boom top and pin to boom top lugs View B 2 Lift jib butt into position at end of boom top View Pin jib butt to lugs on boom top with hinge pins nstall washers as pins are inserted to limit jib butt side play to 1 8 in 3 mm 3 Lower jib butt onto blocking approximately 6 in 152 mm high Install Jib Inserts and Top See Figure 4 6 for following procedure 1 Determine jib length required for lift to be made A WARNING Collapsing Jib Hazard Install removable lacings if removed before raising jib SETUP AND INSTALLATION Check that removable diagonal lacings are securely fastened to each jib insert see Removable Lacings 44 Jib topic and Figure 4 4 Assemble jib inserts in proper sequence shortest inserts nearest butt see Luffing Jib Assembly Rigging drawing a Lift in
16. e ec ee 1 1 Identification And Location Of Components 1 2 Outline Dimensions ccs ne g O TIER Brew 1 4 Crane Weights gps 1 6 English And Metric Conversions 1 10 Direct Conversion iiio come mer ENERO RE EAE REPRE EE ER 1 10 Inverse 1 1 10 Manitowoc Crane Care 0 1 11 SECTION 2 Role Ve hoa n eae D Safety Information Diesel Englne EXxhaust c ume ee ente e tee rep Ree n b RA 2 1 Nameplates and 2 1 Safety Messages sie se eee e Vae ate ewe ala ce ts TR 2 1 Generali donem ex ama m oe 2 1 Safety Alert Symbol ERE Irae uui eai 2 1 Signal Words pu pu A eap arte ara a laa CHR 2 1 Satety Symbols etes xod eg ia es eng a te o 2 1 Luffing Jib Attachment Access 2 5 General ua aaa as oup RR ie ee 2 5 Getting On or 2 5 Personnel Fall Protection
17. 9 9 SE 10 10 11 E12 12 4 22 390 30 L N 1 9 9 10 ett 2 6 772 1 28 9 9 1 10 10 miz 12 4 80 NA v N 4i 9 9 1810 11 1 a ipee E eg 9 9 1 10 10 asja 27 BS R60 R59 pgg R60 R67 mg H R58 R58 View B B RE BN 8 of 22 R51 nl 76 R77 R78 l R77 R78 R86 R73 R73 R72 R74 R72 R74 MET NM 1 91 10 10 9 12 4 2 9 12 92 8 92 94 95 94 95 Bd 8 92 5 K 92 94 95 25 12 94 95 80 8 80 79 81 79 81 mede T 75 85 3 f 85 86 87 86 87 72 8 72 73 74 73 74 66 66 723 7374 24 73 74 63 8 63 64 65 64 65 63 7 63 6465 24 UP 64 65 47 3 47 48 49 48 49 38 L 46 T 38 473 c 47 48 49 41 12 49 48 39 41 42 39 View MANITOWOC CRANES INC Stored 27 30 or 32 1 Position 1 9 10 12 1 RAMIS CNL V Bu Boom Stop Deflector Sheave Insert Connectors And Inser
18. Ladder Operator s Cab Steps Carbody Has Non Skip Surface Shaded Areas Indicate Steps and Walkways Ladder Both Sides Counterweight Boxes and Trays Have Non Skip Surfaces FIGURE 2 2 2 6 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL OPERATOR S MANUAL CAPACITY CHART STORAGE General Manitowoc provides the following manuals and other important literature with your crane and attachment Luffing Jib etc Operators Manual Serial Numbered Contains safety information crane specifications assembly erection procedures operating instructions lubrication and maintenance checks e Parts Manual Serial Numbered Contains illustrations and part numbers of replaceable parts e Capacity Chart Manual Serial Numbered Contains lifting capacities and related information wire rope specifications drum and lagging information etc e Maintenance Checks and Lube Guide Contains lists of maintenance checks and lube services and their prescribed intervals Rated Capacity Indicator Limiter Operation Contains Load capacity operation
19. View A 2 vee When step 5 performed jib stop will swing past adapter frame into proper operating position FIGURE 4 16 mm Published 06 20 08 Control 033 07 4 29 SETUP AND INSTALLATION Lowering Boom and 44 Luffing Jib General A WARNING Falling Boom And jib Hazard Select and confirm LUFFING JIB mode Operating in any other mode with luffing jib attached is prohibited Luffing jib limits are disabled when LUFFING JIB mode is off Boom and jib could be pulled over backwards A WARNING Moving Part Hazard Warn all personnel to stand clear of jib point rollers while lowering boom and jib As defined in the raising procedure chart one of two methods can be used to lower the boom and jib depending on the boom and jib combination In Line Method or Jack Knife Method See the chart to determine which method can be used Be sure crane is properly configured for selected method NOTE Use digital display in cab to monitor boom and boom to luffing jib angles while lowering boom and jib In Line Lowering Procedure See Figure 4 16 for following procedure A WARNING Tipping Crane Hazard Observe boom to luffing jib angles specified on raising procedure chart e f required by raising procedure chart lower boom and jib over blocked crawlers Lower load block and or weight ball to ground before lowering boom and jib 4 30 Published 06 20
20. 185 184 171 Dead End Left Side 9 Load Link Wired 70K 27 173 12 ft Lg 175 1 166 Lower Point Multi Part Line Switch Location With Lower Point Reeving Right To Left Dead End On Left Side 14 of 20 View 6 Plate Plate Keeper Keeper 186 170 170 186 185 185 184 169 169 184 171 168 W 175 A T 1 J I N I I 12 ft Lg 173 hut 173 12 ft Lg 175 175 167 Upper Point 165 Single Part Line Switch Location With Lower Point Reeving Left To Right Plate Plate Keeper 18 GNI 5 184 169 169 184 I 172 z 168 175 12 f Lg 173 173 12ft Lg 175 175 167 165 Upper Point Single Part Line Switch Location With Lower Point Reeving Right To Left View 7 546054 591121 612456 667042 710304 81000194 15346 15488 15486 15368 81000201 546052 612363 710708 4 CONTROL WIRING Boom amp Limits DESCRIPTION OF PART NUT Hex 3 8 16UNC 2B REEL Cable SCREW Hex Cap 3 8 16UNC 2A x 1 1 4 long STRAP Stay 8 max dia see Note 6 WASHER Lock 3 8 CABLE Electric Boom PWR COMM WBM 150440 LINK Load Cell 70K Wireless 2 4 GHz see Note 10 LINK Load Cell 70K Wired see Note 10 CABLE Electric Load Link 20 long TRANSCEIVER 2 4 GHz 125K baud see Note 11 CABLE Electric Boom Jumper
21. 27 22 27 Each Carbod Each Carbody Both Sides Counerweight Tray CounerweightTray 1 a 21 Front View y JA VIR T p Boom Equalizer Rail VM M A Se 8 Must Be Readable Boom Top 66 From Engine Side lt 23 Horizontally Center Decal With Sight Gauge E Q Hydraulic Tank e Must Be Readable With 19 f Mast Down Over Rear Horizontally A 39 Center Decal i With Sight Gauge Radiator Fuel Tank 8 ing 33or 34 Above 55 29 0 Rotating Bod Each Side 28 7 35 Of Jacking Oylinder m Carbody Left Front View 23 31 e 42 18 Front Bottom Edge Of Adapter Frame Lalal E 2 Both Sides Of Both Steps ASSEMBLY REVISION 0625 08 A06702 Y 1 of NAMEPLATE amp DECALS MANITOWOC CRANES INC 9 20 20 Vertical ol a Vertical Surface Of Surface Of Cross Beam Cross Beam Engine Cover Top View Rotating Bed Counterweights Next To Rear View Next To Lifting Lug Lifting Lug Vent Behind Right Console Cab Door On Interior Interior 35 Right Side Window Operators Cab ref 4 13 3 Ll i
22. 55 backstay strap with connector links each 1 220 553 Backstay link attached to boom butt each 115 52 Luffing jib stop assembly 1 850 839 Upper point single sheave with rollers 1 220 553 FIXED JIB NO 79A 20 ft 6 1 m butt 79A 10 295 4 669 30 ft 9 1 m top with double straps upper heavy duty and lower point and wire rope guide 27 780 12 600 20 ft 6 1 m insert No 79 with double straps 7 835 3 553 40 12 2 m insert 79 with double straps 13 180 5 978 28 ft 2 15 16 in 8 6 basic strap each 355 161 20 ft 6 1 jib strap with links each 290 131 40 ft 12 2 jib strap with links each 525 238 Equalizing link each 375 170 10 ft 3 0 m strap with connector links each 20 degree offset 355 161 7 ft 2 1 m strap with connector links each 345 156 419 in 1 4 strap with pin each 195 88 4 ft 9 in 1 4 m link with pin seteach 185 83 6 ft2 in 1 9 strap with pin each 265 120 Jib stop assembly each s
23. 30 F 1 C 1600 psi 110 bar 50 F 10 C 1665 psi 115 bar 70 F 21 C 1730 psi 119 bar 90 F 32 C 1796 psi 124 bar 3 Put 2 1 2 gallons 10 L of MCC A03745 Arctic 15 pre filtered hydraulic oil in reservoir Leave fill cap off 4 Prime pump by pressuring reservoir slightly with user supplied air pressure 5 Begin pumping hand pump Bleed cylinder and accumulator lines When fluid flows clear close lines Continue pumping hand pump Cylinders will extend When cylinders are fully extended signal operator to retract cylinders with mode switch Weight of jib stops will retract cylinders 8 Repeat steps 6 and 7 for 3 cycles to expel all air from cylinders and lines 9 Pump hand pump until cylinders are fully extended 10 Adjust tank oil level to top mark on dipstick Dipstick should rest on tank fitting for proper oil level check 4 40 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL 11 Pump until oil level is at low mark on dipstick Gauge reading must be 2 450 2 500 psi 169 172 bar Record pressure on inspection record 12 Seal fill and dipstick ports with hydraulic sealant Procedure For Raising Boom And Jib 1 Pump hand pump until pressure gauge reads 2 500 psi 172 bar 2 Disengage safety latch using hand winch in jib top 3 Set spring tension adjustment 8 3 4 in 222 mm minimum to 9 in 229 mm maximum see Set Up Jib Stop Positio
24. 55 or 55A Boom without Luffing Jib e 385 for 44 or 79A Luffing Jib on 140 180 ft 42 7 54 9 m of 55 79A 55 or 55A 87 44 or 79A Luffing Jib on 200 340 ft 61 0 103 6 m of 55 79A 55 or 55 Boom A WARNING Falling Attachment Hazard Do not operate crane unless automatic boom stop is properly adjusted and operational Do not adjust MAX operating angle higher than specified Boom could be pulled over backwards or collapse Operation See Figure 6 4 for following instructions When the boom is below the MAX angle the limit switch is closed and its LED light emitting diode is on View A The boom hoist can be operated as long as the switch is closed When the boom is raised to its MAX angle the actuator rod opens the limit switch and the LED goes off View B Boom hoist operation stops automatically because the open limit switch turns off power to the boom hoist electric circuit The boom hoist pump shifts to neutral and the brake applies to stop boom movement Maintenance At least once weekly check that the automatic boom stop stops the boom at the specified MAX angle If not replace any defective parts and or adjust the boom stop MAINTENANCE Boom and Mast Stability To maintain boom stability when operating at high boom angles adhere to the minimum load requirements specified in the capacity chart for the boom and luffing jib combination in use Boom will settle ba
25. ic oie iid SS eee RIPE xw Operation Standard Hand Signals for Controlling Crane Operations 3 1 General Operation t ses ein ee BA ee ln Ed 3 4 Luffing Jib Operating 8 3 4 1 Crane Mode Select Confirm 3 4 2 Drum 4 Boom Hoist Park 3 5 3 Drum 6 Luffing Hoist Park 3 5 4 Boom Hoist and Whip Hoist 3 5 5 Luffing Hoist and Swing 3 5 6 Normal Limit Bypass Switch 3 5 Digital Display s eo eee Se RE BL EL 3 6 8 Mechanical Boom Angle 3 7 9 Mechanical 1 3 7 Automatic Jib Stop not 3 7 Operating Precautions 3 8 Wind Conditions Rd hA pue 3 8 44 Luffing Jib 55 79A Boom with 100 foot 30 5 m 3 9 79 Luffing Jib on 55 or 455A Boom without MAX ER Attachment 3 10 79A Luffing Jib on 55 or 455A Boom with MAX
26. ko UR Rua a RR ea anc 4 1 Crane Weights ii eeni erase ERA rms ehe eatem ee o e pc 4 2 Operating 4 2 Counterweight 4 2 Blocked Crawlers ete one ndr pae ae UR n BUR RR Ren 4 2 Rigging Drawings sea km RR kk ke ray 4 2 Luffing Jib Raising 4 2 Identifying Jib 4 2 Handling 4 2 Retaining Connecting Pins 4 3 Shipping Crane 4 3 Removable Lacings 44 0 4 3 Luffing Jib Rigging 4 44 4 7 General ee ee 4 7 Assist Crane Requirements 4 7 Installing 44 Luffing 4 4 7 Lower BOOM CE 4 7 Prepare Boom and Jib 4 7 Install iR t a A ent oe ee ee 4 9 Install Jib Inserts and 4 9 Comp
27. 29 ft 8 8 m main strut butt Main strut stop assembly each 8 ft 9 1 4 in 2 7 strap each 4 ft 1 2 m link with pins each set 3 ft 10 1 2 in 14 2 m adjustable strap each 20 ft 6 1 m backstay strap with link each 40 ft 12 2 backstay strap with link each 10 ft 3 0 m backstay strap with link each 1 ft 11 1 2 in 0 6 backstay link with pin each set Boom dolly with adapter frame pins BOOM OPTIONS Drum 6 assembly luffing hoist with Standard upper boom point single sheave Heavy duty upper boom point single sheave 661 USt 600 t load block 500 USt 454 t load block 450 USt 408 t load block 350 USt 318 t load block 100 USt 91 t load block self erect 30 USt 27 t hook weight ball 15 USt 14 t hook and weight ball WIRE ROPE Mast hoist 1 230 ft 375 m of 22 mm wire 1 80 Ib per ft 2 68 kg m Boom hoist 4 370 ft 1 332 m of 1 1 8 in 28 6 mm wire 2 60 Ib per ft 3 87 kg m Luffing Jib Hoist 1 in 25
28. 4 Retain connecting pins 5 View B with collars 6 View C and retaining pins 7 Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION working P2149 Item Description Description 1 Fill Plug 7 Manifold Valve 2 Support Frame 8 Pressure Gauge 3 Reservoir 4 7 gal 17 8 L 9 Pump Manual 4 Drain Plug 10 Pump Handle 5 Jib Stop Positioner 11 Accumulator 5 gal 18 9 L 6 Boom Top 12 Dipstick 13 Jib Stop FIGURE 4 19 mm Published 06 20 08 Control 033 07 4 39 SETUP AND INSTALLATION Jib Stop Positioner Hydraulic System Operation CAUTION Structural Damage Read and adhere to these instructions to prevent structural damage to components Positioner cylinders are extended and retracted using crane mode switch in operator s cab Read Section 3 in this manual and Section 3 in the crane Operator s Manual for mode selection instructions A WARNING System Under Pressure Do not disconnect any part of system until system is depressurized Components may shift suddenly causing bodily injury See Figure 4 19 for following procedure NOTE This procedure requires two persons one at the boom top and an operator in the cab Initial Setup 1 Cylinders begin retracted and connected to jib stops 2 Verify that accumulator pressure corresponds to pressure in following table depending on ambient temperature Ambient Temperature Pressure Interpolate as Required
29. Do not raise boom and jib combinations longer than specified on raising procedure chart e Raise boom to desired operating angle and position jib at required operating radius before lifting load block and or weight ball from ground 4 26 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL 1 Install load block and or weight ball if not already done 2 Slowly luff up to raise jib strut until jib straps clear strap storage brackets on jib and stop It will be necessary to use limit bypass switch to luff up if MAX UP 1 limit is on CAUTION Structural Damage Do not exceed 70 jib strut angle while boom is on ground Use mechanical angle indicator on jib strut to monitor strut angle 3 Slowly boom up to raise boom until jib straps are taut and stop Jib point rollers will roll along ground as boom and jib rise Pay out load lines as boom is raised CAUTION Jib Stop Damage Jib stop will not swing past boom top to operating position if steps 4 and 5 are not performed Damage could occur Jib stop will not operate properly 4 Continue to slowly boom up to raise boom and jib until boom angle is 60 or higher and stop Pay out load lines as boom is raised 5 Check boom to luffing jib angle If angle is more than 160 luff down until angle is 160 or less Jib stop will swing past boom top into operating position It will be necessary to use limit bypass switch to luff down if BLOCK U
30. 18000 LUFFING JIB OPERATOR S MANUAL Top to OR Bottom to Bottom FIGURE 4 39 3 Avoid reverse bend when winding wire rope onto drum wind from top of reel to top of drum or from bottom of reel to bottom of drum as shown in Figure 4 39 4 Avoid dragging wire rope in dirt or around objects that can scrape nick cut or crush wire rope Seizing and Cutting Wire Rope Apply tight seizings of annealed wire to the ends of all wire rope If not done the rope wires and strands may slacken This action will result in overloading of some strands and underloading of others Bird caging and breakage of the wire rope can occur Before cutting wire rope apply seizings on both sides of the point where the cut will be made Then cut the wire rope with a torch rope cutter or abrasive cut off wheel See Figure 4 40 for e Number of seizings to be applied to the ends of wire rope and to both sides of the point where a cut will be made Proper application method Each seizing should be one rope diameter long er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION Seizings Required A Preformed 1 WARNING Non preformed 2 Falling Load Hazard 22 mm Diameter or Smaller Wire rope can be pulled out of drum if following steps are Non preformed not taken 26 mm Diameter or Larger Wire Rope Type Install straight wedge so corrugated s
31. 2 16 Maintenance Instructions 2 16 Safe Maintenance 2 16 Boom Disassembly 2 18 General ee ta hte do tn dv tem 2 18 LOCATION RE 2 18 REMOVAL va a a ans is 2 18 Disassembly 2 18 Personnel Handling 2 20 Pedestal barge Mounted 2 21 Pedestal Mounted Crane 2 21 Barge Mounted 2 22 Published 06 20 08 Control 033 07 Index i TABLE OF 5 18000 LUFFING JIB OPERATOR S MANUAL Capacity Charts PE COEM oe ps 2 23 Shock Ladiga siess deese Pgiups 2 23 Operation On 2 24 Crane 2 24 Transporting Crane on Barge 2 24 Safety and Information 2 25 Maintaining Signs 1 2 25 Ordering 51905 ue ebore a p dud ede eid e t dte NEAR 2 25 SECTION
32. 2 Upper Boom Point and Jib Point Dimension A Left Hand Shown 1 04 in 26 mm Right Hand Opposite 4 FIGURE 6 12 mm Published 06 20 08 Control 033 07 6 19 ALPHABETICAL INDEX 44 Luffing Jib Lubrication lleeeeee RR 5 5 179A Luffing Jib Lubrication 47 5 5 Accessing Parts esl aas Ree dle maie 4 1 ecc M Dn 2 15 Approved Grease ois da e tec eet en e RR 5 1 Automatic Boom Stop 6 9 Block Level Sensor 4 94 Blocked Grawlers sonne imp o xm RU EVER WEAR Bee 4 2 Block Up Limit Installation and 6 14 Boom and Luffing Jib Angle Indicator Calibration 6 14 Boom Disassembly 2 18 Counterweight 4 2 Crane data c ec teen a Perseo pg RH Sh RON ER X
33. ar 1 6 jquuessy 917 T 1 abuis mr 8146 juiog woog os qir i J9 07 J9AQ SUI Hed Z UMA 8 ur gt peo1 JO uoneoo ur peo1J0 L f ti w ylusuej S dol woog 6 99S png uyn GEL dojs Jeylepy ci 14 6196 dol pedoo3 eg LEL JO Hed H H 6 ees 184 2 Lvl PSL 16 d Gununow jO 991 uonisog lutod pr 6 ees BLL Z 1 F ae Sun Bu 6 910 5 ce 6 910N 5 22 jexoeig Bununolwg REVISION 5 of 20 gt m z lt MANITOWOC CRANES NC 155 153 153 142 143 143 142 153 E 153 149 149 148 148 Ji ilb 11 141 K 144 EJ 150 9 ft Lg 1 146 Strain Relief 9 ft Lg rain Relie 9 Part Of Item
34. 2 5 Operators Manual Capacity Chart 2 7 Gerieral 2 LEVE usu suska nspa 2 7 Storing Manuals a ese utet cae 2 7 Safe Operating 2 8 Generali 3 1 E RSCLRPULROVLIQLLESRLRTLINO LES 2 8 Read Operator s 2 8 Operator 2 8 Operator Conduct nienti de Oo a Oe eee 2 8 Handling Load est ee aa ae ke ae ee dee 2 10 Signals 25525 tie tbe tici Dam betae o Dots todo oui seme tubes 2 12 Qperational Alds 2 5 Se tee a ees 2 13 Operating Near Electric Power Lines And Transmission 2 13 Electrocution 2 13 Set Up and 2 14 Electrocution Hazard 2 14 Electrical Contact teens 2 15 PROPUCNIAG x m Re RU ou 2 15 Fire Extinguishers hee doa ee 2 15 Accidents e eder PEE don RR 2 15 Safe Maintenance Practices
35. Removing Luffing Jib Perform the following steps to bypass the luffing jib stops and block up limits when the luffing jib is removed If you fail to perform these steps the operating limit alert will come on and you will not be able to boom down or hoist loads See Figure 6 1 for following procedure 1 Unplug electric cords from receptacles R1 R4 on boom node controller 1 2 Coil electric cords and fasten to boom top adapter frame for storage 3 Connect terminating plugs T1 T4 to receptacles R1 R4 on boom node controller 1 Boom Stop Adjustment For operation with luffing jib installed the boom stop must be set at 44 Luffing Jib e 85 44 Luffing Jib on 140 180 ft 42 7 54 9 m of 55 79A Boom e 87 44 Luffing Jib on 200 300 ft 61 0 91 4 of 55 79A Boom 79A Luffing Jib e 85 for 79A Luffing Jib on 140 180 ft 42 7 54 9 m of 55 or 55A Boom e 87 for 479A Luffing Jib on 200 340 ft 61 0 103 6 m of 55 or 55A Boom For operation with luffing jib removed the boom stop must be set at 83 Published 06 20 08 Control 033 07 6 1 MAINTENANCE 18000 LUFFING JIB OPERATOR S MANUAL Lead Wire Seal and R2 Roll Pin Typical Receptacle Terminal System Operation 51 1 White 1 22 24 Volts DC 1 2 Black 1 21 MAX UP 1 R1 3b S2 1 Green 52 21 UP 2 4b 52 2 Black Not Used S2 3 White S2 22 24 Volts DC S3 1 Whit
36. 12566 11643 81001117 192249 10486 12556 11594 81001107 Decal Warning Coolant Burn Hazard Italian Language see Note1 Decal Warning Coolant Burn Hazard Korean see Note1 DECAL Crawler Pins Controls English Language DECAL Crawler Pins Controls Chinese Language DECAL Crawler Pins Controls Spanish Language DECAL Crawler Pins Controls Italian Language DECAL Crawler Pins Controls Korean DECAL Caution Boom Equalizer Rails English Language DECAL Caution Boom Equalizer Rails Chinese Language DECAL Caution Boom Equalizer Rails Spanish Language DECAL Caution Boom Equalizer Rails Italian Language DECAL Caution Boom Equalizer Rails Korean DECAL Warning Crush Hazard English Language DECAL Warning Crush Hazard Chinese Language DECAL Warning Crush Hazard Spanish Language DECAL Warning Crush Hazard Italian Language DECAL Warning Crush Hazard Korean DECAL Warning Crush Hazard English Language DECAL Warning Crush Hazard Chinese Language DECAL Warning Crush Hazard Spanish Language DECAL Warning Crush Hazard Italian Language DECAL Warning Crush Hazard Korean DECAL Warning moving Part Hazard English Language DECAL Warning moving Part Hazard Chinese Language DECAL Warning moving Part Hazard Spanish Language DECAL Warning moving Part Hazard Italian Language DECAL Warning moving Part Hazard Korean A07388 DECAL Warning Pinch Point Hazard Englis
37. And Switch Asm Item 26 With 2 4 6 8 Or 10 Parts Of Line Over Lower Boom Point Load Pin 1 Can In Mounting Bracket On Boom Top Luffing Jib Angle Max Working Ref See Note 8 9 19 73 See Note 9 26 68 77 Upper Boom Point A08516 Ref 29 21 29 21 See Note 9 View K K Luffing Jib Angle Max Ref See Note 8 Wind Speed Ref Digital Output Ref Load Pin 2 Can Out See Note 8 Block Up Limit Lower Boom Point See Note 8 Block Up Limit Upper Boom Point See Note 8 View Of Bottom Of Boom Node Controller 10 of 20 Item 23 73 9ft Lg See Note 9 CRANES INC N e Load Sensor Link WIRELESS 5 LMI 07389 RANSCEIVER 6060 e ome JB 81000200 Limit Switch Assembly BLK UP X Block Up erminator denim Plug V WBM150440 WN12 81000194 81000201 81000196 A15346 A15488 0 15488 Cable Reel ie r On Boom Butt 81990290 5 54 Dx 199749 o 591121 06154 NC Upper Boom Lower Boom With Tandum Po
38. Boom Disassembly see Note 1 DESCRIPTION OF PART DANGER DECAL ENGLISH 1 147852 2 DECAL Danger Boom Hazard see Notes 2 amp 3 DANGER DECAL DUTCH 1 386315 2 DECAL Danger Boom Hazard see Notes 2 amp 3 DANGER DECAL CHINESE 1 386299 2 DECAL Danger Boom Hazard see Notes 2 amp 3 DANGER DECAL SPANISH 1 386300 2 DECAL Danger Boom Hazard see Notes 2 amp 3 DANGER DECAL FRENCH 1 386301 2 DECAL Danger Boom Hazard see Notes 2 amp 3 DANGER DECAL PORTUGESE 1 386492 2 DECAL Danger Boom Hazard see Notes 2 amp 3 DANGER DECAL GERMAN 1 A10090 2 DECAL Danger Boom Hazard see Notes 2 amp 3 DANGER DECAL RUSSIAN 1 A12529 2 DECAL Danger Boom Hazard see Notes 2 amp 3 DANGER DECAL ITALIAN 1 11581 2 DECAL Danger Boom Hazard see Notes 2 amp 3 Note 1 Applies to all pin connected booms jibs masts and towers Note 2 Two decals required on bottom chords 1 per side of butt and each insert at male connec tor end Note 3 Apply decal to clean smooth surface as close as possible to both bottom male connectors as shown ASSEMBLY REVISION PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 175916 NAMEPLATE amp DECALS BOOM DISASSEMBLY MANITOWOC CRANES INC Group A A o 9 9 d 9 69 72 E Es Rotating Bed B L m Front View Each Carbody
39. CAUTION Machinery Damage Before lengthening lubrication intervals check that all parts are receiving an adequate supply of clean lubricant otherwise parts will be damaged from a lack of lubrication Contact your Manitowoc Crane Care distributor for recommendations on lengthening lubrication intervals OVER LUBRICATION Over lubrication is not only wasteful but also harmful or grease which drips onto walkways can cause personnel to slip and be hurt An extra shot of grease if too stiff or under too much pressure can pop out a bearing seal LUBRICATION TIPS e Keep oil and grease dispensers and containers tightly closed and stored in a dirt and moisture free locations e Clean grease fittings before and after applying grease Apply grease until the bushing or bearing is purged so dirt and water cannot enter Wipe up excess grease OIL CAN POINTS Oil all pins not equipped with grease fittings with engine oil every 40 hours of operation even if the crane is not being operated WIRE ROPE LUBRICATION New wire rope is lubricated during manufacturing but this lubricant is only adequate for initial storage and the early stages of operation To prevent the damaging effects of corrosion and to reduce wear the wire rope must be lubricated at regular intervals Contact your wire rope manufacturer dealer for lubrication recommendations The lubrication interval and the type of lubricant used depends on the
40. Disconnect strut top straps 14 from strut butt straps 15 Store connecting pins in holes on strut top straps Rotate connecting links 9 View D to stored position Remove strap shipping pins 16 from holes and install in holes A as shown in View D Remove strap shipping pins 16 View C from holes A and install in holes B to secure strut straps to main strut top Pin adjustable links 6 to brackets 18 with connecting pin 7 as shown in View E If necessary adjust link 6 to shorter length Figure 4 21 View M before pinning Description Strap Bracket Strut Backstay Straps Strut Handling Pendants Counterweight Backstay Strap strut top Backstay Strap strut butt Strap Shipping Pin Link Strap Bracket er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION Jib Strut Supported Sling Attached to Lugs with Slings from in Jib Strut Top Main Strut Assist Crane Fully Lowered Boom Top and Required Inserts Supported on Blocking Figure 4 35 Main Strut Fully Rai Backstay Straps Raised Connected Raise and Lower Jib Jib Straps Disconnected ca NNUS x AVAVA VES 4 195 Jib Inserts Supported on Blocking as Required Figure 4 36 mm Published 06 20 08 Control 033 07 4 71 SETUP AND INSTALLATION Store Main Strut Top See Figure 4 21 for following procedure 1 Support main strut top 3 View A with slings from assist crane 2 Remov
41. PAST PRODUCTION General The luffing jib attachment is equipped with three limit switches Figure 6 1 which automatically stop the luffing hoist and apply its brake when the luffing jib is raised or lowered to the following angles NOTE Luffing jib angles given in this section can vary plus or minus 1 Luffing Jib Max Up 1 maximum working angle which automatically stops the luffing hoist when the boom to luffing jib angle is 168 The appropriate limit bypass switch must be turned to the bypass position to allow the jib to be raised an additional 1 2 to 2 to LUFFING JIB MAX UP 2 limit Luffing Jib Max Up 2 maximum angle which automatically stops the luffing hoist when the boom to luffing jib angle is 169 2 to 170 This limit can be bypassed with the limit bypass switch only when the attachment is lowered to ground boom below 50 Luffing Jib Max Down minimum angle 70 boom to luffing jib angle This limit cannot be bypassed The operating limit alert yellow light and buzzer in operator s cab comes on when the jib reaches any of the limits The operating limit alert also comes on any time the luffing jib is lowered below horizontal A WARNING Falling Attachment Hazard Do not operate crane unless luffing jib stops are properly adjusted and operational Operating luffing jib above MAX UP limit or below MIN limit is neither intended nor approved Jib can be pulled over backwards or collapse
42. 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 Crane Care distributor for a new one 2008 Manitowoc Published 06 20 08 Control 033 07 To Contact Us Manitowoc Cranes 2401 South 30th Street m Manitowoc WI 54220 920 684 6621 920 683 6277 fax http www manitowoccranegroup com MCG_MC Home EN BrandHome asp Grove Worldwide 1565 Buchanan Trail East P O Box 21 Y Shady Grove PA 17256 G ROVE 717 597 8121 717 597 4062 fax http www manitowoccranegroup com MCG_GRO Home EN BrandHome asp National Crane Corporation 1565 Buchanan Trail East P O Box 21 NATIONAL Shady Grove PA 17256 WV CRANE 717 597 8121 717 597 4062 fax http www manitowoccranegroup com MCG_NAT Home EN BrandHome asp Grove Worldwide 1565 Buchanan Trail East P O Box 21 Shady Grove PA 17256 PO TA IN 717 597 8121 717 597 4062 fax http www manitowoccranegroup com mcg_pot_am home en brandhome asp Technical Field Factory Publications Service Service Training 18000 LUFFING JIB OPERATOR S MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index heh memes Introduction Crane Dre UE 1 1 Crane attachment 1 1 Crane Orientation
43. 06179 81000193 WNBE 81000196 81000192 A15488 A15488 AT P 81000200 up Reel Cable Reel M Barsa On Jib Butt 54 195749 esas E On Boom Butt Optional Lower Boom 591121 Lower Luffing Upper Luffing 591121 Location Point Jib Point Jib Point Wiring Interconnect Diagram 79A Boom Top With 44 Luffing Jib And Upper Luffing Jib Point Luffing Jib Max Working A06182 0 Operating Angle S1 672710 er Luffing Jib Maximum 06180 1 Operating Angle S2 672710 Luffing Jib Minimum ea Operating Angle S3 06181 672710 Portal Node Boom Node Controller 165 Not Released Controller Adapter 9 5 9 08627 477333 a LUFF JIB SENSOR sucus 173732 477491 572390 Ref 477442 17 2M los E 59 195749 Lower QOr U Luffing nid Luf ng 02371 Jib Point Ji Point Jib Point 15488 6 Existing Can Bus 64 Cable Reel Boom Top From 2250 Construction A15486 25 06154 On Jib Butt Luffing Jib Maxer 2000 Optional Lower Boom 591121 Junction Box 15346 Location Point 268368 amp Wiring Interconnect Diagram 9 79A Boom Top With 2250 Existing Field 44 Luffing Jib And Upper Luffing Jib Point ASSEMBLY REVISION A05580 12 of 20 MANITOWOC CRANES INC OL woog 1 ddn p pu lx3 4 E 081 eur ejBuis eur HNN
44. 1 478 930 670 831 1 513 720 686 611 104 435 47 370 88 335 40 068 95 900 43 499 57 800 26 217 57 875 26 251 35 960 16 311 88 255 40 031 12 050 5 465 18 000 8 164 1 290 585 528 000 239 496 28 000 12 700 44 000 19 958 250 118 320 000 145 149 9 660 4 381 5 250 2 381 14 700 6 667 1 765 800 65 29 410 185 33 905 15379 20 485 9291 13 940 6 323 8 490 3 850 Q anitowoc Crane Care 18000 LUFFING JIB OPERATOR S MANUAL INTRODUCTION Weight Description Pounds Kilograms 7 ft 1 in 2 2 m upper backhitch strap each 485 219 13 ft 4 1 4 in 4 1 lower backhitch strap each 615 278 40 ft 6 1 m backhitch strap with connector links each 1 805 818 14 ft 8 in 4 5 backhitch strap each 665 301 Mast stop tube each with strut and pins 1 030 467 Mast support each 335 151 Wire rope guide on mast butt for whip line 490 222 Wire rope guide on 20 ft 6 1 m insert for whip line 600 272 Boom hoist drum without 8 110 3 678 BOOM NO 55 79A 20 ft 6 1 m 55 18 440 8 364 30 ft 9 1 m top with straps upper and lower point and wire rope guide 26 620 12 074 20 f
45. 12 54 gt k eih E Operator s Cab Kick Plate kan ua Left Side View Above Opening On Rotating Bed 29 Fach 330r34 Side 7 Jacking 35 32 n Cylinder i 22 344 Radio zm lt Remote Control 7 d Right Side Crawler Drive Left Side Similar 2 of 8 1uBi wu lunoo REVISION Y ASSEMBLY A06702 3 of 8 MANITOWOC CRANES INC uoe3 E E pjeoqino yoer uoe3 19 pieoqinO s pis 19 8S f o 09 64 oie 96 0S 3 70 Li apis 6 LS eon 2 2 16 A puy apis Jeon e e je 4 puy 1u
46. 5 420 2 458 Luffing jib adapter 4 600 2 086 31 ft 1 3 16 in 9 5 m basic strap each 400 181 20 ft 6 1 m strap with connector links each 290 131 40 ft 12 2 m strap with connector links each 525 238 Adjustable strap each with pins 1 565 709 mm Published 06 20 08 Control 033 07 1 7 C INTRODUCTION 18000 LUFFING JIB OPERATOR S MANUAL Weight Description Pounds Kilograms 50 ft 15 2 m jib strut with guide sheave luffing sheaves and links 13 285 6 025 47 ft 14 3 main strut with luffing sheaves and links 9 425 4275 Luffing wire rope guide 1 070 485 38 ft 2 in 11 6 m backstay basic strap with connector links each 510 231 10 ft 3 0 m backstay strap with connector links each 175 79 20 ft 6 1 backstay strap with connector links each 290 131 40 ft 12 2 m backstay strap with connector links each 525 238 40 ft 12 2 m transition backstay strap with connector links each 525 238 10 ft 3 0 m No 55 backstay strap with connector links each 405 183 20 ft 6 1 No 55 backstay strap with connector links each 675 306 40 ft 12 2
47. Adjustment with luffing 6 11 Physical Boom Stop sereset teeseen eer RP PRG need 6 12 General sc tacos dain hares Sais Pai gd Peed Aes SE wa he eee eels 6 12 2 gah Sa dels aye Ge Q 6 12 Boom and Luffing Jib Angle Indicator Calibration 6 14 Block Up Limit Installation and 6 14 General o ror gue IER Ree AEE PONO EDU AO De ene 6 14 Block Up Limit Control 6 14 Disconnecting Block Up Limit 6 17 Removing Upper Boom Point or Jib 6 18 Storing Electric 6 18 ert eie oo SR PM sage aah 6 18 y a bep epe 6 19 18000 LUFFING JIB OPERATOR S MANUAL MAINTENANCE SECTION 6 MAINTENANCE GENERAL MAINTENANCE This section contains maintenance and adjustment instructions for the limit devices used with the luffing jib attachment For maintenance and inspection of the following components see the Service Manual supplied with your crane Straps e Wire Rope e Load Block and Weight Ball Boom and Jib JIB STOP ADJUSTMENT
48. Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL LUFFING JIB RIGGING GUIDE 79A General The following installation raising lowering and removal instructions apply to the 79A luffing jib mounted on 55 or 155A boom As shown on the Luffing Jib Assembly drawing 20 ft 6 1 m and 40 ft 12 2 m inserts from a 79 boom can be used to make the desired jib length However the jib has a different 20 ft 6 1 m butt with a special 20 ft 6 1 m insert and a different top Assist Crane Requirements An assist crane is required for jib installation and removal SETUP AND INSTALLATION The heaviest individual parts to be lifted are the strut tops which are shipped assembled together This assembly weighs approximately 18 500 Ib 8 392 kg The assist crane must also be capable of handling the following weights e Main Strut 50 000 Ib 22 680 kg during strut raising and lowering The assist crane must have a hook height of 110 ft 33 5 m minimum maximum of 100 000 Ib 45 360 kg when lifting jib point onto the dolly This is 1 2 the weight of the maximum jib length Published 06 20 08 Control 033 07 4 35 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL THIS PAGE BLANK 4 36 Published 06 20 08 Control 033 07 Gan c Crane Care 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION View C P1231 E X nu AN pol 4 all pe 7 2 1B Vie
49. Control 033 07 6 7 MAINTENANCE 18000 LUFFING JIB OPERATOR S MANUAL Limit Switch Wiring Switch Terminal 22 Receptacle Operation Max Angle LED Ground Bus 24V DC System Bus Description 1 Lower Boom Point 2 Load Block 3 Platform 4 Spring Washer 5 Spring 6 7 8 Dowel Pin Actuator Rod Jam Nut 9 Adjusting Rod 10 Store Extra Adjusting Rod Here 11 Coupling 12 13 Limit Switch 14 Boom Butt 15 Roller Over Travel 3 1 2 in 89 mm Boom Only Pre 3 in 76 mm with Luffing Jib a A831 HI D 8 14 4 oe 5 11 View A SWITCH CLOSED Center of Freely lt W Suspended Load Block or Single Part Line 15 8 Front Edge of Rotating OFF 2 Bed Adapter Frame at Center of Crane View B SWITCH OPENED FIGURE 6 4 6 8 Published 06 20 08 Control 033 07 c Crane Care 18000 LUFFING JIB OPERATOR S MANUAL AUTOMATIC BOOM STOP ADJUSTMENT See Figure 6 4 for the following procedure Maximum Operating Angle A limit switch Figure 6 4 automatically stops the boom hoist and applies its brake when the boom is raised to the following angle e 83 for 55 79 Boom without Luffing Jib e 83 for 55 79A Boom without Luffing Jib e 83
50. Manitowoc Cranes Inc Serial 18005910 WIND CONDITIONS FOLIO 2067 WIRE ROPE SPECIFICATIONS 8516 A SECTION 2 SAFETY INFORMATION TABLE OF CONTENTS Diesel Engine Exhaust sse ete emo e eme ae 2 1 Nameplates and 2 1 Safety Messages cies eg mese e Wd ede RR q bee p RU 2 1 Generale sah ax dus deli dte aca e use Se 2 1 Safety Alert Symbol 2 1 Signal Words nao e wea accen A d n u enn 2 1 Safety Symbols iain pauta mex atc acredite Au rede 2 1 Luffing Jib Attachment Access 2 5 CCCII 2 5 Getting On 2 5 Personnel Fall Protection 2 5 Operators Manual Capacity Chart 2 7 General sed laa a ha Heise Rte 2 7 Storing Manuals recae om aE OW occae ne in anc aqata ne 2 7 Safe Operating 2 8 General EE 2 8 Read Operator s 2 8 Operator 2 8 Operator Conduct sls E e 2 8 Handling LOAD rte tee tee ct ce t ed
51. Spanish Language DECAL Warning Tipping Hazard Italian Language DECAL Warning Tipping Hazard Korean Language DECAL Caution Tire Inflation English Language see Note 6 DECAL Caution Tire Inflation Chinese Language see Note 6 DECAL Caution Tire Inflation Spanish Language see Note 6 DECAL Caution Tire Inflation Italian Language see Note 6 DECAL Caution Tire Inflation Korean Language see Note 6 LUFFING JIB OPTION 181503 A10003 A10003 A15471 A11648 81001122 1 1 1 1 1 DECAL 1 0 USA Made English Language DECAL Operating Instructions English Language DECAL Operating Instructions Chinese Language DECAL Operating Instructions Spanish Language DECAL Operating Instructions Italian Language DECAL Operating Instructions Korean Language 80 BOOM LADDER OPTION 69 177837 09072 13358 11588 8100725 DECAL Warning Boom Ladder English Language DECAL Warning Boom Ladder Chinese Language DECAL Warning Boom Ladder Spanish Language DECAL Warning Boom Ladder Itallian Language DECAL Warning Boom Ladder Korean Language 81 BOOM LADDER OPTION 72 8 of 8 177837 A09072 A13358 A11588 8100725 DECAL Warning Boom Ladder DECAL Warning Boom Ladder Chinese Language English Language DECAL Warning Boom Ladder Spanish Language nt DECAL Warning Boom Ladder Itallian Lan
52. View F Storage Cylinder Lug 4 126 1 View G Retaining Pin as storage hole m trap Store Locking Pin Here M gt Strap Cable Pin with Collar Locking Pin and Retaining Pin FIGURE 4 12 erection position 4 20 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Raise Jib Strut See Figure 4 12 for following procedure unless otherwise noted WARNING Moving Part Hazard Do not stand on boom top or jib butt while either strut is being raised or lowered Wait until struts are stopped and supported by an assist crane or luffing hoist wire rope before climbing onto boom top or jib butt NOTE While raising strut use mechanical angle indicator mounted on jib strut to monitor strut angle 1 Haul in luffing hoist wire rope until main strut is near vertical and jib strut just starts to rise View A 2 Attach both erection pendants to storage bar on main strut with shackles on ends of pendants Figure 4 9 View A 3 Continue hauling in luffing hoist wire rope to slowly raise jib strut to approximately 45 and stop View G 4 While raising jib strut observe strut stop cylinder rod ends Following adjustments were made at factory and should not require field adjustment a Make sure rod ends do not interfere with any part of strut stop frames View B If interference occurs readjust washe
53. Working Ref See Note 8 9 19 73 See Note 9 26 68 77 Upper Boom Point A08516 Ref 29 21 29 21 See Note 9 View K K Luffing Jib Angle Max Ref See Note 8 Wind Speed Ref Digital Output Ref Load Pin 2 Can Out See Note 8 Block Up Limit Lower Boom Point See Note 8 Block Up Limit Upper Boom Point See Note 8 View Of Bottom Of Boom Node Controller 8 of 20 Item 23 73 9ft Lg See Note 9 MANITOWOC CRANES INC pexi4 10 gir Burn V6Z pedoo eg ISN 9 JO Hed Jolley 5 jutog woog 1 A01 epis 1e dol pexiJ 10 v67st uonisod d ASIA ul umoys png air eur 2 Hed ju a 2 Jayiwusues JuDI9AA ejBuy xoolg qir 4901 X L _ aun 10 sued Assy 1exoelg 9 0 10 89v Z UIM LINSM 00 woog VSS JO SS dojuooguo 9 JONY 2 _ pg 20 Bian JO uoneoo1 9 9 30N ME c s 304 SS JIAA Sun 2 v9 ss x 42 yur 8 96 2 air 6 7 89 3005 616 88 88 9 6101 BTU ZI 66 99 eun dol qif uo xooH 4 22 8p v podoo1 eg
54. X N Al X 49 ft 5 1 4 in e 15 07 I 5 ft 10 in 1 78 i A I 5ft 1 52 m 23 ft 3 3 4 in a 1 7 11 m dil 21 ft 6 3 4 i LL 6 57 m Ar 2 47 ft 10 1 4 in U zo rame E 11 41 2 5 44 m 3 46 8 ft 6 1 4 in 6ft gt ds ft 5 in 2 6 ft 3 1 4 in 25 0 Te 2 60 m 2 07 m 5 00 Y Y vey 7 Y Y Y 1 102 Outline Dimensions Continued on Next Page 1 4 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL R 33 ft 4 3 4 in 10 18 m Tailswing P 9 ft 10 in 3 00 m 33 ft 4 in ug 10 16 m 29 ft 6 3 4 in 9 01 m Ln ft 4 1 4 n 3 46 m 1 103 1 52 1 52 Published 06 20 08 Control 033 07 51 ft 2 3 4 in 15 62 INTRODUCTION 52 ft 7 3 4 in 16 05 m 1 5 INTRODUCTION 18000 LUFFING JIB OPERATOR S MANUAL CRANE WEIGHTS Description LIFTCRANE Upperworks and lowerworks complete 4 swing drives counterweight 30 ft 9 1 m live mast backhitch 100 ft 30 5 m No 56 Mast mast stops 30 USt 27 t hook and weight ball boom stops and load lines includes self erect and MAX ER prep When equipped with fully rigged 120 ft 36 6 m Boom No 55 79A standard upper boom point 500 USt 454 t block When equipped with fully rigged 120 ft 36
55. and fill tank though fill port with pre filtered Arctic 15 hydraulic oil MCC A03745 If oil level is more than 1 2 cups of oil low thoroughly inspect system for oil leaks Repair as required Move pump handle 4 back and forth until oil level is at low mark on dipstick Gauge reading must be 2 450 2 500 psi 169 172 bar 10 Apply hydraulic thread sealant to threads and securely reinstall dipstick 3 and fill plug 2 Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL LUBRICATION Item Description Hydraulic Tank Fill Plug Dipstick Pump Handle Accumulator Pressure Gauge Jib Stop Safety Latch Positioner Cylinder Lock Nut Valve Screw o 00 Both sides of Boom FIGURE 5 2 ads Published 06 20 08 Control 033 07 5 7 SECTION 6 TABLE OF CONTENTS MAINTENANCE General Maintenance 6 1 Jib Stop Adjustment Past 6 1 entend ehe Hentai ten de x eaves 6 1 Removing Luffing 1 6 1 Boom Stop Adjustmeht tma odo alee ER Let 6 1 44 Luffing JID z dee etd a Seiten Ernte Eten acted he ge 6 1 FTOALUTING UID cs tpa m rer ath ane d iet 6 1 Maintenance x zoe PAR dax hax me ases hace 6 3 AQJUSIMON
56. automatically by the crane s programmable controller as part of the load indicator calibration procedure See Rated Capacity Indicator Limiter Operation manual for instructions Potentiometer Mounted Inside Typical Node Controller Installation on Boom or Luffing Jib Top FIGURE 6 7 BLOCK UP LIMIT INSTALLATION AND ADJUSTMENT General A block up limit control also called anti two block device is a two blocking prevention device which automatically stops the load drum from hoisting and the boom from lowering when a load is hoisted a predetermined distance DEFINITION Two blocking is the unsafe condition in which the load block or the weight ball contacts the sheave assembly from which either is suspended Two blocking can result in failure of sheaves and wire rope possibly causing load to fall 6 14 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL A WARNING Two Blocking Hazard Block up limit control is a protective device designed only to assist operator in preventing a two blocking condition any other use is neither intended nor approved Block up limit control may not prevent two blocking when load is hoisted at maximum single line speed Operator must determine fastest line speed that allows block up limit control to function properly and thereafter not exceed that line speed The block up limit system consists of the following components See to Figure 6 8 1 Normally clo
57. or jib butt during disassembly Haul in assist crane load line until erection pendant is hanging vertically above main struts Keep pendant slack 4 Disconnect basic backstay straps from backstay straps 1 out luffing jib hoist line Drum 6 to lower jib strut MOW E Coil hoses and tie them to jib strut for storage Continue lowering strut until jib straps are restingin 5 Pin links in storage position on boom Figure 4 14 View strap brackets and adjustable straps are fully retracted B Figure 4 10 View G Strut will be at approximately 45 6 Attach taglines to end of basic backstay straps Taglines Remove locking pins from storage holes and install in should be about 20 ft 6 1 m long adjustable straps Figure 4 10 View H Luff up or down 7 Slowly haul in luffing hoist wire rope while paying out to align holes in straps load line from Drum 1 to pull main strut forward 3 Disconnect inner straps from jib straps Figure 4 10 Match rate of speed that luffing hoist wire rope is View J Luff up or down to loosen pins hauled in with speed that load line from Drum 1 is Store pins in inner straps payed out so strut moves smoothly past vertical 4 Store adjustable straps a Release ratchet on hand winch Figure 4 10 View 2 e Guide basic backstay straps into storage brackets b Disconnect cable from storage lug on jib strut on side of strut with taglines Figure 4 10
58. state or federal regulations Engage boom hoist pawl when operating with boom at a fixed radius traveling operator shall take following precautions a Sound signal horn before traveling intermittently while traveling especially when approaching personnel Carry boom in line with lowerworks and facing direction of travel Do not position boom so high that it could bounce over backwards whether traveling with or without load Lock upperworks against rotation except when it is necessary to negotiate a turn and then only when operator is seated at controls or the boom is supported on a dolly Lash or otherwise restrain unused hooks so they cannot swing freely Before traveling with a load operator shall take following additional precautions WOL Published 06 20 08 Control 033 07 2 11 72 SAFETY INFORMATION a A designated person shall be responsible for operation Decisions such as necessity to reduce crane ratings load position boom position ground support and speed of movements shall be in accordance with designated person s decision b Maintain specified tire pressures truck cranes C Avoid sudden starts and stops Use taglines or other restraints to control position of load Multiple Load Line Operation Multiple load line operation is becoming common practice for applications like panel tilt up pile tilt up pile driving rolling fabricated sections etc The multiple lines
59. without luffing 6 10 Adjustment with luffing 6 11 Physical Boom Stops eoe aire Ee Pa aka aa ha aa UR PCR 6 12 General Roses ore antes n DO RC Bebe Pete A 6 12 Operation tests deed eden urat aq XEM RH 6 12 Boom and Luffing Jib Angle Indicator 6 14 Block Up Limit Installation and Adjustment 6 14 UP 6 14 Block Up Limit Control Operation 6 14 Disconnecting Block Up Limit 6 17 Removing Upper Boom Point or Jib 6 18 Storing Electric Cable 6 18 un e oe 6 18 Adjustment ee Ed de Eas ace enr 6 19 Index iv Published 06 20 08 Control 033 07 Cansrowoc SECTION 1 INTRODUCTION TABLE OF CONTENTS Grane data uuu a tard PDT 1 1 Crane attachment Identification 1 1 Crane Orientation E ee Sok ke Sen aab a e hen ac e ee la 1 1 Identification And Location Of Components 1 2 Outline DIMENSIONS eid
60. x 4 1 2 long PIN 1 2 dia x 4 1 8 long PIN PIN TIMBER 3 1 2 x 3 1 2 NUT Lock NE 3 8 16 PIN Cotter 3 16 x 1 1 2 long PIN Cotter 1 4 x 1 3 4 long PIN Safety 1 4 O D x 5 long SCREW Hex Cap 3 8 16 x 4 1 2 long grade 5 WASHER Flat 3 8 GUIDE ASSEMBLY Wire Rope BOOM POINT ASSEMBLY PIN 1 Hole w Hd PIN 2 Hole COLLAR STRAP 28 2 15 16 LINK 10 SCREW Machine 5 16 18 x 1 1 4 long ZC Steel NUT Hex 5 16 18 ZC PIN Cotter 1 8 x 1 1 2 long WASHER Lock 5 16 SIGN Boom Manitowoc 37 x 96 N N N gt N N N G o MODEL 18000 LUFFING JIB RIGGING 44 Luffing Jib on 55 79A Boom with 100 Mast DESCRIPTION OF PART If boom top does not have lugs to support roller assembly A05312 item 22 use roller assembly A00678 in place of A05312 3144 2 piece butt requires modification 417346 44 1 piece butt requires modification 417345 Shim cylinder lugs to center cylinder rod end on boom top cylinder guides 28 mm wire rope 1 wire rope Tighten locknuts efficiently to clamp bearing inner race For 1 4 wire rope Items required for adding luffing jib to existing equipment or use same items from insert assemblies for machines with luffing jib equipped With wire rope guides for luffing jib O 539 562 573 890 1208 O 1209 O 1224 O 1225 1409 07766 PLEASE GIVE MACHINE SE
61. yellow light and buzzer comes on and the digital display indicates which limit has been reached Three jib stop limits are provided e Luffing Jib Max Up 1 maximum working angle which automatically stops the luffing hoist when the boom to luffing jib angle is 168 The appropriate limit bypass switch must be turned to the bypass position to allow the jib to be raised an ppum Identification additional 1 2 to 2 to LUFFING JIB MAX UP 2 limit Main Hoist 1 in boom insert e Luffing Jib Up 2 maximum angle which Main Hoist 2 in boom butt automatically stops the luffing hoist when the boom to Whip Line Hoist luffing jib angle is 169 2 to 170 Boom Hoist in mast butt Mast Hoist This limit can be bypassed with the limit bypass switch only when the attachment is lowered to ground boom below 50 Luffing Jib Hoist in boom butt The luffing jib can be lowered after either limit is contacted A WARNING Falling Boom Jib Hazard Do not raise luffing jib above Max Up 2 limit Structural damage will occur possibly causing boom and luffing jib to be pulled over backwards Make sure luffing jib limits are enabled for normal operation bypass switch turned counterclockwise FIGURE 3 4 Description orizonta Luffing Jib Down limit which automatically stops the Boom Angle luffing hoist when the boom to luffing jib angle is 70 Boom to Luffing Jib Angle Luffing Jib Ang
62. 0 0283 Cubic Inch in Pump Displacement Cubic Centimeter cm 16 3871 18000 LUFFING JIB OPERATOR S MANUAL INTRODUCTION To Convert Symbol Application To Symbol Multiply By VOLUME LIQUID Ounce 07 Milliliter mL 29 5735 Pint pt Liter L 0 4732 Fluid Capacities Quart qt Liter L 0 9464 Gallon gal Liter L 3 7854 Gallon Per Minute gpm Pump Flow Liters Per Minute L min 3 7854 WEIGHT Pound Ib Unit Component Kilogram kg 0 4536 US Ton 2 000 Ib USt Metric Ton t 0 9072 Load Ratings 7 US 2 000 Ib USt Kilogram kg 907 1847 MANITOWOC CRANE CARE DISTRIBUTORS To locate the Manitowoc Crane Care distributor nearest you 4 Follow on screen instructions to locate your Manitowoc Crane Care distributor When calling a distributor with parts or service questions you need to know the model and serial number of your crane or attachment This information is located on the Crane Identification Label on the crane cab or on the attachment 1 Goto www manitowoc com 2 Click on Manitowoc logo 3 Click on Dealers Published 06 20 08 Control 033 07 1 11 OPERATOR S MANUAL SECTION 1 INSERTS 18000 Luffing Jib Serial Number 18005910 Basic Specs Basic Specs 08 13 2008 Serial 180059 10 BASIC SPECIFICATION TYPE LUFFING JIB ATTACHMENT MODEL 18000 LUFFING JIB S O NUMBER 1850 SERIAL NO 18005910 MONTH SHIPPED AUGUST 2008 BOOM D
63. 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL NOTE Itis normal for BLOCK UP UP 1 and MAX UP 2 limits to come on during the lowering procedure 1 Swing upperworks in line with lowerworks so boom is over front of crawlers 2 Travel crawler rollers onto blocking if required 3 Swing boom and jib slightly to either side of center and lower load block and or weight ball to ground 4 Swing boom and jib in line with crawlers CAUTION Jib Stop Damage Jib stop will not rotate to proper storage position if step 5 is not performed 5 Position boom at 60 or higher boom angle and lower luffing jib to 160 or less boom to luffing jib angle View E 6 Slowly boom down until jib point rollers contact ground It will be necessary to use limit bypass switch to boom down if BLOCK UP limit is on Haul in load lines as boom and jib are lowered but do not lift load block and or weight ball off ground CAUTION Structural Damage Do not exceed 70 jib strut angle while boom is on ground Use mechanical angle indicator on jib strut to monitor strut angle 7 Perform Jack Knife Lowering Procedure steps 7 12 to lower boom and jib remaining distance e 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 1275 ITEM NUMBERS CORRESPOND JACK KNIFE LOWERING PROCEDURE STEPS LAU 4 144 FIGURE 4 17 mm Published 06 20 08 Control 4 033 07
64. 1 1 Crane Orientation 1 1 Crane Orientation 4 1 Crane Weights Ae aV ee od decia ed 1 6 Crane Weights cnr eld PARV ex V P dry 4 2 Crane attachment 1 1 Diesel Engine Exhaust dac aat eren 2 1 English And Metric Conversions 1 10 Fire Extlngulshers eue Lco e Erde ee NDS ies 2 15 General 5 1 General Maintenance 6 1 General 2 0 3 4 General Setup and Installation 4 1 Handling 2 4 2 Identification And Location Of Components 1 2 Identifying Jib 4 2 Jib Stop Adjustment Current 6 4 Jib Stop Adjustment Past 6 1 Load Line Reeving 44 Luffing 4 80 Load Line Reeving 7
65. 1 Hole w Hd PIN 2 Hole COLLAR STRAP 55 79 Transition LINK 55 79 Transition BOOM INSERT ASSEMBLY 20 79 Boom INSERT 20 see O 562 PIN PIN PIN STRAP LINK Strap PIN Strap PIN Strap Bracket COLLAR TIMBER J S N N N FANNON N S N N MODEL 18000 LUFFING JIB RIGGING 44 Luffing Jib on 55 79A Boom with 100 Mast DESCRIPTION OF PART 194378 PIN Luffing Jib Equipped see Note 8 96 179839 2 STRAP 97 192250 LINK Strap 98 179863 PIN Strap 99 78292 PIN Strap Bracket 100 179862 COLLAR 101 179959 PIN TOP 79A BOOM 180 05401 181 05460 R182 78292 R183 179862 R184 179863 R185 179959 186 193888 R187 193889 R188 194123 R189 548342 R190 562085 R191 562106 R192 563640 R193 612480 R194 709703 R195 05882 R196 A06074 R197 A06149 R198 A06150 R199 A06151 R200 A06348 R201 A06349 R202 254555 R203 546053 R204 562045 R205 710303 R206 A02735 OPTIONAL PARTS 102 07773 500T HOOK ASSEMBLY see 1209 103 A07752 450T HOOK ASSEMBLY see O 1208 104 237074 250MT HOOK ASSEMBLY see O 1224 105 236505 100T HOOK ASSEMBLY see O 1225 106 A00816 SWIVEL HOOK ASSEMBLY 30T 107 A14753 250 M Tonne Hook Assembly O 1409 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER A07766 21 of 22 BOOM TOP ASSEMBLY 79A TOP Boom machining see O 562 PIN COLLAR 3 dia x 1 long PIN 1 Hole w Hd 2 1 4 dia
66. 1 REEL Cable 94 7126151256 4 SCREW Hex Serrated Flange M6 x 25 95 612456 4 SCREW Hex Cap 3 8 16UNC 2A x 1 1 4 long 96 624633 1 SHACKLE Anchor 5 16 round pin 97 667007 3 STRAP Stay see Note 7 98 667042 12 STRAP Stay see Note 6 99 669280 3 STUD Wire Tie see Note 7 100 A18332 8 WASHER Lock External Countersink 1 4 see Note 9 101 710304 4 WASHER Lock 3 8 103 A07759 1 CABLE Electric Luffing Jib WLJ3K325 104 A08628 1 CONTROLLER Boom Luffing Jib Node 105 07068 1 CABLE Electric Block Up Limit 106 A06179 1 CABLE Electric Boom Extension WBNE18 A05580 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 16 of 20 CONTROL WIRING Boom amp Limits DESCRIPTION OF PART ADD FOR 44 LUFFING JIB NEW CONSTRUCTION 112 142403 113 195749 116 334101 118 A18331 119 546054 120 591121 122 7126151256 123 612456 124 624633 126 667042 128 18332 129 710304 131 81000191 132 08628 133 81000192 134 81000195 WEIGHT SWITCH ASSEMBLY CHAIN Straight Link 9 long NUT KEPS M 1 0 zinc NUT Hex 3 8 16UNC 2B REEL Cable SCREW Hex Serrated Flange M6 x 25 SCREW Hex Cap 3 8 16UNC 2A x 1 1 4 long SHACKLE Anchor 5 16 round pin STRAP Stay see Note 6 WASHER Lock External Countersink 1 4 see Note 9 WASHER Lock 3 8 CABLE Electric Boom PWR COMM WBM250 CONTROLLER Boom Luffing Jib Node CABLE Electric Block Up Limit 6 long CABLE Electric Boom Extension PWR
67. 13 14 15 Remove pin 6 from Hole B and insert in Hole A so cylinders cannot extend View E Pay out Drum 3 load line so line is slack Luff up as needed to remove load from pins 9 View B Remove pins 9 View B from lower holes and store in upper holes View A Luff down to retract strut stop tubes Remove tube retaining pins 8 View G from Hole A and insert in Hole B Luff up slightly to remove load from strut stop pins 5 View F Remove pins 5 and luff up until stops can be swung to strut View E Continued on Next Page Component Identification for Figure 4 33 Item Description Description 1 Luffing Hoist Line Drum 6 Main Strut Strut Stop Boom Top Pin with Cotter Pins Cylinder Rod Retaining Pin Lug Tube Retaining Pin Strut Locking Pin Handling Pendants O Q OMN Published 06 20 08 Control 033 07 11 12 13 14 15 16 17 18 19 Crane Counterweight Boxes Sling and Shackle Retaining Pin with Cotter Pins Shackle user supplied Links Link Socket Pin with Cotter Pin Drum 3 Load Line er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 3 working P2129 View H 3 1 stored 2 P2130 View G POSITION C 12 POSITION B 9 s POSITION 13 ataa VAVA VAV ITA VAVA VAAT ES A 8 AIM 7 6 View A 9 16 T 14 15
68. 131 Node E Must Be Looped Over Controller T Hook On Jib Top SS 132 1 4f E E Pise Ul n WBMJ8 Sh 12 Y Gi gt 150 777 150 p 255 SHE 2 D SX E VA ingle Pa Ise p Line Y a View J J NN 2 Jib Top iew J NET Z Left Side Upper Luffing Jib Point 131 ZZ Y 174211 Ref From Cable NN Q 2 14 Reel A ie 22 11 Wind Speed 7 Transceiver Ref Out To Jib Top Node Controller TEN L Digital Output View 3 MOM WED 9759 r Load Load Pin 2 Pin 1 eS Can In Block Up Limit Lower Jib Point See Note 8 Can Out See Note 8 Block Up Limit Upper Jib Point See Note 8 View Of Bottom Of Jib Node Controller Item 132 6 of 20 MANITOWOC CRANES INC Location Of Load Link Item 9 189 with 12 Or More Parts Of Line Location Of Load Link Item 9 9 Over Lower Boom Point And Switch Asm Item 26 With 2 4 6 8 Or 10 Parts Of Line Over Lower Boom Point Boom Point Lower Assy poe 55 Or 55A Ref E m 79 Sid Far 71 68 Near Side 52 50 Side Upper Boom Point Node Controller 23 Note Direction Of Load Link Location Of Load Link Item 8 With 2 Part Line ver Upper Boom Point Over Upper Boom Poi Boo
69. 20 ad Published 06 20 08 Control 4 033 07 4 41 SETUP AND INSTALLATION Installing 79A Luffing Jib Install Jib and Main Strut Butts See Figure 4 20 for following procedure NOTE Main strut butt 1 and jib strut butt 2 are shipped together as shown in View A Main strut butt is above jib strut butt 1 Using appropriate slings lift jib strut main strut butts into position at boom top 3 and align jib strut butt connecting holes View A 2 Connect jib strut butt 2 to boom top 3 with connecting pins 4 View D pin heads toward outboard side 3 Securely fasten keeper plates 5 View D to pins 4 4 Temporarily attach end plates 6 View D over ends of pins 2 Block top end of jib strut butt approximately 3 ft 0 9 m high 5 Lower main strut jib strut butts onto blocking about 3 ft 0 9 m high 6 Support main strut butt 1 with slings from assist crane and remove shipping pins 9 View A 7 Remove pin 8 View A from strut support A 7 8 Rotate strut support A 7 to stored position on jib strut butt and connect to lugs with pin 8 View Main strut butt is now separated from jib strut butt 9 Lift main strut butt about 1 ft 300 mm clear of jib strut butt 10 Store shipping pins 9 View C in lugs on jib strut butt 11 Lift main strut butt 1 into position at boom top 3 and align connecting holes 12 Using pins 12 View M connect main strut butt to boom top 13 Remove st
70. 4 44 The dead wraps of wire rope on the drum can become slack during operation even if the utmost care is used during installation of the wire rope This slackening is caused by the normal stretch that occurs in a new wire rope under tension and periodically throughout the wire rope s life from release of the load When slackness is noted tightly wind the dead wraps of wire rope onto the drum If left uncorrected a wedging action with subsequent layers will occur and the resultant abrasion may cause broken wires in the dead wraps Canrrowoc 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION PAD EYE USAGE FOR WIRE ROPE 3 Inspect pad eye prior to each use Replace it if REEVING e Original dimensions have changed Figure 4 45 See Figure 4 45 for following procedure e Cracks or breaks exist in metal or weld General Some rotation resistant wire rope supplied by Manitowoc is A WARNING equipped with a No 1 5 pad eye welded to the leading end of the wire rope Flying Part Hazard Pad eye on end of wire rope has been provided for A sucker line can be attached to the pad eye to make it reeving purposes only Any other use is neither easier to reeve the load block intended nor approved Safety Pad eye can break and fly apart with considerable force if it is overloaded not used properly or not maintained 1 For No 1 5 pad eye do not exceed 4 45 KN single line properly pull 2 Make sure sucker line and rope cli
71. 4 mm wire rope 2 00 Ib per ft 2 98 kg m 1 700 ft 518 No 44 LuffingJib 3 100 ft 945 m No 79A LuffingJib Load lines 32 mm wire rope 3 74 Ib per ft 5 57 kg m 3 700 ft 1 128 m Drum 3 400 ft 1 036 Drum 2 28 mm wire rope 2 76 Ib per ft 4 11 kg m 4 800 ft 1 463 m Drum i 4 000 ft 1 158 Drum2 Whip lines 28 mm wire rope 2 76 Ib per ft 4 11 kg m 1 900 ft 579 m Drum 3 5 5 5 5 5 p A de Published 06 20 08 Control 033 07 C INTRODUCTION Weight Pounds Kilograms 495 224 115 52 180 81 850 385 100 45 120 54 380 172 340 154 2 715 1231 40 18 8 790 3 987 5 900 2 676 8 550 3 878 5 365 2 433 1 980 898 260 117 180 81 160 72 610 276 1 120 508 360 163 115 52 7 800 3 538 11 615 5 268 1 115 505 1 630 739 25 100 11 385 24 500 11113 21 300 9 661 17 400 7 892 3 900 1 769 2 800 1270 1 800 816 2 215 1 004 11 360 5152 3 400 1542 6 200 2812 13 840 6 277 12 715 5 767 13 250 6010 11 040 5 007 5 245 2 379 1 9 ENGLISH AND METRIC CONVERSIONS Direct Conversion MULTIPLY x known value by conversion factor to obtain equivalent value in desired units For example 12 ft is converted to meters m as follows 12 ft x 0 3048 3 6576 m Inverse Conversion DIVIDE 1 known value by conversion factor to obtain equiva
72. 7 Inserts Boom Insert Supported on Blocking FIGURE 4 37 Published 06 20 08 Control 033 07 4 73 SETUP AND INSTALLATION WIRE ROPE INSTALLATION NOTE Wire rope installation instructions from various Original Equipment Manufacturers OEM are provided at the end of this section If a conflict exists between the following instructions and the OEM instructions the OEM instructions apply Wire Rope Storage Store wire rope in coils or on reels off the ground or floor in a clean and dry indoor location If outdoor storage is necessary the wire rope must be covered with a protective wrapper Keep the wire rope away from acids fumes and other corrosives Keep the wire rope away from heat that can dry out the lubricant If the storage period will be long lubricate the wire rope and perform periodic inspection given in this section at least monthly Removing Wire Rope from Shipping Reel CAUTION Wire Rope Damage Shipping reel must rotate when wire rope is unwound Attempting to remove wire rope from a stationary reel can result in a kinked wire rope and wire rope will be ruined 1 Mount wire rope shipping reel on a shaft supported at both ends by jacks or blocks as shown in Figure 4 38 Shipping Reel FIGURE 4 38 2 Provide a brake at shipping reel see Figure 4 39 so wire rope can be wound tightly onto drum 4 74 Published 06 20 08 Control 033 07
73. B P2122 View D View C Figure 4 34 P2123 Published 06 20 08 Control 4 033 07 4 69 SETUP AND INSTALLATION Lower Main Strut continued See Figure 4 34 for following procedure steps 16 17 18 19 20 21 22 Remove retaining pins 3 View G from lugs on main strut 2 Pin strut stops 1 to main strut View H Luff down to lower main strut until strut backstay straps 11 can be disconnected POSITION E View B Guide boom backstay straps 8 into strap brackets 10 View F on boom Remove pins 7 View F to disconnect adjustable links 6 from connecting links 9 and boom backstay straps 8 Store pins 7 in adjustable link 6 Store links 9 with boom backstay straps 8 Disconnect rear tie links on counterweight boxes 13 as shown in Figure 4 21 View E Raise strut handling pendants 12 with assist crane so links and hook from assist crane are slightly higher than top of main strut Pay out Drum 3 load line while raising pendants Slowly luff up to raise main strut while paying out Drum 3 load line and following with assist crane Do not induce any side load in main strut with assist crane Load line from assist crane should remain vertical during strut lowering procedure CAUTION Overload Hazard Do not allow crane counterweight 13 to rise off ground at any time during strut lowering procedure Load line and pendants could be overloaded po
74. CAUTION Strut Damage If luffing jib will be operated when air temperature is below 32 F 0 C drain and refill hydraulic systems crane and boom with Petro Canada Premium Plus hydraulic oil MCC 549318 Be sure strut stop cylinders and supply lines are completely drained before refilling For operation below 10 F 12 C use a thinner fluid such as Petro Canada Premium Arctic 15 MCC 03745 See Figure 4 10 for following procedure The strut stop hydraulic hoses have quick couplers with dust caps The dust caps must be removed before making the connections 1 2 Stop engine crane and boom butt entire length of boom View D Connect luffing hoist hydraulic hoses View A between Connect hoses between ends of boom inserts along SETUP AND INSTALLATION Connect hydraulic hoses from jib strut to couplers on boom top View E Start engine Strut stop cylinders should fully extend if not already done Check fluid level in overflow tank Tank should be empty If tank is not empty possible causes include e Wrong oil viscosity for cold weather operation see CAUTION above e Drain line hydraulic connections not made Bent or kinked drain line blocking oil flow e Drain line check valve on transition insert incorrectly installed Attach an accurate hydraulic pressure gauge to coupler at accumulator on front of rotating bed View A Verify that system pressure is 2 900 psi 200 bar o
75. COMM WBNE18 RRA BR RA ek 135 A06191 1 JIB STOP ASSEMBLY Automatic 44 Luffing Jib ADD FOR 44 UPPER LUFFING JIB POINT REF 174211 NEW CONSTRUCTION 138 93657 1 BLOCK Lift single part line 139 142403 1 WEIGHT multi part line 140 162273 WEIGHT 141 168091 LUG 142 170120 BRACKET 143 174713 PLATE Mounting 144 195749 SWITCH ASSEMBLY 146 334101 CHAIN Straight Link 9 long 148 546054 NUT Hex 3 8 16UNC 149 612456 SCREW Hex Cap 3 8 16UNC 2A x 1 1 4 long 150 624633 SHACKLE Anchor 151 667007 STRAP Stay see Note 7 152 669280 STUD Wire Tie see Note 7 153 710304 WASHER Lock 3 8 154 81000193 CABLE Electric Block Up Limit 15 long 155 710304 6 SCREW Cap 3 8 16 UNC 2A x 7 8 Long ADD FOR 279A LUFFING JIB 157 A15542 1 JIB STOP ASSEMBLY Automatic 79A Luffing Jib 158 81000198 1 CABLE Electric Luffing Jib Stop ADD FOR UPPER BOOM POINT 170419 REF EXISTING FIELD 555 777 888 999 M250 2250 163 81000196 1 CABLE Electric Block Up Limit ADD FOR EXTENDED UPPER BOOM POINT 165 93657 BLOCK Lift single part line 166 142403 WEIGHT multi part line 167 162273 WEIGHT PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER A05580 17 of 20 G GQ O O Ii N N CONTROL WIRING Boom amp Limits DESCRIPTION OF PART 168 168091 169 170120 170 174718 171 A06154 172 A10556 173 334101 175 624633 176 667007 LUG BRACK
76. D for following procedure 1 Slowly luff up to raise end of jib strut to desired working height 2 Support links 1 so they cannot fall and remove link storage pins 3 from shipping holes View D 3 Lower links 1 Store link storage pins 3 in shipping holes 4 Connect links 4 spreaders 7 8 and jib straps 6 to jib strut 14 as jib strut is raised Views B and C 5 Attach a 20 ft 6 1 m long sling to end of each strap 12 Slings will be used to pull jib strut down later in procedure 6 Slowly luff up to raise jib strut to no higher than 65 to 70 as shown in View A Install Jib See Figure 4 26 Views E G for following procedure NOTE Jib assembly is identical to boom assembly The following instructions assume that assembly personnel already know how to assemble the 18000 LUFFING JIB OPERATOR S MANUAL Wrap slings around chords only Do not use lifting lugs on butt or inserts and do not lift against lacings c Lift jib butt and inserts into position at end of boom top 20 as shown in View G d Guide jib butt as required so jib stops 17 are outside of jib strut 14 as shown in View F e Align connecting holes in jib butt 13 with holes in boom top 20 and install keeper plates 15 View E and end plates 16 f Apply Loctite to jib strut and jib butt keeper plate cap screws Securely tighten keeper plate screws Torque to 100 ft Ib 136 Nem g Lower jib inserts
77. ER Attachment 3 11 SECTION 4 eret eek esd Setup And Installation General Setup and 4 1 Crane Orientation iore nl unlike E e aie n s ae ave sd a aa 4 1 ACCESSING PAIS series e 4 1 Crane Weights 4 2 Operating 2 4 2 Counterweight 4 2 Blocked iGrawlers Ae le es ae RA 4 2 Rigging Drawings eee em gebe ken ke we Rx Ee da 4 2 Luffing Jib Raising 4 2 Identifying Jib Components 4 2 Handling Components 4 4 2 Retaining Connecting 4 3 Shipping Crane 4 3 Removable Lacings 44 Jib 4 3 Luffing Jib Rigging 444 4 7 22 20 EOD 4 7 Assist Crane 4 7 Installing 44 Luffing 2 4 7 Pre Raising
78. Hazard Boom and jib sections can collapse when connecting pins are removed Block or support ends of boom and jib sections with slings from an assist crane before removing connecting pins e Never work under or inside boom or sections that are not securely blocked or supported with slings from an assist crane Boom See Figure 4 35 for following procedure To prevent parts from collapsing and possible death or serious injury to personnel observe following safety precautions when changing boom length e Know weight of what you are lifting and size assist crane and all lifting slings accordingly e Lower pin boom hoist equalizer to rails on boom insert Do not disconnect boom straps until this step is performed Equalizer could slide off rails Lower main strut fully Perform Lower Main Strut steps 2 18 Connect slings from assist crane to both sides of jib strut and hoist so slings are just taut Do not disconnect backstay straps until this step is performed Do not attempt to handle boom with equalizer pinned to rails Structural failure will result and boom will fall Handle boom only with nylon slings securely attached to chords as close to end of inserts as possible Do not lift against lacings or lifting lugs on inserts Do not cantilever more than 40 ft 12 2 m of insert from end of inserts being lifted Attach nylon slings to both inserts as shown in Figure 4 37 Do not disconnect ass
79. Hinge Pins Barge Deck L Degrees of Machine List Maximum allowable is specified on Capacity Chart FIGURE 2 12 Crane Inspection To aid in preventing harmful and damaging failure as previously indicated regular inspection for signs of overloading in the following load bearing components is required Correct each defect found before placing the crane into service Boom e Gantry e Rotating Frame e Wire Rope Pendants and Straps Turntable Bearing When equipped with hook rollers it is recommended that each hook roller assembly be inspected daily for any sign of overloading to include Deformation of roller path Proper hook roller adjustment e Deformation or cracks in hook roller hanger Bent hook roller shaft Damaged bearings Transporting Crane on Barge If it is necessary to transport the crane on a barge ship or floating platform when dynamic conditions will be experienced the boom shall be lowered onto a cradle or other support and the boom crane upperworks and lowerworks shall be secured against movement If the crane Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL is equipped with a mast the mast shall be securely tied down with guylines Failing to take these steps can result in shock load or side load damage to the boom and mast SAFETY AND INFORMATION SIGNS Maintaining Signs The crane owner user shall make sure that all
80. Italian Language see Note 5 81001115 DECAL Warning Fall Hazard Korean see Note 5 A18077 DECAL Cauton Hydraulic Tank Fill English Language A18991 DECAL Cauton Hydraulic Tank Fill Chinese Language A18858 DECAL Cauton Hydraulic Tank Fill Spanish Language A18994 DECAL Cauton Hydraulic Tank Fill Italian Language 81000724 DECAL Cauton Hydraulic Tank Fill Korean 98739 DECAL Warning Crush Hazard English Language 386224 DECAL Warning Crush Hazard Chinese Language A12555 DECAL Warning Crush Hazard Spanish Language A11573 DECAL Warning Crush Hazard Italian Language 81000711 DECAL Warning Crush Hazard Korean A06703 DECAL Hydraulic Oil Level English Language see Note1 A10481 DECAL Hydraulic Oil Level Chinese Language see Note1 A12557 DECAL Hydraulic Oil Level Spanish Language see Note1 A11634 DECAL Hydraulic Oil Level Italian Language see Note1 81001113 DECAL Hydraulic Oil Level Korean see Note1 A04412 Decal Warning Coolant Burn Hazard English Language see Note1 A09043 Decal Warning Coolant Burn Hazard Chinese Language see Note1 A09569 Decal Warning Coolant Burn Hazard Spanish Language see Note1 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER A06702 5 of 8 NAMEPLATE DECALS DESCRIPTION OF PART A11630 81000741 07321 10482 12564 11641 81001116 194183 10483 09365 11595 81001108 07339 10484 12565 11642 81000743 07353 10485
81. Jack Knife Lowering Procedure 4 32 Removing 44 Luffing 4 33 Lowering Jib Strut RII 4 33 Lowering Main Strut 4 33 Remove Struts 4 33 Removing Jib 4 34 Luffing Jib Rigging Guide 479A 4 35 General a p hi ede tia nd 4 35 mm Published 06 20 08 Control 033 07 44 x 18000 LUFFING JIB OPERATOR S MANUAL Assist Crane 4 35 Preparing Crane Boom and 4 38 Install Backstay Straps on Boom 4 38 Jib Stop Positioner Hydraulic System Operation 4 40 hb bob pee dud RR aude acp Sek 4 40 Procedure For Raising Boom And Jib 4 40 Procedure For Lowering Boom And Jib 4 40 Periodic Check Of Oil 4 40 Installing 79A Luffing Jib 4 42 Install Jib and Main Strut Butts 4 42 Install Jib Strut Top 4 42 Install Luff
82. PIN 1 Hole w Hd PIN 2 Hole COLLAR LINK 55 Boom PIN 2 Hole 5 8 dia x 6 3 4 long PIN 2 Hole 5 8 dia x 6 long BOOM INSERT ASSEMBLY 20 55 Boom INSERT 20 machining see O 573 ROLLER PIN Roller TIMBER PIN 1 Hole w Hd 62 A05197 63 A06149 64 A06150 65 A06151 66 A06457 67 A07033 68 A07034 INSERT 20 6 10 129 05383 130 05449 R131 A06651 R132 06653 133 194123 R134 07561 R135 A06099 PIN 1 Hole w Hd R136 563640 PIN Safety Luffing Jib Equipped see Note 8 69 562045 PIN Cotter 1 8 x 1 1 2 long 70 562105 PIN Cotter 1 4 x 1 1 2 long 71 A05196 STRAP 20 55 Boom 2 x 3 3 4 72 A06149 PIN 1 Hole w Hd 73 06150 2 Hole 74 A06151 COLLAR 75 A06457 LINK 55 Boom 76 A07033 PIN 2 Hole 5 8 dia x 6 3 4 long 77 A07034 PIN 2 Hole 5 8 dia x 6 long TRANSITION INSERT 40 12 19 M R137 A05400 TRANSITION INSERT ASSEMBLY 40 R138 A05459 TRANSITION INSERT 40 machining see O 573 R139 170799 PIN R140 179862 COLLAR 3 dia x 1 long R141 179959 PIN 1 2 dia x 4 1 8 long R142 194123 TIMBER R143 562043 PIN Cotter 1 8 x 1 long R144 562085 PIN Cotter 3 16 x 1 1 2 long R146 06099 1 Hole R147 06683 LINK Eq to 479 Boom Strap R148 A06944 PIN 1 Hole w Hd 2 1 4 dia x 6 9 32 long R149 A06947 PIN 1 Hole w Hd 4 1 2 dia x 6 9 32 long R150 07161 COLLAR 6 dia x 1 3 4 long R151 A07561 PIN 1 Hole w Hd
83. Properly match socket wedge and clip See Table 1 to wire rope size Align live end of rope with center line of pin e See Figure 1 Secure dead end section of rope See Figure 1 Tighten nuts on clip to recommended torque Table 1 e Do not attach dead end to live end or install wedge backwards See Figure 2 Use a hammer to seat Wedge and Rope as deep into socket as possible before applying first load Copyright 2002 The Crosby Group Inc Loads may slip or fall if the Wedge Socket is not properly installed A falling load can seriously injure or kill Read and understand these instructions before installing the Wedge Socket Do not side load the Wedge Socket Apply first load to fully seat the Wedge and Wire Rope in the socket This load should be of equal or greater weight than loads expected in use Do not interchange wedges between S 421T and US422T or between sizes FIGURE 1 TAIL LENGTH No Go M q Go Length Standard 6 to 8 strand wire Rotation Resistant Wire Rope A minimum of 6 rope diameters but not less than 6 A minimum of 20 rope diameters but not less than 6 TABLE 1 1 tightening torque values shown are based upon the threads being clean dry and free of lubrication 225 WRONG Wedge Backward Tail Clipped p Backward to live Line Figure 2 Operating Safety Apply firs
84. TION BRACKET Block Up Limit OINT OR UPPER JIB POINT REF 170419 BLOCK Lift single part line WEIGHT multi part line 15 of 20 CONTROL WIRING Boom amp Limits DESCRIPTION OF PART 49 162273 1 WEIGHT 50 168091 1 LUG 51 170120 2 BRACKET 52 195749 1 SWITCH ASSEMBLY 55 334101 2 CHAIN Straight Link 9 long 57 546054 11 NUT Hex 3 8 16UNC 58 612456 11 SCREW Hex Cap 3 8 16UNC 2A x 1 1 4 long 59 624633 3 SHACKLE Anchor 60 667007 3 STRAP Stay see Note 7 61 669280 3 STUD Wire Tie see Note 7 62 710304 11 WASHER Lock 3 8 63 81000196 1 CABLE Electric Block Up Limit ADD FOR 79A UPPER LUFFING JIB POINT OR UPPER BOOM POINT 55 55A OR 79A REF A08516 65 93657 1 BLOCK Lift single part line 66 142403 1 WEIGHT multi part line 67 162273 1 WEIGHT 68 168091 1 LUG 69 A04984 2 BRACKET 71 195749 1 SWITCH ASSEMBLY 73 334101 2 CHAIN Straight Link 9 long 75 546054 11 NUT Hex 3 8 16UNC 76 612456 11 SCREW Hex 3 8 16UNC 2A 1 1 4 long 77 624633 3 SHACKLE Anchor 78 667007 3 STRAP Stay see Note 7 79 669280 3 STUD Wire Tie see Note 7 80 710304 11 WASHER Lock 3 8 81 81000196 1 CABLE Electric Block Up Limit ADD FOR 79A LUFFING JIB OR 79A FIXED JIB 84 142403 1 WEIGHT 85 A06154 1 SWITCH ASSEMBLY 88 334101 1 CHAIN Straight Link 12 long 90 A18331 4 NUT KEPS M 1 0 zinc 91 546054 4 NUT Hex 3 8 16UNC 2B 92 591121
85. Transceiver Hook On Boom Top Out To Boom Top Node Controller 6 WBM150440 Boom Top From Cable Left Side Reel View 2 Luffing Jib Luffing Jib Angle Max Angle Max Ref xc See Note 8 Ref 8 Wind Speed Ref Luffing Jib Angle Min Ref See Note 8 Load Pin 1 Can Out See Note 8 Block Up Limit Lower Boom Point Block Up Limit See Note 8 Upper Boom Point See Note 8 View Of Bottom Of Boom Node Controller Item 41 4 of 20 See Note 9 34 34 See Note 9 41 View G G 41 Controller Dead End On Upper Boom Point 32 44 Load Link Dmm 9 Wired 70K View Q Q Location Of Load Link Item 9 And Switch Asm Item 32 With 2 4 6 8 Or 10 Parts Of Line Over Lower Boom Point Digital Output Ref Load Pin 2 MANITOWOC CRANES INC Buyin UUM Z 001 woog 6 dol woog eg JSN JO Hed jeje 6 woog dol qir Buyin pps epis 1e4 ueq niniw dol pesoyouy 00 eun 7 BM la eun ued 2 103 3u6I9M JO uoneoo 302 SS IWA Sur peor ued 2 NI OSL yur peo
86. UTSIDE PLATE BLOCK NON MOVING LINE DEAD END DO NOT SCALE THIS DRAWING CUSTOMER FURNISHED LIMIT CONTROL ACTUATOR BILL OF MATERTAL A DESCRIPTION EE or tue NOTE 1 LIMIT CONTROL ACTUATOR MUST ENCLOSE THE LINE TO EITHER THE DEAD END OR UNIVERSAL WIRE ROPE ANCHOR JOINT THE LOCATION OF THIS LINE DEPENDS 01 31 97 NVS ON THE PARTS OF LINE REQUIRED AND THE TYPE OF ON REEVING THE X DISTANCE MUST BE SUFFICENT TO PROVIDE ADEQUATE CLEARANCE WITH ADJACENT PARTS OF LINE AND ALSO PROVIDE A BASE FOR WEIGHT TO SET ON THE Y DISTANCE MUST BE SUFFICENT FOR ACTUATOR TO SUPPORT THE WEIGHT WHEN THE ACTUATOR IS ATTACHED TO A BLOCK ROTATED 10 SEE VIEW A LIMIT CONTROL ACTUATOR LENGTH Z MUST SUPPORT THE WEIGHT WHEN THE ACTUATOR IS ATTACHED TO A BLOCK ROTATED 10 SEE VIEW LIMIT CONTROL ACTUATOR MUST BE STRUCTURALLY STRONG ENOUGH TO WITHSTAND THE IMPACT OF HITTING THE WEIGHT WHILE HOISTING THE BLOCK IT IS THE CUSTOMERS OBLIGHTION TO ADEQUATELY ATTACH THE ACTUATOR TO HIS BLOCK 184433 Manitowoc Cranes LOAD BLOCK Manitowoc Wisconsin CONVERSION FOR p WM eza CONTROL ASSEMBLY E TECHNICAL BULLETIN BRIDON AMERICAN 280 New Commerce Boulevard Wilkes Barre PA 18706 Telephone 570 822 3349 1 800 521 5555 FAX 1 800 2
87. WBMJS see Note 11 NUT Hex 1 4 20UNC SCREW Hex Cap 1 4 20UNC x 2 long WASHER Lock 1 4 int shakeproof ADD FOR 55 OR 55A BOOM 18 19 20 21 23 24 25 26 27 28 29 ADD FOR 79A BOOM TOP 31 32 33 34 35 36 37 38 39 41 42 ADD FOR SINGLE 624633 667007 669280 A18332 A08627 81000196 142403 A06154 334101 A18331 7126151256 142403 A06154 334101 A18331 7126151256 624633 667007 669280 A18332 A08627 81000196 ADDO 000 2 ARAB a SHACKLE Anchor 5 16 round pin STRAP Stay see Note 7 STUD Wire Tie see Note 7 WASHER Lock External Countersink 1 4 see Note 9 CONTROLLER Boom Node CABLE Electric Block Up Limit WEIGHT SWITCH ASSEMBLY CHAIN Straight Link 12 long NUT KEPS M 1 0 zinc SCREW Hex Serrated Flange M6 x 25 WEIGHT SWITCH ASSEMBLY CHAIN Straight Link 12 long NUT KEPS M 1 0 zinc SCREW Hex Serrated Flange M6 x 25 SHACKLE Anchor 5 16 round pin STRAP Stay see Note 7 STUD Wire Tie see Note 7 WASHER Lock External Countersink 1 4 see Note 9 CONTROLLER Boom Node 1 CABLE Electric Block Up Limit HOIST DRUM REEVING LOWER POINT WITH 10 OR LESS PARTS OF LINE 55 55 OR 79 TOPS 44 45 144853 A15357 ADD FOR UPPER NEW CONSTRUC 47 48 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 93657 142403 1 BOOMP
88. Z E E 28 28 28 8 17 19 33 33 33 33 230 Jib a 2425023 pg 11 R6 R63 R58 peg 28 32 32 28 32 32 EMEND REN 1 27 28 28 28 17 19 29 33 33 33 33 Ru 240 Jib 24 25 or 28 ONI S3NVHO9 90MOLINVIN MANITOWOC CRANES INC 38 50 62 66 88 89 R89 R86 Backstay Straps y us BoomStraps noo R100 R107 R120 R138 R200 140 38 50 62 66 71 75 88 89 R89 R86 V 46 Backstay Straps Boom Straps R201 R147 pem R100 R107 R130 R138 160 Boom 38 50 62 66 71 75 88 89 90 91 R89 R86 Backstay Straps m y mur Boom Straps R201 R100 R107 R120 R130 R138 R157 158 200 180 Boom 38 50 62 66 71 75 8889 96 97 R89 R86 ie Backstay Straps Boom Straps R100 R107 R120 R130 R138 R147 R171 R172 R200 200 Boom R167 R181 55 79A Boom Assembly Reference Boom Rigging Assembly 10
89. all parts of your body away from moving parts Maintain constant verbal communication between person at controls and person performing maintenance or repair procedure Wear clothing that is relatively tight and belted Wear appropriate eye protection and approved hard hat Never climb onto or off a moving crane Climb onto and off crane only when it is parked and only with operator s permission Use both hands and handrails steps and ladders provided to climb onto and off crane Lift tools and other equipment which cannot be carried in pockets or tool belts onto and off crane with hand lines or hoists Boom and gantry are not intended as ladders Do not attempt to climb lattice work of boom or gantry to get to maintenance points If boom or gantry is not equipped with an approved ladder lower them before performing maintenance or repair procedures Do not remove cylinders until working unit has been securely restrained against movement Pinch points are impossible to eliminate watch for them closely Pressurized air coolant and hydraulic oil can cause serious injury Make sure all air coolant and hydraulic lines fittings and components are tight and serviceable Do not use your hands to check for air and hydraulic oil leaks e Use a soap and water solution to check for air leaks apply to fittings and lines and watch for bubbles Use a piece of cardboard or wood to check for hydraulic oil leaks Relieve pre
90. and lowered using Jack Knife Method See the Liftcrane Luffing Jib Capacities Chart to determine the following e Counterweight Requirements crane and MAX ER Boom to Luffing Jib Angle e Maximum Boom and Jib Lengths Raised or Lowered Over end or side of blocked crawlers Over end or side of unblocked crawlers Jack Knife Lowering Procedure A DANGER Moving Part Hazard Warn all personnel to stand clear of jib point dolly while lowering boom and jib Death or severe crushing injuries will occur if personnel come in contact with tires See Figure 4 30 for following procedure NOTE Item numbers in Figure 4 30 correspond to numbered steps in following procedure It is normal for the BLOCK UP MAX UP 1 and MAX UP 2 limits to come on during the lowering procedure 1 Swing boom and jib slightly to either side of center and lower load block or weight ball onto ground Then swing boom and jib to desired position with relation to crawlers and apply swing brake Adhere to raising and lowering limitations given in Liftcrane Luffing Jib Capacities Chart A WARNING Tipping Crane Hazard Lower load block or weight ball onto ground before lowering boom and jib Structural damage can occur and attachment can collapse if this precaution is not observed 4 62 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL A DANGER Tipping Crane Hazard Do not lower boom and jib to ground until bo
91. and luffing jib can then be set to desired operating angle and radius Luffing jib radius must be within capacity chart before swinging over side of machine Reverse this procedure when lowering boom and luffing jib CAUTION Failure to lower luffing jib to 160 degree boom to luffing jib angle will not allow luffing jib stop to engage Structural damage may result The following combinations may be raised and lowered using this method Maximum Boom And Luffing Jib Lengths Lifted Unassisted Using Standard In Line Method Over End of Over Side of Boom Blocked Crawlers Crawlers Length Luffing Jib No 44 Luffing Jib No 44 Feet Meters Feet Meters Feet Meters 21 3 73 2 21 3 73 2 21 3 73 2 21 3 73 2 21 3 64 0 21 3 64 0 21 3 54 9 21 3 51 8 21 3 45 7 21 3 36 6 21 3 33 5 21 3 24 4 Load blocks hook and weight ball on ground until boom luffing jib are erected 8542 A 4 14 04 GA S N 18005910 Page 1 of 2 Manitowoc Cranes Inc Manitowoc Wisconsin 54220 U S A Luffing Jib Raising Procedure 18000 Luffing Jib No 44 On Boom No 55 79A with 100 Ft Mast No 56 B Jack Knife Method Longer boom and luffing jib combinations must be raised and lowered using jack knife method Haul in luffing hoist line luff up until adjustable jib straps are raised to clear strap stowage brackets on luffing jib approx 50 to 68 degree jib strut to horizontal angle Do not exceed 70 degree jib
92. boom Securely fasten load line to jib point before raising attachment Connect Electric Cords Adjust Electronic Devices 1 Connect electric cords to respective junction boxes and switches See Boom Wiring Diagram at the end of this section e Angle indicator on jib butt e Jib stop limit switches on boom top limit reel in jib butt Block level sensor switches e Jib stop positioner electrical valve e For hard wired load links if equipped install load link associated links and swivel Route and secure load link cord so that during erection and operation the link can pivot without pulling on the cord or interfering with other parts 2 Connect all unused electric cords to proper terminating plugs on junction boxes NOTE Block up limit electric cords will be connected to limit switches after boom and jib are jack knifed to required angle 3 Adjust electronic devices according to instructions in Section 6 of this manual Boom stop Luffing jib stop limit switches e Jib angle indicator Block level sensor switches in this section 4 56 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Install Wind Speed Indicator Assembly Install wind speed indicator if removed for shipping Use star washers to attach mounting bracket to jib top to provide good a ground see Wind Speed Assembly drawing at end of this section Connect electrical cable at base o
93. boom at maximum operating angle Automatic boom stop must be installed and properly adjusted General The physical boom stops Figure 6 6 Assist in stopping the boom smoothly at any angle above 772 6 12 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL e Assist in preventing the boom rigging from pulling the boom back when traveling or setting loads with the boom at any angle above 772 e Assist in moving the boom forward when lowering the boom from any angle above 77 e Provide a physical stop at 89 Operation See Figure 6 6 for following instructions 1 When boom is raised to 77 springs in boom stop tubes begin to compress 2 Asboomis raised higher spring compression increases to exert greater force against boom 3 If for any reason boom is raised to 89 boom stop springs fully compress to provide a physical stop Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL MAINTENANCE 1258 9 Physical Boom Stops 7T Start of Spring Cushioning 89 Physical Stop Boom Butt 6 106 GOD d d FIGURE 6 6 mm Published 06 20 08 Control 033 07 6 13 MAINTENANCE BOOM AND LUFFING JIB ANGLE INDICATOR CALIBRATION The angle indicator potentiometers are located inside the node controllers mounted on the boom top and on the luffing jib top The boom and luffing jib angles are calibrated
94. comply with instructions in this manual in Crane Operator s Manual and in Luffing Jib Rigging drawings and Capacity Charts 3 4 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL a On Cab Support Outside Right Window FIGURE 3 1 LUFFING JIB OPERATING CONTROLS See Figure 3 1 for Location of Controls 1 Crane Mode Select Confirm Switch See Operating Controls in Section 3 of your Crane Operator s Manual for operation of the crane mode switch This switch is used to select and confirm the following modes e LUFFING JIB mode for normal operation e LJIB STOP mode for extending and retracting the jib stop positioner cylinders during the luffing jib raising and lowering procedures When the luffing jib mode is selected and confirmed LUFFING JIB ON appears on the display as shown in Figure 3 2 The luffing hoist and boom hoist control handles switch to the locations shown in Figure 3 1 If equipped with a MAX ER attachment the MAX ER mode must also be selected and confirmed Once selected and confirmed the M on the right end of the display indicates that the MAX ER mode is on Figure 3 2 Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL Luffing Jib MAX ER Mode Mode ON ON Crane Mode LUFFING JIB ON M FIGURE 3 2 To operate the 4794 jib stop positioner cylinders during luffing jib raising and lowering proceed as follows 1 Select proper 79A luffin
95. during boom disassembly usually result from one of three primary causes Workers are not familiar with equipment or are not properly trained e Disassembly area is not suitable Safe procedures are overlooked because not enough time is allocated for the task General Safety decals Figure 2 4 are placed near the connectors on the boom sections as shown on the Boom Disassembly Decal Drawing at the end of this section Workers involved with boom disassembly must be trained and experienced in the operation and disassembly of construction cranes Everyone must read and understand these instructions the information in the Boom Assembly Drawing and the instructions in Section 4 of this manual before beginning disassembly Anyone who has a question should ask for an explanation One worker who does not fully understand or fails to follow correct procedures can endanger other workers Location Select a suitable location for boom disassembly It must be firm level and be free of obstructions It should have enough open space to accommodate the crane the length of boom and if required movement of an assist crane or other equipment If possible secure the area to keep unauthorized personnel and vehicles away Pin Removal When removing pins from boom sections stand clear of pins being removed Even though the boom is resting on 2 18 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANU
96. equipment such as magnetic particle or ultrasonic capacity chart a 0 degree machine list capacity procedures is recommended for this inspection chart rating applies to machine list not to exceed 1 2 degree All other machine list ratings 1 2 NOTE Manitowoc does not recommend crane operation and 3 must NOT be exceeded under dynamic conditions However if operation under dynamic conditions is required Manitowoc Shock Loading will consider issuing a capacity chart for dynamic Aem conditions only after the crane user has provided Definition the information listed on Technical Data Sheet Shock loads to the crane can be experienced when the T S 100 This technical data sheet is available to barge is subjected to up and down movement of wave action the crane user upon request manito ye Published 06 20 08 Control 033 07 2 23 C SAFETY INFORMATION Operation On Barge General Machine list and or dynamics will be experienced when a crane is operated on a barge ship or floating platform Both of these conditions reduce the crane s capacity and each must be taken into account for safe operation on a barge ship or floating platform A WARNING Tipping Crane Hazard Tie downs which only prevent crane from shifting as in barge ship or floating platform mounting may not provide adequate support when using a capacity chart for pedestal mounting Before operating a crane on a barge ship or floating platform crane
97. equipped with these devices Insulating links installed into the load line afford limited protection from electrocution hazards Links are limited in their lifting abilities insulating properties and other properties that affect their performance Moisture dust dirt Canrrowoc 18000 LUFFING JIB OPERATOR S MANUAL oils and other contaminants can cause a link to conduct electricity Due to their capacity ratings some links are not effective for large cranes and or high voltages currents The only protection that may be afforded by an insulated link is below the link electrically downstream provided the link has been kept clean free of contamination has not been scratched or damaged and is periodically tested just before use for its dielectric integrity Boom cages and boom guards afford limited protection from electrocution hazards They are designed to cover only the boom nose and a small portion of the boom Performance of boom cages and boom guards is limited by their physical Size insulating characteristics and operating 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 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 loca
98. er 18000 LUFFING JIB OPERATOR S MANUAL 4 197a 16 17 18 mm Published 06 20 08 Control 033 07 Item Description SETUP AND INSTALLATION 44 LUFFING JIB Drum 3 Whip Line in Crane Guide Sheaves in Mast Guide Sheaves in Jib Strut Guide Sheaves in Jib Top For Luffing Hoist Only Wire Rope Guide on Boom Top Guide Sheaves in40 ft 13 1 m Insert Guide Sheaves in 10 ft 3 0 m Insert Drum 1 Hoist in 10 ft 3 0 m Insert Drum 5 Luffing Hoist in Boom Butt Drum 2 Hoist in Boom Butt Wire Rope Guide see page 4 83 Lower Jib Point see page 4 83 Upper Jib Point see page 82 Dead End Wedge Socket with RCL Load Cell Link Hook and Weight Ball Load Block Wireless Receiver from Boom Top FIGURE 4 47 4 81 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL 44 UPPER JIB POINT 1 Part DE _ 5 Wire Rope Wire Rope 1 Pin with Cotter Pin 2 Link 3 Pin with Cotter Pin 4 Load 70 000 Ib 31 751 kg 5 Wedge Socket 1 1 8 in 28 mm 6 Link 7 Pin with Cotter Pin 8 Swivel Weight Ball FIGURE 4 47 continued 4 82 Published 06 20 08 Control 033 07 er 18000 LUFFING JIB OPERATOR S MANUAL Drum 3 q Drum 1 Whip Fon ir Hoist atl JIB TOP GUIDE SHEAVES
99. es 2 10 Size of Load ocolos ees eet ee doe eee em ete redi 2 10 Attaching Load m ce t e et ied 2 10 Lifting Moving 2 10 Multiple Load Line Operation 2 12 Holding Load Lor Tcr Det Tee iat ttem t eed 2 12 Surita D 2 12 Operational AldS 2 2 se epe usu as 2 13 Operating Near Electric Power Lines And Transmission 5 2 13 Electrocution 2 13 Set Up and 2 14 Electrocution Hazard 2 14 Electrical Contact eser Le ___ _______ 2 15 eT AER E qud SPA e quie pute quie Egi e Rupee els 4 2 15 Fire Extihgulshers ee eese eem Debs od dos 2 15 de ERU ee REN NES ege etur 2 15 Safe Maintenance Practices 2 16 Maintenance Instructions 2 16 Safe Maintenance 2 16 Boom Disassembly 2 18 General aad sage ad ua d piece diete d 2 18 EOCALOFI e nire 2 18 etre ane QE 2 18 Disassembly
100. flat firm surface that will support load placed on pads or floats Do not set jack pads or floats in holes on rocky ground or on extremely soft ground When dictated by ground conditions install wood blocking or steel plates under jack pads or floats to properly distribute loading on the supporting surface While SAFETY INFORMATION Wood blocking or steel plates used under jack pads or floats shall be Free of defects Strong enough to prevent crushing bending or shear failure Of sufficient thickness width and length to completely support the jack pad or float transmit the load to the supporting surface and prevent shifting toppling or excessive settlement under load Fully retract and lock jacks and outrigger beams so they cannot extend when not in use Operate with extreme caution when using two or more cranes to lift same load One designated person shall be responsible for operation when two or more cranes are used to lift same load Designated person shall analyze lift and instruct all personnel involved in proper rigging and positioning of load and all movements to be made Decisions such as necessity to reduce crane ratings load position boom position ground support and speed of movements shall be in accordance with designated person s decision Do not lower load or boom to a point where less than two full wraps of wire rope remain on the respective drum or as otherwise indicated in local
101. from or to ground until crawlers are blocked RIGGING DRAWINGS See the end of this section for applicable jib rigging drawings 4 2 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL The boom and jib components butts inserts tops pendants straps must be assembled in proper sequence according to the rigging drawings Two tables are provided on the luffing jib rigging drawing one table lists the boom sections and backstay pendants required for various boom lengths the other table lists the boom sections required for various jib lengths Make sure proper table is referred to Read and comply with insert and pendant notes on the rigging drawing LUFFING JIB RAISING PROCEDURE See the Luffing Jib Capacity Chart Manual for applicable luffing jib raising and lowering procedures Luffing Jib Angle Q L ffing Jib Horizontal Boom to Luffing Jib Angle Horizontal FIGURE 4 1 IDENTIFYING JIB COMPONENTS Jib sections are marked for proper identification as shown in Figure 4 4 View A all four chords of each boom or jib section Straps and connecting links are marked for proper identification as shown in Figure 4 4 View B Pendants when used are marked for proper identification as shown in Figure 4 4 View C HANDLING COMPONENTS Handle boom and jib components with care to avoid damaging lacings and chords Lift against chords o
102. gear oil used in drum planetaries on crane See Periodic Check of Jib Stop Positioner Hydraulic Oil Level in this section Sheaves marked with an asterisk have sealed bearings and do not require periodic lubrication Repack sheave bearings with grease at overhaul Published 06 20 08 Control 033 07 5 5 LUBRICATION PERIODIC CHECK OF JIB STOP POSITIONER HYDRAULIC OIL LEVEL This procedure applies to the 79A Luffing Jib Perform the following procedure ONCE YEARLY when the attachment is on the ground See Figure 5 2 NOTE It is normal for jib stop positioner cylinders 9 to extend if retracted when engine is stopped 1 Stopengine 5 6 Unlatch safety latches 8 with hand winch in jib top Loosen lock nut 10 and slowly turn valve screw 11 counterclockwise to transfer oil from accumulator 5 to hydraulic tank 1 Positioner cylinders 9 will fully retract jib stops lower when this step is performed Once oylinders are retracted turn valve screw 11 fully clockwise and tighten lock nut 10 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Stroke pump handle 4 back and forth until positioner cylinders 9 are fully extended Remove dipstick 3 slowly to vent pressure in tank Wipe dipstick 3 clean and reinstall so it rests on tank fitting for proper oil level check Remove dipstick 3 Oil should be at top mark on dipstick If necessary remove fill plug 2
103. limit bypass key clockwise to bypass minimum angle and lower jib Luffing hoist must stop and be inoperable in down direction when boom to luffing jib angle is approximately 67 If minimum stops do not operate properly troubleshoot system Actuator Rod Replacement See Figure 6 3 for following procedure 1 Remove damaged actuator rod 1 2 Slide spring washers 3 and 5 and spring 4 over new actuator rod while sliding actuator rod into bracket assembly 3 Position actuator rod 1 so tapered end just touches limit switch 6 roller View A Actuator rod must not depress limit switch roller 4 Drill 1 4 in 6 35 mm hole through spring washer 3 and actuator rod 1 5 Install dowel pin 2 6 Check limit switch roller to insure there is over travel as shown in View B Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL MAINTENANCE View B Switch Activated Circuit Opened Roller Over Travel LED 1 Ps 6 JIB MAXIMUM DOWN Limit Switch Shown mic View A JIB MAXIMUM UP 2 Limit Switch Opposite HI Switch Deactivated Circuit Closed Description qm Actuator Rod Limit Switch Wiring Receptacle Switch Terminals Operation Dowel Pin Spring Washer 1 green 22 B 14 Jib Max Up or Jib Max Down Spring Spring Washer 2 black A 13 LED Limit Switch 3 white 21 24 VDC Supply Cover Bracket Assembly FIGURE 6 3 A die Published 06 20 08
104. load Excessive rotation will cause imbalance and reduction in strength Under a shock load or overload condition the strength of these ropes can be reduced as much as 50 BAC does recognize that there are certain applications where safety or operating requirements demand the use of a swivel with Rotation Resistant Ropes In these cases it is mandatory that the design factor be strictly followed the ropes are not shock loaded Rotation Resistant Ropes and the ropes are frequently inspected by a qualified person BAC recommends that each application requiring the use of a Swivel with Rotation Resistant Ropes be reviewed and approved by a qualified person There has been some confusion about swivels attached between the rope and the dead end attachment point and swivels below the traveling block between the block and the load For the purpose of the previous discussion we are referring to the swivel attachment between the rope and the dead end attachment point Most swivels below the traveling block are not anti friction ball bearing swivels MULTIPLE PART REEVING Endurance 19 ropes are not recommended for multiple part reeving These ropes do not perform well and tend to become imbalanced when used in this manner Endurance 8RR Endurance Dyform 18 Endurance Dyform 34LR and Endurance 35LS are more stable constructions and can be used in multiple part reeving SINGLE PART HOISTING All Rotation Resistant Ropes can be used in
105. mL 6 3 Preliminary Adjustment 6 3 Max Up 1 Limit 6 3 Max Up 2 Limit 6 3 Max Down Limit Adjustment 6 3 Final Adjustment Steps 6 3 Operational Checks 6 4 Jib Stop Adjustment Current 6 4 CIC 6 4 e NEA 6 4 Pre Erection 6 4 Jib Maximum Up 1 and 2 Limit Checks 6 4 Jib Maximum Down Limit Checks 6 6 Operational Checks 6 6 Actuator Rod 1 6 6 Automatic Boom Stop 6 9 Maximum Operating 6 9 iocum 6 9 Maintenance pest Oates oe See SQ bowls BEE 6 9 Boom and Mast 6 9 Actuator Rod 6 10 Adjustment without luffing jib 6 10
106. not insulated Do not allow unnecessary personnel in the vicinity of the crane while operating Permit no one to lean against or touch the crane Permit no one including riggers and load handlers to hold the load load lines tag lines or rigging gear Even if the crane operator is not affected by an electrical contact others in the area may become seriously injured or killed It is not always necessary to contact a power line or power source to become electrocuted Electricity depending on magnitude can arc or jump to any part of the load load line or crane boom if it comes too close to an electrical power source Low voltages can also be dangerous 2 14 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Set Up and Operation During crane use assume that every line is energized hot or live and take necessary precautions Position the crane such that the load boom or any part of the crane and its attachments cannot be moved to within 20 ft 6 m of electrical power lines or equipment This includes the crane boom and all attachments Overhead lines tend to blow in the wind so allow for lines movement when determining safe operating distance A suitable barricade should be erected to physically restrain the crane all attachments and the load from entering into an unsafe distance from electrical power lines or equipment Plan ahead and always plan a safe route before traveling under powe
107. not lift against lacings 4 Remove end plates 15 View D keeper plates 16 and pins connecting jib butt to boom top Store pins and keeper plates in boom top holes after butt and inserts are removed 5 Remove jib butt and inserts Guide jib butt as required so jib stops do not hit lacings 6 Disassemble inserts from butt if desired Lower Jib Strut Slowly luff down to lower luffing jib 2 As luffing jib is lowered disconnect links 4 spreaders 7 8 and jib straps 6 from jib strut Figure 4 26 Views B and Do not remove links 1 3 Lower jib strut onto blocking approximately 3 ft 0 9 m high Place blocking at front of butt just behind connecting pins 4 Store links as shown in Figure 4 26 View D Canrrowoc 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION Hook from View A Assist Crane P2132 3 9 working working Hole C Hole D P2135 5 4 7 5 FIGURE 4 33 Published 06 20 08 Control 4 033 07 4 67 SETUP AND INSTALLATION Lower Main Strut See Figure 4 33 for following procedure steps 1 4 68 Anchor end of jib strut to counterweight a Remove one top crane counterweight box from each side of crane counterweight Boxes must be equipped with tie link lugs b Stack counterweight boxes 11 View D one at a time at jib strut top Secure lifting lugs on top counterweight box 11 to lugs on ji
108. on main strut 13 and raise links 2 3 ft 0 6 0 9 m Store pins 8 in same holes after links are raised 8 Slowly raise pendants 6 until it is taut POSITION A View A Pay out Drum 3 load line 1 if required 9 Continue to hoist pendants 6 to raise main strut 13 to POSITION B Pay out Drum 3 load line 1 and luffing hoist wire rope 16 as strut rises Keep pendants 6 vertical during this step NOTE Control hoist speed by observing upper counterweight box 17 View A Upper box must not lift off lower box during strut raising procedure 4 48 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL CAUTION Overload Hazard Do not allow upper crane counterweight 17 box to lift off lower box at any time during strut raising procedure Load line and pendants could be overloaded possibly resulting in damage 10 Once main strut is at approximately 45 POSITION C View A slowly haul in Drum 3 load line 1 while paying out luffing hoist wire rope 16 11 Follow with assist crane pay out load line and travel while performing step 10 Do not induce any side load in main strut with assist crane Load line from assist crane should remain vertical during strut raising procedure 12 When main strut is approaching vertical POSITION D pay out load line from assist crane so that pendants 6 and Drum 3 load line 1 start to pull in a straight line 13 Continue to luf
109. pah id 2 25 Ordeting 9lgtis tat memes Saepe ede eps dade Rune t pa dre ame ir 2 25 Published 06 20 08 Control 033 07 Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL SAFETY INFORMATION SECTION 2 SAFETY INFORMATION DIESEL ENGINE EXHAUST CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm NAMEPLATES AND DECALS See drawing at the end of this section SAFETY MESSAGES General The importance of safe operation and maintenance cannot be over emphasized Carelessness or neglect on the part of operators job supervisors and planners rigging personnel and job site workers can result in their death or injury and costly damage to the crane and property To alert personnel to hazardous operating practices and maintenance procedures safety messages are used throughout the manual Each safety message contains a safety alert symbol and a signal word to identify the hazard s degree of seriousness Safety Alert Symbol This safety alert symbol means ATTENTION Become alert your safety is involved Obey all safety messages that follow this symbol to avoid possible death or injury Signal Words A DANGER Identifies imminent hazards that will result in death or serious injury if the message is ignored A WARNING Identifies potential hazards that could result in deat
110. procedure chart er 18000 LUFFING JIB OPERATOR S MANUAL D E E Crawlers blocked if required by raising procedure chart See Crawler Blocking Diagram for blocking procedure All installation steps given in this section performed Boom and jib inserts installed in proper sequence according to rigging drawings Upper jib point roller installed Boom jib and backstay straps installed in proper sequence according to rigging drawings Adjustable jib straps locked in proper position All connecting pins installed and properly secured Main and jib struts in operating position All hydraulic connections made Jib stop in operating position Jib strut stop cylinders extended and adjusted SETUP AND INSTALLATION Boom and luffing hoist wire rope anchored properly to drums spooled tightly onto drums and engaged with proper sheaves see Rigging Drawings and Wire Rope Installation and Maintenance in this section Load lines anchored properly to drums spooled tightly onto drums and engaged with proper sheaves see Reeving Diagrams and Wire Rope Installation and Maintenance in this section Wire rope guard pins bars or rollers installed to retain wire rope in sheaves If load line will be installed after boom and jib are jack knifed into position make sure load line going to jib point is securely attached to end of jib point so load line cannot fall off jib and boom All blocking tools an
111. racha a Re db xe Eh aC e Sedan Sn unu has 1 4 Crane Weights ci creneng eran dee den ia 1 6 English And Metric Conversions 1 10 Direct 1 10 Inverse GOnVersiOFH uu uy cine eS daria ha ea atone gad S OA 1 10 Manitowoc Crane Care Distributors 1 11 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL SECTION 1 INTRODUCTION CRANE DATA See the end of this section for crane data specific to your crane e Basic Specifications Declaration if applicable CRANE ATTACHMENT IDENTIFICATION An identification label is attached to the outside of the operator s cab see Figure 1 1 and to the attachments i e luffing jibs MAX ER s and Ringers available for this crane The crane or attachment model application and serial number are provided on the label INTRODUCTION For the exact location of the identification labels on your crane and attachments refer to the Nameplates and Decals Drawing in Section 2 of this manual CRANE ORIENTATION The terms RIGHT LEFT FRONT REAR used in this manual refer to operator s right left front and rear sides when seated in the operator s cab looking forward e Operator s cab is at front of upperworks Crawler motors a
112. rope shall NOT pass thru the No Go hole in the wedge Important Safety Information Read and Follow Inspection Maintenance Safety Always inspect socket wedge and pin before using Do part showing cracks Do not use modified or substitute parts Repair minor nicks or gouges to socket or pin by lightly grinding until surfaces are smooth Do not reduce original dimension more than 1096 Do not repair by welding Inspect permanent assemblies annually or more often in severe operating conditions Donotmix and match wedges or pins between models or sizes Always select the proper wedge and socket for the wire rope size Assembly Safety Use only with standard 6 to 8 strand wire rope of designated size For intermediate size rope use next larger size socket For example When using 9 16 diameter wire rope use a 5 8 size Wedge Socket Assembly Welding of the tail on standard wire rope is not recommended The tail length of the dead end should be a minimum of 6 rope diameters but not less than 6 See Figure 1 To use with Rotation Resistant wire rope special wire constructions with 8 or more outer strands ensure that the dead end is welded brazed or seized before inserting the wire rope into the wedge socket to prevent core slippage or loss of rope lay The tail length of the dead end should be a minimum of 20 rope diameters but not less than 6 See Figure 1
113. shown in View D 20 Remove pins 5 View D A WARNING Cylinder Movement Hazard Strut cylinder will extend forcefully if cylinder rod pin 6 View D is removed and cause personal injury Extending cylinder will damage strut by twisting Strut may fall 21 Swing strut stops 3 to rear and position main strut 2 as needed to align holes in strut stop 3 with lugs 7 on boom top View E 22 Pin strut stops 3 to lugs 7 on boom using pins 5 View E 23 Remove tube retaining pins 8 View H and store as shown in View G 24 Remove strut locking pins 9 View A from stored position 25 Insert pins 9 in lower holes on outer stop tube View Luff up as needed to align holes in strut stops 26 Pull strut slightly to rear by slowly hauling in Drum 3 hoist line slightly to remove load on cylinder rod retaining pins 6 View E CAUTION Strut Damage Pulling strut too far to rear will damage strut and or strut stop cylinders 4 50 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL 27 Remove retaining pins 6 View E and store as shown in View F 28 Slowly pay put Drum 3 hoist line Cylinder rods will extend allowing strut to rotate forward View F 29 Store handling pendants 10 and links a Leave assist crane attached to the links at end of handling pendants 10 b Lower links with assist crane and pay out Drum 3 hoist line until handling pendants are hang
114. signs are legible and installed at the proper locations on the crane If a sign has been defaced or removed it must be replaced immediately See Nameplates and Decals Drawing in this section for the installation locations of signs Ordering Signs Order replacement signs from your Manitowoc Crane Care distributor or from the factory at the following address Manitowoc Crane Care SAFETY INFORMATION When ordering a sign give the crane model number the serial number and the name and part number of the sign Figure 2 13 If the sign has a figure number it can be used if the drawing number is missing Rotating Fan Blades KEEP FEET AND HANDS CLEAR Stop engine and remove ignition key before you attempt to service crane in area near radiator fan 05839 0 2401 So 30th St NES Manitowoc WI 54220 Phone 920 684 6621 FIGURE 2 13 Fax 920 683 6278 E mail latticeteam manitowoc com Published 06 20 08 Control 033 07 2 25 OPERATOR S MANUAL SECTION 2 INSERTS 18000 Luffing Jib Serial Number 18005910 Drawing 175916 G Nameplates and Decals Boom Disassembly Drawing A06702 06 25 2008 Nameplate And Decals 08 13 2008 MANITOWOC CRANES INC Group F 7 Insert MALE Bottom Male CONNECTOR Connector A Ja Box Section Tubular Eng Rev 02 22 05 MODEL All NAMPLATE amp DECAL ASSEMBLY
115. straps to float up and down 3 6 in 76 162 mm above strap brackets at end of jib top It will be necessary to use limit bypass switch to luff down if BLOCK UP limit is on WARNING Tipping Hazard Structural Damage Do not allow jib or backstay straps to become too tight during lowering steps Crane will tip or structural damage will result Do not allow jib and backstay straps to become too slack during lowering steps Jib strut could fall onto jib butt 10 Continue with Jack Knife Lowering Procedure steps 7 9 until boom top is resting on blocking at ground level 11 Slowly luff down to lower jib strut until jib straps rest in strap storage brackets on jib er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION If boom will be removed disconnect hydraulic hoses between boom inserts Figure 4 8 View D Install dust caps 12 Lower struts as described in Removing Jib later in this 8 section Removing 44 Luffing Jib Lowering Main Strut Lowering Jib Strut 1 Disconnect both erection pendants from storage bar on main strut Figure 4 7 View A A 2 Connect one erection pendant to load line from Drum 1 WARNING Figure 4 7 View C Moving Part Hazard 3 Connect other erection pendant to sling from assist Do not stand on boom top or jib butt while either strut is crane being lowered Wait until struts have been stopped and are supported by load line or luffing hoist line before climbing onto boom top
116. strut to horizontal angle Check jib strut position by viewing angle indicator Slowly raise boom while jib point rollers are allowed to roll on ground Tension should be applied to luffing jib hoist to keep adjustable jib straps off luffing jib during boom raising Boom up until boom to luffing jib angle reaches value specified in table or jib is vertical whichever occurs first Tighten luffing jib suspension with luffing jib hoist Boom and luffing jib are then raised together using boom hoist until boom reaches desired boom operating angle Luffing jib radius must be within capacity chart before swinging over side of machine Position boom at 70 degrees or greater prior to lowering luffing jib Lower luffing jib until boom to luffing jib angle reaches value specified in table Lower boom until luffing jib point is just above ground If luffing jib is hanging vertical raise luffing jib a few degrees forward of vertical Continue to lower boom while luffing jib rolls along ground Keep enough tension on luffing jib hoist to keep adjustable jib straps off luffing jib and lower boom to ground CAUTION Do not under any condition allow boom to luffing jib angle to become less than 70 degrees The following boom and luffing jib combinations require jack knifing to a specified boom to luffing jib angle for raising and lowering Maximum Boom And Luffing Jib Lengths Lifted Unassisted Using Jack Knife Method Over End of Over Side of Blocked Crawlers Crawl
117. supports on insert raise or lower jib strut so there is no load on locking pin in Remove locking pins View H and store in holes in outer 4 21 SETUP AND INSTALLATION Strut Stop Cylinder Cylinder Rod Roller Bottomed Out in Strut Stop Pocket Install Load Lines Depending on your lifting requirements the luffing jib can be operated with load lines over either jib point lower or upper 1 See Capacity Chart for lifting limitations and required deducts when handling loads from selected locations 2 See Wire Rope Specifications Chart in Luffing Jib Capacity Chart Manual to determine parts of line required for your job Size load block accordingly 3 Route load line from desired drum through proper guide sheaves on boom See Load Line Reeving in this section 4 f jib will be raised using In Line Method install load block and weight ball from jib points before boom and jib are raised 5 will be raised using Jack Knife Method proceed as follows a Reeve load lines through guide sheaves in jib point b Pull load lines approximately 20 ft 6 1 m past end of jib and lay lines on ground c Securely tie off load lines to jib point Install load block and weight ball after boom and jib are jack knifed into position just prior to raising jib point rollers off ground WARNING Run Away Wire Rope For long boom and short jib combinations wire rope on boom side of attachment can overhau
118. topic in Section 3 of Operator s Manual 4 Tighten jam nut The sensors monitor guide sheave rotation speed The cranes s programmable controller uses signals from the 5 Check for proper operation without load Drums should sensors to equalize the rotation speed of the drums so the operate at same speed and load block should remain load block remains level level Readjust sensor if required Sensor 2 79 Boom Sheave __ 0 39 in 9 906 mm Sensor 2 MAXIMUM Boom Mounting Bracket Sheave Sheave A Drum 1 Drum 2 A VN han Drum 6 Sheave Sensor Sheavefor H Drum 3 li Jam SN Front View of Boom Top Guide Sheaves FIGURE 4 57 4 94 Published 06 20 08 Control 033 07 r c Crane Care OPERATOR S MANUAL SECTION 4 INSERTS 18000 Luffing Jib Serial Number 18005910 RIGGING RAISING PROCEDURES ELECTRICAL WIRING amp WIRE ROPE DATA Drawing A07766 Raising amp Lowering Chart 8542 A Electrical Assembly Drawing A05580 Drawing 184433 OEM Wire Rope Data TBRR 192 P N2010170 08 13 2008 01 30 2007 04 14 2004 06 19 2008 01 31 1997 08 01 1996 05 01 2002 Luffing Jib Asm 44 Luffing Jib Luffing Jib Raising Proced
119. 0 81000730 15212 ROTATING BED JACKS 42 176856 09064 09344 176856 81000744 4 NAMEPLATE amp DECALS DESCRIPTION OF PART DECAL OFF DECAL OFF Chinese Language DECAL ON DECAL ON Chinese Language DECAL Decal Battery Disconnect English Language DECAL Decal Battery Disconnect Chinese Language DECAL Decal Battery Disconnect Spanish Language DECAL Decal Battery Disconnect Italian Language DECAL Decal Battery Disconnect Korean DECAL Pump Drive Oil Dipstick DECAL Warning Read Manual English Language DECAL Warning Read Manual Chinese Language DECAL Warning Read Manual Spanish Language DECAL Warning Read Manual Italian Language DECAL Warning Read Manual Korean Language DECAL Engine Oil Dipstick NAMEPLATE DECALS OPTION DECAL Warning Crush Hazard English Language DECAL Warning Crush Hazard Hazard Chinese Language DECAL Warning Crush Hazard Hazard Spanish Language DECAL Warning Crush Hazard Hazard Italian Language DECAL Warning Crush Hazard Hazard Korean Language EUROPE NAMEPLATE DECALS OPTION 45 46 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER A04559 197151 09066 01153 11623 81000740 177828 05714 181503 95494 386218 386219 11570 81000708 538663 181503 176856 09064 09344 11585 81000716 195270 13438 1 1 1 NAMEPLATE QSX15 Tier 2 Emission Tag DECAL Fire Extinguisher English Language DECAL Fire
120. 0 Mast A05379 6 of 22 MANITOWOC CRANES INC 38 50 62 66 71 75 8889 96 97 96 97 96 97 R89 R86 Backstay Straps Boom Straps 46 R201 R100 R107 R120 R130 R138 R147 R171 R172 R171 R172 R171 R172 R200 38 50 62 66 71 75 8889 9001 96 97 96 97 R89 R86 46 Backstay Straps Boom Straps R201 R100 R107 R120 R130 R138 R147 R157 migg 17 R172 R171 R172 R200 260 Boom R153 R167 R167 R181 38 50 62 66 71 75 8889 96 97 96 97 R89 R86 46 Backstay Straps Boom Straps R201 R100 R107 R120 R130 138 R147 171 R172 171 R172 R200 240 Boom 38 50 62 66 71 75 88 89 90 91 96 97 R89 R86 Backstay Straps Boom Straps R201 46 R100 R107 R120 R130 R138 R147 R157 R158 R171 R172 R200 220 Boom R153 R167 R181 55 79A Boom Assembly Reference Boom Rigging Assembly 100 Mast A05379 7 of 22 MANITOWOC CRANES INC 8 8 9 9 a t0 ot 28 41 712 gt 06 9 9 1 10 103 12 12 2 BS Ai 9 9 C 10 10775 712
121. 000 LUFFING JIB OPERATOR S MANUAL SAFETY INFORMATION A10415 View A WRONG DANGEROUS and there is No Blocking Under Boom Sections If Boom is Off Ground and Supported by Straps Boom will COLLAPSE when Lower Pins are Removed View B WRONG DANGEROUS 2 Handling Pendants are Slack and there is No Blocking Under Boom Sections If Boom Point is on Ground Boom will COLLAPSE when Lower Pins are Removed 1 View C Handling Pendants Taut RIGHT SAFE and Supporting Boom Straps Fully Lowered onto Supports Before Removing Pins before Removing Boom Sections Lowered Bottom Pins and Securely Blocked FIGURE 2 5 mm Published 06 20 08 Control 033 07 2 19 SAFETY INFORMATION PERSONNEL HANDLING POLICY In 1998 the American Society of Mechanical Engineers issued a new American National Standard entitled Personnel Lifting Systems ASME B30 23 1998 This standard provides lifting and lowering of personnel using ASME B30 Standard hoisting equipment shall be undertaken only in circumstances when it is not possible to accomplish the task by less hazardous means Unless all of the applicable requirements of this volume are met the lifting or lowering of personnel using ASME B30 Standard equipment is prohibited The ASME Standards recognize that mobile and locomotive cranes are primarily designed and intended for handling m
122. 033 07 4 83 4 204 18000 LUFFING JIB OPERATOR S MANUAL Wire SETUP AND INSTALLATION S S 3 3 pu m occum S uo MS S vic 58 55 59 _ O E zie WE S amp Y 53 o amp c E lt 28 lt 56 55 S 58 38 a 5 P te ee S n S _ S jare s M ETE lt NES QM lt 25 z S SG S i S S 8 5 So nee eS 5 amp m amp S C3 S S _ P ON Ge ao SS MES a lt gt Qua 2 PART 6 I I l ma OA O 8 PART 0 l I I l c Canitowoc FIGURE 4 49 Published 06 20 08 Control 033 07 14 PART 4 84 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION THIS PAGE BLANK mm Published 06 20 08 Control 033 07 4 85 SETUP AND INSTALLATION LOAD LINE REEVING 79 LUFFING JIB Load Block Identification See the Luffing Jib Assembly Drawings at the end of this section for a complete list of load blocks and weight balls available for this crane WARNING Falling Load Hazard Use only a hook and weight ball or load block with a capacity equal to or greater than load to be handled Avoid overloading bearings in load bloc
123. 07766 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 16 of 22 CABLE ASSEMBLY 60 SPACER GUARD Rope PIN PLATE Keeper NUT Bearing Lock see Note 6 WASHER Bearing Lock NUT Hex 1 4 20 NUT Hex 3 8 16UNC SCREW Cap 3 8 16UNC 2B x 5 8 long SCREW Hex Cap 1 4 20 x 3 4 long SCREW Hex Cap 3 8 16 x 4 long ROLLER Sheave 1 4 dia see Note 7 WASHER Flat 3 8 WASHER Lock 1 4 WASHER Lock 3 8 ROLLER TUBE Round HYDRAULIC CYLINDER ASSEMBLY WINCH SHIM 3 32 18 GA SUPPORT SHIM PACK SUPPORT Keeper Plate amp O gt N N A N N N N STRAP ASSEMBLY STRAP Adjustable Length Jib Weldment COLLAR PIN LINK Strap EXTENSION Strap PIN Strap Adjust COLLAR PIN PIN PIN HANDLE N N N N N gt DNDN MODEL 18000 LUFFING JIB RIGGING 44 Luffing Jib on 55 79A Boom with 100 Mast DESCRIPTION OF PART MAIN STRUT Weldment see O 539 PIN COLLAR PIN SHAFT LINK ASSEMBLY SPACER SPACER SPACER SHAFT PIN LINK ROLLER ROLLER STRAP PIN SPACER NUT Bearing Lock see Note 6 WASHER Bearing Lock R75 194161 R76 194682 R77 194683 R78 194684 R79 194880 R80 194907 R81 194908 R82 194909 R83 194910 R84 194911 R85 194914 R86 194979 R87 194987 R88 194988 R89 194993 R90 194994 R91 195004 R92 225105 R93 225111 R94 276935 PENDANT R95 624779 PIN Shackle 2 1 4 dia R96 646246 1 W
124. 3 Strain Relief on Cable Must be Connected to Hook in Boom and Jib Point 10 Description Lift Block Weight 1 Part Weight Multiple Part 8 Ft 2 4 m 1 or 2 each 2 3 4 5 Upper Boom or Jib Point Block Up Limit at 55 79A Boom Point Shown 6 7 8 Block Up Limit at 79 Boom Point at 55 Boom Limit Switch Assembly Point and at Luffing Jib Points is Similar Lower Boom Point Boom Node jj 9 Load Cell Receiver 10 Cable From Cable Reel 11 Lift Plates 12 Load Block 13 Chain 12 ft 3 7 m o h H FIGURE 6 8 mm Published 06 20 08 Control 033 07 6 15 MAINTENANCE 18000 LUFFING JIB OPERATOR S MANUAL A1131 Item Description 1 Electrical Cable Typical Cable Reel Boom Butt or Fixed Jib Butt kuting Jih Butt Brackets Cable ai c FIGURE 6 9 Dead End Load Line A837 or Slowest Live Line Lo E Lower or Upper Boom Point Description multiple part 1 Weight See Load Block Reeving in Section 4 Shackle for Suggested Location of Weight Chain Connecting Pin Lift Plate Lift Block i Y 3 ft 0 9 m to Top of Weight Ball 1 Part Reeving Two Chains Prevent Weight from Turning in um oak wh o Upper Boom
125. 3 20 ft 6 1 m insert No 79 without straps 6 700 3 039 40 12 2 m insert 79 with double straps 13 180 5 978 28 ft 2 15 16 in 8 6 basic strap each 355 161 20 ft 6 1 jib strap with links each 290 131 40 ft 12 2 m jib strap with links each 525 238 Equalizing link each 375 170 8 63 0 2 m link pins each set 85 38 1 8 Published 06 20 08 Control 033 07 c Crane Care 18000 LUFFING JIB OPERATOR S MANUAL Description 17 ft 10 1 2 in 5 4 strap each 14611 0 5 link each Spreader with pins 13 ft 10 1 4 4 2 strap Spreader link pins 14611 0 5 link each 4ft2in 1 3m strap each Jib hinge pins link assembly each Jib stop assembly each Automatic jib stop assembly 30 ft 9 1 jib strut top with point sheaves 29 ft 8 8 jib strut butt with wire rope guide 21 ft 6 4 m main strut top with point sheaves and raising pendant
126. 33 8362 Website http www bridonamerican com E mail bridon bridonamerican com Form No TBRR 192 Rotation Resistant Ropes Rotation Resistant Ropes are defined as stranded ropes designed to generate reduced levels of torque and rotation when loaded and are comprised of an assembly of two or more layers of strands laid helically around a center The direction of lay of the outer strands being opposite to that of the underlying layer Rotation Resistant Ropes are grouped into the following categories based on construction Rotation Resistant Rope category 1 Stranded rope constructed in such a manner that it displays little or no tendency to rotate or if guided transmits little or no torque has at least fifteen outer strands and comprising an assembly of at least three layers of strands laid helically over a center in two operations the direction of lay of the outer strands being opposite to that of the underlying layer i e Endurance Dyform 34LR Endurance 35LS Rotation Resistant Rope category 2 Stranded rope constructed in such a manner that it has significant resistance to rotation has at least ten outer strands and comprising an assembly of two or more layers of strands laid helically over a center in two or three operations the direction of lay of the outer strands being opposite that of the underlying layer i e Endurance Dyform 18 Endurance 19 Rotation Resistant Rope category 3 Stranded rope construct
127. 4 31 SETUP AND INSTALLATION Jack Knife Lowering Procedure See Figure 4 17 for following procedure A WARNING Tipping Crane Hazard Observe boom to luffing jib angles specified on raising procedure chart Use digital display in cab to monitor boom and boom to luffing jib angles e f required by raising procedure chart lower boom and jib over blocked crawlers Lower all load block and or weight ball to ground before lowering boom and jib A WARNING Moving Part Hazard Warn all personnel to stand clear of jib point rollers while lowering boom and jib NOTE It is normal for the BLOCK UP MAX UP 1 and MAX UP 2 limits to come on during the lowering procedure 1 Swing upperworks in line with lowerworks so boom is centered over front of crawlers Travel crawler rollers onto blocking if required Swing boom and jib slightly to either side of center and lower load blocks and or weight balls onto ground Then swing boom and jib in line with crawlers and apply swing brake A WARNING Tipping Crane Hazard Do not lower boom jib to ground until boom has been positioned at minimum boom angle of 70 and jib has been positioned at specified boom to luffing jib angle Use digital display in cab to monitor boom and boom to luffing jib angles A WARNING Falling Jib Hazard Do not lower jib to any boom to luffing jib angle less than minimum stop 70 Structural damage to jib butt will occur possibly causi
128. 6 Slowly continue with Jack Knife Raising Procedure steps 3 5 A WARNING Falling Jib Hazard Structural Damage Do not lower jib to any boom or jib angle less than minimum stop 70 7 Stop raising boom when boom and jib have been positioned at required boom to luffing jib angle or jib is vertical whichever occurs first Monitor this angle on digital display 8 Slowly luff up until jib straps start to go into tension and stop 9 Boom up to raise jib point rollers clear of ground apply swing brake and install load block and or weight ball see Install Load Lines in this section Untie load lines from jib after installing load block and or weight ball A WARNING Falling Load Hazard Raise boom to desired operating angle and position jib at required operating radius before lifting load block and or weight ball from ground 10 Slowly raise boom to desired operating angle See Capacity Chart for allowable boom angles 11 Pay out load lines as boom and jib are raised 12 Luff up to position jib at required operating radius for load to be handled 13 Travel forward as required to position load block and or weight ball below jib points and lift load block and or weight ball to desired operating position er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION ITEM NUMBERS CORRESPOND TO IN LINE LOWERING PROCEDURE STEPS 8 See View E Vi US 7 VY VA
129. 6 IWRC ROTATION ENDURANCE 8RR DEGREES M ENDURANCE 19 DYFORM 18 ENDURANCE 35LS DYFORM 34LR ROPE TENSION P MBL MINIMUM BREAKING LOAD Rotation Resistant Ropes SEIZING AND CUTTING Because Rotation Resistant Ropes can be difficult to properly identify by sight it is recommended that all Rotation Resistant Ropes be tightly seized with wire strand or tape or welded before cutting It is important that all Rotation Resistant Ropes be prevented from unlaying when cut regardless of construction General guidelines for seizing and welding are shown in detail below Endurance 3515 and Endurance Dyform 34LR should have welded ends and not seized ends PREFORMED NON PREFORMED Rotation Resistant Ropes are special ropes and are produced with special manufacturing techniques to meet all of the required operating parameters of the ropes To prevent confusion as to which are preformed partially preformed and non preformed Bridon American attaches a warning tag on Rotation Resistant Ropes to indicate that they should always be properly seized when cut wb aede A E w NOTE Two seizings are recommended for non preformed rope two rope diameters in length and seizing for preformed rope one diameter in length WELDED ENDS A welded rope end can facilitate the installation of a Rotation Resistant Rope in a wedge socket A welded rope end combined with a tail of less than 20 rope
130. 6 m Boom No 55 or 55A heavy duty upper boom point and 661 USt 600 t block UPPERWORKS REAR MACHINERY MODULE Rotating bed rear section with pin pullers upperworks jacking system 30 ft 9 1 m live mast mast hoist with mast hoist line Cummins QXF15 power plant hydraulic reservoir full fuel tank 1 2 full and operators cab drum and catwalks removed Upperworks jacking system removed ADAPTER FRAME WITH CARBODY Rotating bed adapter frame with bearing turntable 4 swing drives and carbody includes MAX ER prep MAST 56 BUTT TOP SHIPPING PACKAGE 20 ft 6 1 m mast butt boom hoist drum with rope boom hoist drum guide rollers wire rope guide sheave mast stops mast butt supports boom equalizer 20 ft 6 1 m mast top with sheaves and straps includes MAX ER prep BOOM NO 55 BUTT SHIPPING PACKAGE 20 ft 6 1 m boom butt load hoist drum with rope luffing drum with rope rigging winch with rope cable reel boom stops and boom hinge pin pullers BOOM 55 10 ft 3 0m INSERT SHIPPING PACKAGE 10 ft 3 0 m insert load hoist drum with rope and wire rope guide CRAWLERS 38 ft 9 in 11811 mm crawler assembly each with drive and 60 in 1 524 treads COUNTERWEIGHT UPPER Tray each
131. 62 R20 179863 R21 179959 R22 194159 R23 194910 R24 194915 R25 194976 R26 194977 R27 194978 R28 194979 R29 194980 R30 194981 R31 194982 R32 194985 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER A07766 15 of 22 PIN TIMBER STRAP Boom Support 40 LINK Boom Support COLLAR PIN INSERT 40 12 19 see 539 PIN 4 2 2 4 4 4 1 4 JIB STRUT ASSEMBLY WASHER Flat see Note 3 BOOM ANGLE INDICATOR ASSEMBLY PLATE Keeper SHEAVE ASSEMBLY see Note 4 SHEAVE ASSEMBLY see Note 5 PIN COLLAR COLLAR PIN PIN WELDMENT Jib Strut see O 539 SPACER SPACER SPACER SHAFT SHAFT LINK PIN PIN STOP Oylinder PIN A N N N N N N MODEL 18000 LUFFING JIB RIGGING 44 Luffing Jib on 55 79A Boom with 100 Mast DESCRIPTION OF PART R33 194997 R34 195005 R35 195006 R36 195194 R37 195195 R38 225105 R39 225111 R40 546052 R41 546054 R42 612451 R43 612353 R44 614033 R45 631528 R46 709440 R47 710302 R48 710304 R49 A00070 R50 00072 R51 A00306 R52 A00355 R53 00874 R54 A01617 R55 A01624 R56 A02831 STRAP R57 194869 R58 194861 R59 179862 R60 179959 R61 194864 R62 194865 R63 194872 R64 194966 R65 194967 R66 194968 R67 194992 R68 195350 MAIN STRUT 35 194162 MAIN STRUT ASSEMBLY R69 139133 PIN R70 169810 PLATE Keeper R71 171964 SHEAVE ASSEMBLY see Note 5 R72 179862 COLLAR R73 179863 PIN R74 179959 PIN ASSEMBLY REVISION A
132. 86 Load Block 4 86 Load Block 0 4 86 Duplex Hook iate ee RR E RR ba ERR Rm ated Bee 4 86 Wire Rope Specifications 4 86 Wire Rope 1 5 4 86 Guide Sheaves and 5 4 86 gau 4 86 Block Level Sensor 4 94 LET 4 94 Sensor 4 94 Published 06 20 08 Control 033 07 4 iii 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION SECTION 4 SETUP AND INSTALLATION A WARNING Avoid Death or Serious injury Read and understand instructions in this section before attempting to install or remove attachment Moving Parts Pinch Points Avoid death or crushing injury during crane assembly disassembly Assembly personnel take every precaution to prevent injury when working near moving parts e Maintain communication between operator and assemblers to avoid accidents KEEP UNAUTHORIZED PERSONNEL WELL CLEAR OF CRANE Falling Load Hazard To prevent lifting equipment from failing and load from dropping crane owner user shall verify following prior to each lift All lifting equipment s
133. 86 Wire Rope Specifications 4 86 Wire Rope 1 4 86 Guide Sheaves and 4 86 4 86 Block Level Sensor 4 94 General resres nde D 4 94 Sensor 4 94 SECTION 455552445505 guide Lubrication General Lubrication 24 222 ble bee 5 1 Lubrication 5 1 Over Lubrication 1 5 1 bubrication TIps terrere tel tree ceo tere de 5 1 Oil Can Mns 5 1 Wire Rope 5 1 Approved Greases 5 1 44 Luffing Jib Lubrication 5 5 179A Luffing Jib Lubrication 2 1 5 5 Periodic Check of Jib Stop Positioner Hydraulic Oil 5 6 SECTION 6 45 3553 5044 e ia sasa a Maintenance General Maintenance 6 1 Jib Stop Adjustment Past 6 1 General exei A
134. 94 Assist Crane Attached Drum 3 Attached to to Erection Pendant Erection Pendant lt item R94 Up to 45 To Remove refer to Operation Manual r9 Line M 10 of 22 26 23 24 25 ivi m MANITOWOC CRANES INC R64 Must Be In R65 Position As Shown 16 ERES s 4 AS Vb 194 34 R89 Handling Pin 17 Stowed Position Erection Position SAX AANA UY Warning Do Not Exceed 70 Jib Strut Angle During Erection While Boom is on The Ground Watch That The Jib Strut Cylinders Do Not Fully Retract 35 R65 Erection R33 R64 Position Adjustable ViewL Erection Position VAT WIL La View K 6 24 25 Storage Working Position View M Storage Working Position 11 of 22 MANITOWOC CRANES INC Greasing Aux Drum Sheave 1 Raise or lower jib until aux drum sheave is in the center of it s saft and grease groove is completely covered by sheave 2 Pump grease through grease zerk in boom butt 3 Before initial boom raising connect grease line sections and pump grease through line until grease begins to come out of grease hone in shaft Aux Drum Sheave Grease Groove A Grease Grease Line Line Grease Zerk
135. 9A Luffing 4 86 Lubrication IntervalS 5 1 Lubrication TIDS meu whe Re Wie gue moie SUE 5 1 Luffing Jib Attachment Access 2 5 Luffing Jib Operating 8 3 4 Luffing Jib Raising 4 2 Luffing Jib Rigging 444 4 7 Luffing Jib Rigging Guide 479A 4 35 Manitowoc Crane Care 0 1 11 Nameplates and 2 1 Oil Gan POINTS Soak REGI qaq NIU GRE oubli NE REP os 5 1 Operating Controls usuy a yu EUER ae RE ea ws ERE 4 2 Operating Near Electric Power Lines And Transmission 2 13 Operating 3 8 Operators Manual Capacity Chart 2 7 Outline 4 1 4 Over Lubrication 5 SEGA RL SE 5 1 Pad Eye Usage for Wire Rope Reeving 4 79 Pedestal barge Mounted 2 21 Periodic Check
136. AL blocking individual pin connections may still be under load Pins can be ejected forcefully if the boom has any pressure on it or if the boom is not supported properly A DANGER DO NOT DEFACE OR REMOVE THIS SIGN FROM 2 18 97 MANITOWOC CR S INC 1478529 FIGURE 2 4 Disassembly Precaution Always block boom sections so they are securely supported and cannot shift or move suddenly when pins are removed If there is any doubt about a boom disassembly procedure block tightly under boom sections before removing any pin A DANGER Collapsing Boom Hazard Boom can collapse or shift violently when pins are removed To avoid death or serious injury Do not remove bottom connecting pins from any boom section when boom is supported by straps as shown in Figure 2 5 View A Do not remove strap connecting pins until straps are fully lowered into supports as shown in Figure 2 5 View C Do not remove bottom connecting pins from any boom section when boom point is resting on ground and handling pendants are slack as shown in Figure 2 5 View B Never work or stand inside boom unless it is lowered and securely blocked as shown in Figure 2 5 View C Do not stand or walk on top of boom unless it has walkways A DANGER Falling Boom Hazard Crane can tip or boom can collapse if excess boom is cantilevered Never cantilever more boom than allowed in rigging drawings or capacity charts Canrrowoc 18
137. ANUAL A1274 A08238 44 Luffing Jib CAUTION Parts Damage If luffing jib is to be operated when air temperature is below 32 F 0 C drain and refill hydraulic systems crane and boom with Petro Canada Hydrex XV hydraulic oil Be sure that jib strut cylinders and supply lines are completely drained before refilling For operation below 10 F 12 C use a thinner fluid such as Petro Canada Premium Arctic 15 Luffing Hoist Top Wire Rope Guide Sheave 79A Luffing Jib Optional Remote Fitting at Base of Boom Butt 5 101 P1378 4 Places Luffing Hoist Top Wire Rope Guide Sheave Optional Remote Fitting at Base of Boom Butt Jib Point Dolly 5 101 5 4 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL 44 LUFFING JIB LUBRICATION Item Description LUBRICATION Required tem Description Required Service see NOTE see NOTE Every 40 Hours or Weekly whichever comes first 1 Weight Ball Swivel Grease 2 Load Block Sheaves Grease if equipped with fittings 3 Load Block Trunnion Swivel Grease if equipped with fittings 4 Bottom Wire Rope Guide Sheave Grease Every 200 Hours of Operation or Monthly whichever comes first 5 Block Up Limit Switch 1 fitting inside each switch Grease each Each Time Boom and Luffing Jib are Lowered to Ground 6 Luffing Jib Wheel
138. ATA 55 79A BOOM RIGGING BOOM LENGTH SECTION LENGTH STRAP 2 194993 2 2 A05198 2 2 A05196 2 2 A05197 2 2 A07111 2 2 179838 2 6 179839 2 LUFFING JIB DATA RIGGING ASSEMBLY A07766 JIB TYPE SECTION PART LENGTH STRAP BUTT 171283 7 12 FT BUTT 171284 6 28 2 179840 179915 9 30 FT 2 179841 INSERT 179912 9 10 2 179837 INSERT 179913 2 20 2 179838 INSERT 179914 2 40 2 179839 MAIN STRUT 194161 2 47 JIB STRUT 194159 9 50 FT MACHINE DATA DRUMS LAGGING LUFFING HOIST A05274 2 NONE LUFFING JIB WIRE ROPE JIB HOIST 1700 FT 1 DYFORM 8PI CAPACITY CHARTS COUNTERWEIGHT ARRANGEMENTS 8577 A DRUM AND LAGGING CHART 8512 A LIFTCRANE BOOM CAPACITIES WITH LUFFING JIB ATTACHED LIFTCRANE BOOM CAPACITIES WITH LUFFING JIB ATTACHED Manitowoc Cranes Inc LENGTH 38 2 BASIC BACKSTAY 10 JIB BACKSTAY 20 JIB BACKSTAY 40 JIB BACKSTAY 40 JIB BACKSTAY 20 JIB BACKSTAY 40 JIB BACKSTAY 44 JIB LENGTH 140 FT LENGTH 2 31 1 BASIC 2 2 10 0 INSERT 2 20 0 INSERT 2 40 0 INSERT WEDGE ROPE SIZE 19616 2 1 14127 3 LIFTCRANE FIXED CAPACITIES ON LUFFING LIFTCRANE LUFFING JIB CAPACITIES 8515 AM MAXIMUM ALLOWABLE TRAVEL SPECIFICATIONS 85 OPERATING RANGE DIAGRAM RAISING LOWERING PROCEDURE 8542 A RANGE DIAGRAM A07738 TRAVEL SPECIFICATIONS 43 A
139. Bi swu lunoo 1o xe y E EPIIT IE MUTA PRS epis apis nng woog 6 ga IS jeoN 9 i 7 8 a 5 m 1 ir i 9 TIT s NAMEPLATE DECALS DESCRIPTION OF PART SIGN Boom Manitowoc see Note 3 DECAL Danger Stay Clear English Language DECAL Danger Stay Clear Chinese Language DECAL Danger Stay Clear Spanish Language DECAL Danger Stay Clear Italian Language DECAL Danger Stay Clear Korean DECAL Danger Electrocution Hazard English Language DECAL Danger Electrocution Hazard Chinese Language DECAL Danger Electrocution Hazard Spanish Language 95494 386218 386219 A11570 81000708 95496 386239 386240 A11571 81000709 97281 386203 386204 A11572 81000710 147834 147848 386272 386273 A11579 81000712 172859 386290 386291 DECAL Danger Electrocution Hazard Italian Language DECAL Danger Electrocution Hazard Korean DECAL Warning Fall Hazard English Language DECAL Warning Fall Hazard Chinese Language DECAL Warning Fall Hazard Spanish Language DECAL Warning Fall Hazard Italian Language DECAL Warning Fall Hazard Korean DECAL Epic 3 X 8 7 8 see Note1 DECAL Patents English Language DECAL Patents Chinese Language DECAL Patents Spanish Language DECAL Patents Italian Language DECAL Patents Korean DECAL Warning Read Manual Remote English Language DE
140. CAL Warning Read Manual Remote Chinese Language DECAL Warning Read Manual Remote Spanish Language A11582 DECAL Warning Read Manual Remote Italian Language 81000714 DECAL Warning Read Manual Remote Korean 175916 DECAL Danger Boom Sections English Language see Note 4 176835 DECAL Made In USA 176882 DECAL Warning Operators Manual English Language A09047 DECAL Warning Operators Manual Chinese Language A01131 DECAL Warning Operators Manual Spanish Language A11586 DECAL Warning Operators Manual Italian Language 81000718 DECAL Warning Operators Manual Korean 176927 DECAL ANSI B30 B English Language A09050 DECAL ANSI B30 B Chinese Language A01161 DECAL ANSI B30 B Spanish Language A11587 DECAL ANSI B30 B Italian Language 81000720 DECAL ANSI B30 B Korean 181503 PLATE Crane 1 0 184679 DECAL Hand Signal English Language 386212 DECAL Hand Signal Chinese Language 386213 DECAL Hand Signal Spanish Language A11591 DECAL Hand Signal Italian Language 81000732 DECAL Hand Signal Korean 197025 DECAL Caution Welding English Language A09061 DECAL Caution Welding Chinese Language A01143 DECAL Caution Welding Spanish Language A11622 DECAL Caution Welding Italian Language A06702 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 4 of 8 gt N N N N N NAMEPLATE DECALS DESCRIPTION OF PART 81000738 DECAL Caution Welding
141. Counterweight is required to prevent jib strut from rising when main strut is raised with luffing hoist If counterweight becomes disconnected from jib strut jib strut will rise part way and then both struts could fall forward violently Minimum capacity required for slings is 25 000 Ib 11 340 kg per side 1 Remove one top crane counterweight box from each side of crane counterweight Boxes must be equipped with tie link lugs 2 Stack counterweight boxes 8 View F one at a time at jib strut top 4 View O 3 Secure lifting lugs on top counterweight box 5 to lugs on jib strut top 4 with shackles and suitable slings 24 View F 4 If desired front counterweight tie links 9 View may be connected at this time Do not connect rear counterweight tie links 9 View E Description Backstay Strap Link Connecting Link Connecting Pin with Collar Retaining Pin and Cotter Pins Removable Strap Bracket Strap Shipping Pin with Cotter Pin Retaining Pin with Cotter Pins Strut Stop Cylinder Adjustable Link Strap Bracket Connecting Pin with Collar Retaining Pin and Cotter Pins Sling and Shackle er 18000 LUFFING JIB OPERATOR S MANUAL Install Backstay Straps on Main Strut 1 Install backstay straps on main strut as shown in Figure 4 22 Store on Main Strut Main Strut Jl el ji Connect to Backstay Straps on Boom Inserts Description 1 3 4 5a 5b 6 7 8
142. E edi 6 1 Removing Luffing 6 1 Boom Stop 6 1 ED eed E 6 3 Published 06 20 08 Control 033 07 TABLE OF CONTENTS Index iii TABLE OF CONTENTS 18000 LUFFING JIB OPERATOR S MANUAL Adjustment neon eo t pa RES OSES 6 3 Operational Checks 224222 AG UR 6 4 Jib Stop Adjustment Current 6 4 General db e De Badge aude gustu de das duis 6 4 Maintenance odas Sasa us a pam qS E WORTH 6 4 Pre Erection Checks 6 4 Operational 6 6 Actuator Rod 6 6 Automatic Boom Stop 6 9 Maximum Operating Angle 6 9 Operation Lati peer docet pate erus teuer d dues ette 6 9 Maintenance ss mee a i eden ipee Ciber dut 6 9 Boom and Mast Stability 6 9 Actuator Rod 6 10 Adjustment
143. EDGE Socket 1 Wire Rope see O 890 OPTIONAL WIRE ROPE GUARD FOR CE CODE 36 A06120 1 GUARD Wire Rope for CE Code BOOM RIGGING A05379 R97 A04342 1 MAST ASSEMBLY 100 EQUALIZER R98 06258 1 EQUALIZER ASSEMBLY BUTT 20 6 10 M 55 BOOM R99 A05403 1 20 BUTT ASSEMBLY 55 Boom R100 A05447 1 BUTT 20 machining see O 573 R101 04989 BOOM STOP ASSEMBLY R102 A04329 DRUM ASSEMBLY Main Hoist R103 193481 PIN PULLER ASSEMBLY R104 A06649 PIN Upper Male Connector R105 168179 INDICATOR Boom Angle Luffing Jib Equipped see Note 8 37 04331 LUFFING DRUM ASSEMBLY 38 A07498 LINK 55 Boom Strap 39 A07517 PIN 1 Hole w Hd 40 A06344 PAWL ASSEMBLY Luffing Drum 41 A06150 PIN 2 Hole 42 06151 COLLAR 43 562105 PIN Cotter 1 4 x 1 1 2 long PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER A07766 17 of 22 N N N N N N E N N N MODEL 18000 LUFFING JIB RIGGING 44 Luffing Jib on 55 79A Boom with 100 Mast DESCRIPTION OF PART INSERT 10 3 05 BOOM R106 A05381 INSERT ASSEMBLY 10 55 Boom R107 A05448 INSERT 10 machining see O 573 R108 A04329 DRUM ASSEMBLY Main Hoist R109 631099 SHEAVE R110 563640 PIN Safety R111 A07561 PIN 1 Hole w Hd R112 06099 PIN 1 Hole w Hd R113 A06649 PIN Upper Male Connector Locking R114 A06173 FRAME Drum Sheave machining R115 A06175 SHAFT R116 A06176 GUARD Rope R117 A06540 PIN Frame R118 A06361 PENDANT Luffing Jib Equip
144. ER Model 18000 with MAX ER Mast Straps 44 Mast 100 ft 39 6 m OR 140 ft 42 7 m Boom Hoist Wire Rope Boom Hoist Equalizer Boom Straps Jib Backstay Straps Wire Rope Guide Adapter Frame Jib Strut Stop Main Strut Stop Jib Stop Main Strut Luffing Hoist Wire Rope Jib Strut Adjustable Jib Strap Load Lines 44 Luffing Jib 79A Luffing Jib Jib Straps Lower Jib Point Wire Rope Guide Upper Jib Point with Wheels Hook and Weight Ball Load Block Counterweight Straps FIGURE 1 2 1 2 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL INTRODUCTION FIGURE 1 2 continued ad Published 06 20 08 Control 033 07 1 3 INTRODUCTION OUTLINE DIMENSIONS 18000 LUFFING JIB OPERATOR S MANUAL 1 100 ft 30 48 m Mast 118 ft 11 in 36 25 m B1 100 ft 30 48 m Mast 123 ft 1 in 37 51 m A2 140 ft 42 67 m Mast 157 ft 3 in 47 93 B2 140 ft 42 67 m Mast 163 ft 1 in 49 70 m B1 or B2 A1 or A2 1 22 BN pd bw y P N N
145. ET PLATE Mounting SWITCH ASSEMBLY SWITCH ASSEMBLY CHAIN Straight Link 12 long SHACKLE Anchor STRAP Stay see Note 7 GQ 177 669280 STUD Wire Tie see Note 7 178 667042 STRAP Stay 180 81000199 CABLE Electric Block Up Limit 36 long 181 81000202 CABLE Electric Block Up Limit 46 long 182 477339 CABLE Harness Extension Micro Change 19 7 long 184 546054 NUT Hex 3 8 16UNC 2B 185 612456 SCREW Hex Cap 3 8 16UNC 2A x 1 1 4 long 186 710304 WASHER Lock 3 8 ADD FOR 55 55A LOWER BOOM POINT OR LOWER JIB POINT WITH TANDUM 2 DRUM REEVING 189 A15488 LINK Load Cell 70k Wired 190 81000200 CABLE Electric load link 20 Note 1 Block up limit control is intended as a protective device It is not to be used as hoist distance control for specific job applications Periodic checks should be made to insure that block up limit control is functioning properly CAUTION Block up limit control system may not function at machines maximum single line speed carefully check each machine for maximum safe line speed For blocks without actuator brackets see modification dwg 184433 customer furnished When locking swivel is placed in the wire rope dead end allow extra length in chain equal to length of the locking swivel added Attach cable to boom or jib by using straps at approximately 10 ft intervals Attach cable to boom top or jib top between junction box and switch
146. Extinguisher Chinese Language DECAL Fire Extinguisher Spanish Language DECAL Fire Extinguisher Italian Language DECAL Fire Extinguisher Korean Language DECAL CE DECAL Sound Power Level 111db ER HANGING COUNTERWEIGHT AND MAX ER WHEELED COUNTERWEIGHT OPTION DECAL 1 0 USA Made DECAL Danger Stay Clear English Language DECAL Danger Stay Clear Chinese Language DECAL Danger Stay Clear Spanish Language DECAL Danger Stay Clear Italian Language DECAL Danger Stay Clear Korean Language DECAL Max er 59 ER WHEELED COUNTERWEIGHT OPTION DECAL 1 0 USA Made English Language DECAL Warning Crush Hazard English Language DECAL Warning Crush Hazard Chinese Language DECAL Warning Crush Hazard Spanish Language DECAL Warning Crush Hazard Italian Language DECAL Warning Crush Hazard Korean Language DECAL Max er Controls English Language DECAL Max er Controls Chinese Language 7 8 MODEL 18000 09372 11598 81001109 195435 13439 09373 11599 81001110 05204 09653 09370 11633 81001111 OQ O O 4 NAMEPLATE amp DECALS DESCRIPTION OF PART DECAL Max er Controls Spanish Language DECAL Max er Controls Italian Language DECAL Max er Controls Korean Language DECAL Warning Tipping Hazard English Language DECAL Warning Tipping Hazard Chinese Language DECAL Warning Tipping Hazard
147. Guide Bar upper Wire Rope Guide Bar lower Dead End Socket er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 5 4 161 DA i9 4 d 7 working E ie 9 View C 6 working 2 lt t 1 z Y a View D stored 8 See Figure 4 20 9 working 160 200 ft 48 8 61 0 m 220 360 ft 67 1 109 7 m FIGURE 4 21 ads Published 06 20 08 Control 033 07 4 43 SETUP AND INSTALLATION Install Main Strut Top See Figure 4 21 for following procedure Connect Main Strut Top to Strut Butt 1 Support main strut top 3 View A with slings from assist crane Adjust slings so butt end of top is higher than top end Remove rear shipping pins 7 View B Remove pins 6 View C from strut support C Lift main strut top clear of jib strut top gv gt Store rear shipping pins 7 View B in lugs on jib strut top 6 Rotate strut supports C 5 View D into stored position and pin to jib strut top with shipping pins 6 7 Move strut top slowly to the rear while paying out luffing hoist wire rope from Drum 6 so that wire rope between struts pays out smoothly without kinking or binding 8 When sufficient wire rope has been paid out position main strut top in front of main strut butt View O Install bottom and top connecting pins 15 Figure 4 20 View K and safe
148. Install Luffing Hoist Wire Rope Shipping jib strut top 13 and main strut top 14 assembled as shown in Figure 4 20 View H allows reeving a sucker line through the luffing sheaves in the strut tops See Luffing Jib Rigging Drawing for wire rope specifications Make sure wire rope is properly anchored to Drum 6 luffing hoist and tightly spooled onto drum Make sure Drum 6 wire rope guide is raised in 40 ft 12 2 m boom insert Make sure wire rope passes under lower sheave and over upper sheave in 40 ft 12 2 m boom insert Make sure wire rope passes under sheave in boom top wire rope guide and rollers 17 View J in main strut butt Pull out upper wire rope guide bar 19a View 1 to the left about half way Remove lower wire rope guide bar completely 19b If this step is not performed wire rope damage can occur when main strut is raised Do not remove upper wire rope guide bar completely You will not be able to reinstall it after main strut is raised Route wire rope through proper sheaves as shown in reeving diagram on Luffing Jib Rigging Drawing Pull lead end of luffing hoist wire rope approximately 100 ft 30 5 m past end of struts and lay on ground This will allow strut to be raised to erection position Anchor lead end of luffing hoist wire rope to socket 20 View G in main strut top 14 Description Connecting Pin with Safety Pin Luffing Hoist Wire Rope Roller Wire Rope Guide Wire Rope
149. JIB The 20 ft 6 1 m and standard 40 ft 12 2 m 44 inserts Removable 7 8 9UNC x 2 1 2 in have removable diagonal lacings These lacings may be Diagonal Grade 5 Hex Bolt removed to allow for storage of other components during Lacing shipping If removed removable diagonal lacings must be reinstalled before operating crane 1 Thoroughly clean all dirt from mating surfaces between lacings and supports on inserts 2 Reinstall proper number of removable lacings in each insert with bolts and stop nuts as shown in Figure 4 4 3 Securely tighten nuts P835 7 8 in Elastic Clean all dirt from between lacings and lacing Stop Nut supports Securely tighten nuts FIGURE 4 3 mm Published 06 20 08 Control 033 07 4 3 SETUP AND INSTALLATION Manitowoc Part Number Boom or Jib Number rd XXXXXX YY Z ZZ ZZ Chord Manufacturing 7 Code View A Manufacturer s Manitowoc Number Part Number PN 277360 PO 96858 90 SET 3 O Manitowoc Purchase Order Number L0 806E971H OUMI HH dl33 ScX9 ZU6IXV ESL Rope Type Length Diameter Aluminum Tag if equipped Published 06 20 08 Control 033 07 Manitowoc View C 18000 LUFFING JIB OPERATOR S MANUAL 4 100 Edge of Strap Part Number or Link both ends XXXXXX View B Part Number Wa URN Pres Purchase Order Number FIGURE 4 4
150. Korean 179030 DECAL Warning Rotating Drive Shaft English Language 386530 DECAL Warning Rotating Drive Shaft Chinese Language A09559 DECAL Warning Rotating Drive Shaft Spanish Language A11589 DECAL Warning Rotating Drive Shaft Italian Language 81000727 DECAL Warning Rotating Drive Shaft Korean A06914 DECAL Drum Identification English Language A10475 DECAL Drum Identification Chinese Language A12562 DECAL Drum Identification Spanish Language A11639 DECAL Drum Identification Italian Language 81001103 DECAL Drum Identification Korean A06726 DECAL Coolant Level English Language A10476 DECAL Coolant Level Chinese Language A12561 DECAL Coolant Level Spanish Language A11638 DECAL Coolant Level Italian Language 81001104 DECAL Coolant Level Korean 81003025 DECAL Radius English Language 81003026 DECAL Radius Chinese Language 81003029 DECAL Radius Spanish Language 81003027 DECAL Radius Italian Language 81003028 DECAL Radius Korean A06725 DECAL Diesel Fuel Level English Language A10478 DECAL Diesel Fuel Level Chinese Language A12560 DECAL Diesel Fuel Level Spanish Language A11637 DECAL Diesel Fuel Leve Italian Language 81001114 DECAL Diesel Fuel Leve Korean A07227 DECAL Warning Fall Hazard English Language see Note 5 A10479 DECAL Warning Fall Hazard Chinese Language see Note 5 A12563 DECAL Warning Fall Hazard Spanish Language see Note 5 A11640 DECAL Warning Fall Hazard
151. Luffing Jib Equipped see Note 8 78 78292 PIN 79 179862 COLLAR 3 dia x 1 long 80 179863 PIN 1 Hole w Hd 2 1 4 dia x 4 1 2 long PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER A07766 19 of 22 N N N N p HRA lS AND N N BRM N N N N S 5 BF N N N N MODEL 18000 LUFFING JIB RIGGING 44 Luffing Jib on 55 79A Boom with 100 Mast DESCRIPTION OF PART 81 179959 82 562045 83 562085 84 562105 85 A06149 86 A06150 87 A06151 88 07111 89 07112 INSERT 20 6 10 R152 194086 R153 193412 R154 193888 R155 193889 R156 193886 R157 179838 R158 192250 R159 179863 R160 78292 R161 179862 R162 194123 R163 179959 PIN R164 194377 ROLLER R165 194378 4 PIN Luffing Jib Equipped see Note 8 90 179838 STRAP 91 192250 LINK Strap 92 179863 PIN Strap 93 78292 PIN Strap Bracket 94 179862 COLLAR 95 179959 PIN INSERT 40 12 19 M 79 BOOM R166 194087 INSERT ASSEMBLY 40 79 Boom R167 193413 INSERT 40 see O 562 R168 193888 PIN R169 193889 PIN R170 193886 PIN R171 179839 STRAP R172 192250 LINK Strap R173 179863 PIN Strap R174 78292 PIN Strap Bracket R175 179862 COLLAR R176 194123 TIMBER R177 179959 PIN R178 194377 ROLLER ASSEMBLY REVISION A07766 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 20 of 22 PIN 1 2 dia x 4 1 8 long PIN Cotter 1 8 x 1 1 2 long PIN Cotter 3 16 x 1 1 2 long PIN Cotter 1 4 x 1 1 2 long PIN
152. NG Overload Hazard A pedestal mounted crane will not tip to indicate to operator that crane s capacity has been exceeded When capacity of a pedestal mounted crane is exceeded turntable bearing hook rollers if equipped or other structural components may break before load lines fail causing crane to separate from pedestal For this reason great care must be taken to operate a pedestal mounted crane within its rated capacity Careful planning is required before a crane can be operated on a barge Crane user shall verify that barge is capable of limiting crane list and or dynamics to maximum allowable specified on capacity charts If specified crane list and or dynamic conditions are exceeded crane s capacity may be exceeded therefore turntable bearing hook rollers if equipped or other structural components may break causing crane to separate from pedestal Definition A pedestal mounted crane is a crane which is securely fastened to a foundation barge ship or floating platform so the crane is restrained from tipping Examples 1 Crane upperworks mounted on a turret or tub which is securely fastened to foundation Figure 2 6 Lees Turret Foundation FIGURE 2 6 Published 06 20 08 Control 033 07 2 21 SAFETY INFORMATION 18000 LUFFING JIB OPERATOR S MANUAL Tie Downs Carbody P Foundation 2 106 94 FIGURE 2 8 2 Crane upperworks
153. NUAL Anchoring Wire Rope to Wedge Socket warnine Falling Load Hazard Inspect all parts prior to use Do not use parts that cracked or otherwise defective Remove minor nicks burrs or rough edges from socket wedge or pin by lightly grinding Do not reduce original dimensions by more than 10 Donot reinstall shipping material bolt plastic strap or wire in hole of wedge or socket after assembling Discard these materials because they can prevent wedge from tightening in socket Only use a wedge and socket which are correct size for wire rope being used Do not mix and match parts from one assembly with parts from another assembly Terminator wedge has go and no go holes to check for proper rope size e Attach wire rope clip to dead end of wire rope after assembling wire rope to wedge and socket e f dead end of wire rope is welded seize end of wire rope and cut off weld before assembling to wedge and socket Weld will not allow strands of wire rope to adjust around bend of wedge resulting in high strands and wavy rope This condition can seriously weaken attachment See Figure 4 44 for following procedure 1 Assemble wire rope and wedge to socket so live end of wire rope is in a straight line with socket pin hole Do not assemble WRONG as shown 2 Allow dead end of wire rope to extend past end of socket amount shown Allow wire rope to assume its natural lay gt Pu
154. ON ELA CSSVVNMINARABR E A ZEN pr ANAABAAAVAAIASSN TA View A POSITION F 14 15 stored Description 1 Drum 3 Load Line 10 Link 2 Socket 11 Strut Backstay Strap 3 Pin with Cotter Pin 12 Pin with Collar and Retaining Pin 4 Links 13 Main Strut 5 55 USt 50 t Shackle 14 Strut Stop 6 Strut Handling Pendants 15 Retaining Pin with Cotter Pins 7 Link 16 Drum 3 Luffing Hoist Line 8 Pin with Collar and Retaining Pin 17 Upper Crane Counterweight P2130 View C 9 Backstay Strap FIGURE 4 24 Published 06 20 08 Control 033 07 4 47 SETUP AND INSTALLATION Raise Main Strut continued See Figure 4 24 for following procedure steps 5 Attach assist crane to main strut lifting links 4 View E with user supplied 55 USt 50 t shackle 5 View E 6 Connect Drum 3 load line 1 to links 4 as shown in View E e Use same socket used to anchor load line to boom or jib point e sure Drum 3 load line passes over Drum 3 guide sheave in mast e Make sure Drum 3 load line passes through center of the slack boom hoist wire rope reeving and over the boom hoist equalizer which should be resting on boom rails NOTE After the main strut is fully raised it will be necessary to lift the boom hoist equalizer slightly to pass the load line under the equalizer 7 Remove pins 8 View E from links 4
155. P limit is on 6 Raise boom and jib to desired operating angle and radius Pay out load lines as boom and jib are raised Travel crane forward until jib point is over load block and or weight ball and lift load block and or weight ball to desired operating position er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 4 137 VIV ITEM NUMBERS CORRESPOND JACK KNIFE RAISING PROCEDURE STEPS VIV ABA MV FIGURE 4 15 4 138 Published 06 20 08 Control 033 07 4 27 SETUP AND INSTALLATION Jack Knife Raising Procedure See Figure 4 15 for following procedure A WARNING Tipping Hazard Structural Damage e See Raising Procedure Chart to determine BOOM TO LUFFING JIB ANGLE that boom and jib must be jack knifed to before jib can be raised Do not raise boom and jib combinations longer than specified on raising procedure chart e Monitor angle on digital display as boom and jib are raised CAUTION Structural Damage Do not exceed 70 jib strut angle while boom is ground Use mechanical angle indicator on jib strut to monitor strut angle e Avoid side loading as boom and jib are raised Disengage swing lock and release swing brake until boom and jib have been raised to required boom to luffing jib angle NOTE t is normal for the following limits to come on during the raising procedure BLOCK UP this
156. Point 1 part Upper Jib Point 1 part Lower Jib Point 1 part FIGURE 6 10 6 16 Published 06 20 08 Control 033 07 Crane Care 18000 LUFFING JIB OPERATOR S MANUAL MAINTENANCE WN18 Node 8 on A Boom Butt T WNEOB8 Node 7 Adapter Frame Description Sealing Cap 3 each Terminating Plug Electric Cable WNE14 Electric Cable WBM150 from Cable Reel 6 Boom Node Controller Sealing 14 each Terminating Plug 5 each Wind Speed Digital Output Block Level Switch 1 Block Level Switch 1 Electric Cable from Boom Cable Reel Block Up Limit Lower Point Boom or Jib Block Up Limit Upper Point Boom or Jib Electric Cable Out to Jib Luffing Jib Max Angle Limit Luffing Jib Max Angle Limit Luffing Jib Min Angle Limit An identical controller less luffing jib angle receptacles is mounted on luffing jib point FIGURE 6 11 Disconnecting Block Up Limit Control If electric cable 3 is terminated all of the block up limits on
157. RIAL NUMBER WITH ORDER 22 of 22 Manitowoc Cranes Inc a Manitowoc Wisconsin 54220 U S A fli ___ __ _ __ ___ ______ _ ___________________________________________ 7 Luffing Jib Raising Procedure 18000 Luffing Jib No 44 On Boom No 55 79A with 100 Ft Mast No 56 Recommended boom and luffing jib raising and lowering procedure Machine must be equipped with 528 000 Lb 239 500 kg crane counterweight and 320 000 Lb 145 150 kg carbody counterweight Refer to luffing jib rigging assembly No A07766 for boom and luffing jib make up of inserts straps struts and strut raising procedure and miscellaneous parts etc Two methods may be used to raise and lower boom and luffing jib combinations depending on length A Standard In Line Method Haul in luffing hoist line luff up until adjustable jib straps are raised to clear strap stowage brackets on luffing jib approx 50 to 68 degree jib strut to horizontal angle Do not exceed 70 degree jib strut to horizontal angle Check jib strut position by viewing angle indicator Slowly raise boom to tighten luffing jib suspension while jib point rollers are allowed to roll on ground After luffing jib suspension is tight boom and luffing jib can then be raised simultaneously using only the boom hoist Raise boom to 60 degrees or greater If boom to luffing jib angle is more than 160 degrees lower luffing jib to obtain this angle to allow jib stop to engage see caution Boom
158. Relief 59 67 train Relie 77 6 Part Of Item 6 NES C 49 Single Part Must Be Looped Over Line Hook On Boom 47 Location Of 65 J Weight 4 T 2 Part Line Wedge ee Note ocke 12ft Lg 95 33 12419 36 36 Load Link F 31 31 Wireless 70K 79A Boom View 2 Location Of Weight Item 31 Actuator Sea Nes With 2 4 6 8 Or 10 P Parts Of Line Over Lower Boom Point Bracket Assy ka Weight Block Angle 9 Transmitter Ref Single Part Line 379A Boom Top 2 of 20 Item 8 With 2 Part Line Boom Point Upper CRANES INC 62 62 58 58 51 57 57 51 50 52 68 59 77 55 55 9 ft Lg 9 ft Lg 73 9 ft Lg 11 77 77 ll 59 59 Single Part ETT 67 Line yli FAN 49 Single Part Line 3 Upper Boom Point View 1 Upper Boom Point 170419 Ref 55 Boom Butt Location Of Cable Reel A08516 Ref Bus Interface Node Controller Ref REVISION ASSEMBLY A05580 3 of 20 MANITOWOC CRANES INC Mounting Bracket On Boom Top 39 39 35 See Note 9 35 See Note 9 14 15 Strain Relief 16 Part Of Item 6 11 Must Be Looped Over
159. View F 8 Lower main strut to approximately 45 and stop C Attach cable to lug on adjustable strap Figure 4 10 Figure 4 7 View D View H 9 Haul in assist crane load line until assist crane is d Remove retaining pin from storage hole in outer supporting strut strap Figure 4 10 View H PETS 10 Lower strut with assist crane while keeping luffing hoist e Using hand winch raise adjustable strap to storage wire rope and load line from Drum 1 slack osition Figure 4 9 View E S p Fig 11 Stop lowering main strut when it comes to rest on jib f Install retaining pin to secure adjustable strap to jib strut strut Figure 4 9 View D 12 Remove taglines 9 preceding steps 4a 4f for other adjustable 13 Disconnect erection pendants from assist crane and Siap Drum 1 load line Lower jib strut onto strut supports Figure 4 9 View F Connect pendants to storage bar on main strut for 6 Continue to luff down until main strut comes to rest on storage boom top wire rope guide Figure 4 9 View F 14 Install strap storage pins in shipping holes to secure 7 Disconnect hydraulic hoses from jib strut at boom top straps to sides of main strut Figure 4 7 View Figure 4 8 View E Install dust caps R Siu emove Struts See Figure 4 13 for following procedure Vitus Published 06 20 08 Control 033 07 4 33 SETUP AND INSTALLATION Remove main strut as follows a Connect chain sling
160. a 8b 9 10 11 12 13 14 Link Pin with Collar and Retaining Pin 3 in dia Link 3 375 in dia Pin with 2 Collars and Retaining Pins Spreader Spreader Strap Link Spreader Spreader Pin with Collar and Retaining Pin 3 in dia Link Strap Link Adjustable Link Strap SETUP AND INSTALLATION Adjust length and position of straps 14 as shown on Luffing Jib Rigging Drawing Connect to Jib Strap Equalizer and Straps on Jib Inserts Jib Strut Length 50 in 10 1 16 in 18 in 10 5 8 in 42 5 16 in 27 31 32 in 14 ft 0 5 8 in 18 in 94 in 84 1 2 in 6 1 2 in 8 5 8 in 105 1 4 in 48 in 46 1 2 in 17 ft 10 1 2 in 1270 mm 256 mm 457 mm 270 mm 1075 mm 710 mm 4 5 457 2 4 2 146 165 219 2 7 1 2 1181 5 5 Quantity 4 P O N N O 1 10 6 main jib 4 8 main jib 2 4 1 2 These in corresponding Strut Top NOTE Links and Straps Hole to Hole Pins are Overall Length Published 06 20 08 Control 033 07 FIGURE 4 22 4 45 SETUP AND INSTALLATION Raise Main Strut See Figure 4 23 for following procedure steps 1 18000 LUFFING JIB OPERATOR S MANUAL Precharge pressure on strut stop pressure gauges 3 View A corresponds to pressure in the following table Make sure all strap storage pins 4 View B 5 View C on main strut 8 are stored Ambient Temperature Pressure Check that strut raising p
161. a x 10 7 8 long R3 396319 PIN Dowel Roll 1 8 x 5 8 long R4 429010 FITTING Grease R5 562176 PIN Cotter 1 2 x 9 long R6 612721 SCREW Hex Cap 3 4 10 x 2 1 4 long grade 5 R7 710308 WASHER Lock 3 4 R8 A06896 ADAPTER FRAME 79A Boom machining R9 A07485 PIN Cotter 5 1 32 dia x 12 3 8 long R10 A07600 BAR Square 3 4 CF 1018 R11 A07623 BRACKET Limit Switch 44 INSERT 10 3 1 1 78292 7 178905 27 179837 28 192250 ASSEMBLY REVISION A07766 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 14 of 22 O GQ CE M NNN N N FN B A BUTT 44 BOOM JIB 40 see Note 2 see O 539 gt a N PIN TIMBER STRAP Boom Support 10 LINK Boom Support NN Z MODEL 18000 LUFFING JIB RIGGING 44 Luffing Jib on 55 79A Boom with 100 Mast DESCRIPTION OF PART 9 179862 COLLAR 10 179863 PIN 29 179912 INSERT 10 3 05 m see O 539 12 179959 PIN 44 INSERT 20 6 1 1 78292 4 PIN 7 178905 TIMBER 30 179838 STRAP Boom Support 20 28 192250 LINK Boom Support 9 179862 COLLAR 10 179863 PIN 31 179913 INSERT 20 6 10 m see O 539 12 179959 PIN 44 INSERT 40 12 2 M 1 78292 7 178905 32 179839 28 192250 9 179862 10 179863 33 179914 12 179959 JIB STRUT 34 194160 R12 144435 R13 168779 R14 169810 R15 171250 R16 171964 R17 174149 R18 178460 R19 1798
162. acket Lugs 8 Spreader 1 20 Boom Top 9 Link 2 21 20 ft 6 1 m or 40 ft 12 2 m Insert 10 Link 4 22 Link 2 11 Pin w Collar and Retaining Pin 4 23 Pin with Snap Pins 6 12 Jib Strap 2 24 Wire Rope Guide 13 Jib Butt 1 25 Lug 2 Number in parenthesis equal quantity See Luffing Jib Assembly drawing for quantity and installation location 4 52 Published 06 20 08 Control 033 07 Oommen 18000 LUFFING JIB OPERATOR S MANUAL Description Jib Insert typical Jib Top Strut Strap Strap Support Bracket Pin with Cotter Pins Pin with Cotter Pins Jib Strap outside Strap Storage Pin Jib Strap inside Equalizer Pin with Cotter Pin Links with Connecting Pin Collar and Retaining Pins Jib Stop Positioner Pin with Cotter Pin Published 06 20 08 Control 033 07 15 16a 16b 17 18 19 20 21 22 23 24 25 26 SETUP AND INSTALLATION Description Pin with Cap Screw and Lock Washer Lug Boom Top Lug Jib Stop Jib Stop Jib Stop Support see Figure 4 26 Jib Stop Cable Cable Sheave Shackle Dolly Sight Glass Tire Inflation Valve Upper Boom Point Pin with Cotter Pins FIGURE 4 27 4 53 SETUP AND INSTALLATION Install Jib Strap Equalizers See Figure 4 27 View B for following procedure 1 Remove strap support brackets 4 from stored position and install in working position 2 Rest outside
163. ad Sensor Link 15 Luffing Jib LM Ass 0 dese Minimum Angl rx imum Ange Limit Switch Assembly 15368 Block U L 81000198 01 EU P ib Stop rransceiver 99495 3 Fixed Or Luffing Jib NM Terminator O Boom Node O Node Controller DES Plug 50 Controller 08628 cor A08627 7 T WLJ3K325 WBMJB J T 81000196 WBM150440 WBME18 81000197 81000201 WN12 81000194 81000195 15346 WNBE 381000196 81000196 n Cable Reel ene e Au 8 Cable Reel 81000200 4 5 On Jib Butt 81000200 4 5 oj 81000200 Upper Luffing On Boom Butt Optional ere Boom 591121 A06154 Jib Point 591121 Location Point Lower Luffing With Tandum Wiri Jib Point or Reeving iring Interconnect Diagram Fixed Jib Point 55 Or 55A Boom Top With 79A Luffing Jib And Upper Luffing Jib Point 55 Or 55A Boom Top With 79A Fixed Jib Luffing Jib Max Working 218098 Operating Angle S1 672710 Load Sensor Link Luffing Jib Maximum LMI 217609 ooze Operating Angle 52 O 972740 Luffing Jib Minimum Limit Switch Assembly 17794 0 Operating Angle 53 Block Up 672710 A15368 WIRELESS TRANSCEIVER 07389 521212116 Luffing Jib bus Terminator 2809 Boom Node ODE Plug Oc Controller o O 08628 CONTROLLER 08627 i WBM250 WBM150440 WBME18 81000191 81000201 WN12 81000194
164. ad is handled Lift load 3 6 in 76 152 mm and fully apply brakes oad must not lower through applied brakes Unused load drums are parked working and parking brakes applied if equipped drum pawls engaged All personnel are clear of swing radius of crane s counterweight 2 While lifting or moving load operator shall take following precautions a Accelerate and decelerate load smoothly to avoid excessive stress on crane boom and machinery Avoid sudden starts and stops while swinging Keep swing speed under control to prevent load from swinging out beyond radius at which load can be handled and to minimize the pendulum action of load Use taglines or other restraints to control load when necessary Do not exceed any swing limitations areas of operation given on capacity chart Do not allow load boom or any other part of crane to contact obstructions Do not use crane to drag a load Do not hoist lower or swing load while personnel are on load or hook See Personnel Handling in this section Avoid carrying load over personnel Loads which are suspended shall be blocked or cribbed before personnel are allowed to work under or between them Before lifting a load which requires use of outriggers or anytime outriggers are used fully extend outrigger beams and jacks so the truck tires do not bear any load Securely fasten outrigger jack pads or floats to jacks and set them on
165. all be qualified to operate the specific type of hoisting equipment used in the personnel lift e The crane operator and occupants have been instructed in the recognized hazards of personnel platform lifts e The crane is in proper working order e Load and boom hoist drum brakes swing brakes and locking devices such as pawls and dogs shall be engaged when the occupied personnel platform is ina stationary position 2 20 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL The crane is equipped with a positive acting device which prevents contact between the load block or overhaul ball and the boom tip anti two block device For friction cranes this implies the addition of spring applied brakes activated by the anti two block device The load line hoist drum shall have a system or device on the power train other than the load hoist brake which regulates the lowering rate of speed of the hoist mechanism controlled load lowering The crane s Operator s Manual is in the crane s cab readily accessible to the Operator e The crane s load capacity chart is affixed inside the crane s cab readily accessible to the operator The total weight of the loaded personnel platform and related rigging shall not exceed 50 percent of the rated capacity for the radius and configuration of the crane e crane is uniformly level within one percent of level grade and located on a firm footing Some c
166. and actuator rod Install dowel pin Adjust actuator rod as needed for correct MAX angle Adjustment without luffing jib Unless otherwise specified see Figure 6 4 for following procedure The automatic boom stop was set at the factory and should not require periodic adjustment However adjustment is necessary when Parts are replaced Luffing jib is installed Luffing jib is removed 1 Travel crane onto a firm level surface or level crane by blocking under crawlers 2 Make sure 3 1 2 in 89 mm long adjusting rod is installed 3 See Table 6 1 to determine Dimension A for boom length in use 4 Boom up slowly Carefully monitor distance between front edge of rotating bed adapter frame and center of load block Dimension A while booming up 6 10 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Stop booming up when boom reaches Dimension A If boom stops automatically at Dimension A further adjustment is not needed If boom stops automatically before reaching Dimension A perform step 6 If boom reaches Dimension A before it automatically stops perform step 7 If boom stops before reaching Dimension A See Figure 6 4 a Loosen jam nut at adjusting rod coupling View A b Turn adjusting rod all the way into coupling c Boom up slowly until boom reaches Dimension d Turn adjusting rod out against boom butt until actuator rod clicks limit switch open and LED on l
167. and be inoperable when boom to luffing jib angle is 169 2 maximum angle 9 Operating limit alert should come indicating LUFFING JIB MAX UP 2 limit has been reached Stop raising luffing jib immediately if limit switch fails to stop luffing hoist Lower boom and jib to ground and readjust MAX UP 2 limit switch 10 SLOWLY lower luffing jib 11 Luffing hoist must stop and be inoperable when boom to luffing jib angle is 70 Stop lowering luffing jib immediately if limit switch fails to stop luffing hoist Lower boom and jib to ground and readjust MAX DOWN limit switch JIB STOP ADJUSTMENT CURRENT PRODUCTION WARNING Falling Attachment Hazard Do not operate crane unless luffing jib stops are properly adjusted and operational Operating luffing jib above MAXIMUM UP 2 limit or below MAXIMUM DOWN limit is neither intended nor approved Jib can be pulled over backwards or collapse General The luffing jib attachment is equipped with three limits which automatically stop the luffing hoist and apply its brake when the luffing jib is raised or lowered to the following angles 6 4 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL NOTE Luffing jib angles given in this section can vary plus or minus 1 e Luffing Jib Max Up 1 maximum working angle which automatically stops the luffing hoist when the boom to luffing jib angle is 168 The appropriate limit bypass switch must be turne
168. and calibration procedures Service Manual Serial Numbered Contains theory of operation maintenance procedures troubleshooting information and shop procedures Vendor Instructions Manual Serial Numbered Contains OEM instructions for servicing purchased components engines pumps valves etc The manuals which must be retained in the operator s cab Operator s Manual Capacity Charts Maintenance Checks and Lube Guide and RCL Operation are supplied in a OPERATOR INFORMATION binder A separate binder is provided for the crane and each applicable attachment The Operator s Manuals and Capacity Charts are stamped with the serial number of the crane or attachment The serial number on the manuals and capacity charts must match the serial number of the crane and attachment in use Using any other manual or capacity chart is prohibited e The crane model and serial number is located on the Crane Identification Label on the crane cab The model and serial number of the attachment other SAFETY INFORMATION If the serial numbers of your manuals and capacity charts do not match the serial numbers of the crane or attachment contact your Manitowoc Crane Care distributor for the proper manual or capacity charts Do not operate crane or attachment if proper Capacity Chart is not in cab Storing Manuals Store the Operator Information Manuals for the crane and each applicable attachment on the bookshelf in the Operator s ca
169. apacity charts require more stringent levelness criteria Cranes with outriggers shall have them all fully deployed following manufacturer s specifications e Manitowoc prohibits personnel handling from its luffing jibs The platform meets the requirements as prescribed by applicable standards and regulations Applicable personnel protection equipment is provided i e personnel fall protection system etc For wire rope suspended platforms the crane is equipped with a hook latch that can be closed and locked eliminating the throat opening e platform is properly attached and secure e Direct attachment of a work platform to a luffing jib is prohibited Personnel platforms must not be used if wind exceeds 20 mph 9 m s e Hoisting personnel within 20 ft 6 m of a power line that is up to 350 kV or within 50 ft 15 m of a power line that is over 350 kV is PROHIBITTED except for work covered in OSHA 29CFR1926 subpart V For operation outside the United States the requirements of the applicable national state and local regulations and safety codes must be met This may include in addition to the above e Automatic brakes such that when the equipment operating controls are released the motions are brought to rest e A holding device such as a load hold check valve shall be provided in the hydraulic or pneumatic systems to er 18000 LUFFING JIB OPERATOR S MANUAL prevent uncontrolled mov
170. art 15 Sheave Block 15 Sheave Block FIGURE 4 55 continued 4 92 Published 06 20 08 Control 033 07 Crane Care 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 4 214 TANDEM HOIST DRUM REEVING 79A O 9 o 9 9 9 j 999 Q 9 8 Part 9 Sheave Block Q o 00 16 Part 9 Sheave Block a 24 Part 13 Sheave Block 9 9 Y 9 9 O O 12 Part 9 Sheave Block Q Q 9 Q 9 20 Part Q 13 Sheave Block Q 28 Part 15 Sheave Block FIGURE 4 56 ad Published 06 20 08 Control 4 033 07 4 93 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL BLOCK LEVEL SENSOR ADJUSTMENT The sensors were adjusted at the factory and need to be readjusted only when a new sensor is installed or the General position of a sensor is changed The block level sensors Figure 4 57 ensure that the load Sensor Adjustment block remains level when two load lines Drums 1 and 2 are routed to the load block over the 79A luffing jib top 1 If necessary attach mounting bracket to guide sheave frame with cap screws NOTE This block level sensor is only on cranes without wireless communication On cranes with wireless 2 Loosen jam nut securing sensor to bracket communication the controller adjusts block level 3 Turm sensor in or out to obtain specified dimension automatically see Crane Diagnostics Block Level between end of sensor and wall of sheave Sensor
171. ate and federal regulations for handling personnel and for personnel fall protection e Access points must kept clear to prevent personal injury and unsafe operation of crane Store clothing and other personal belongings so they do not interfere with controls in operator s cab or with operation of crane Tools oil cans spare parts and other necessary equipment must be stored in tool boxes or other appropriate locations Do not allow these items to lie around loose in operators cab or on steps ladders catwalks and platforms mm SAFETY INFORMATION e Toreduce the risk of slipping non skid material sand in paint has been applied to painted walkways and platforms However walkways and platforms can be slippery when wet and when oil or grease is spilled on them Keep walkways and platforms clean and dry to prevent slipping on them When non skid material wears out reapply it Wear shoes with a highly slip resistant sole material Clean any mud or debris from shoes before entering the crane cab or climbing onto the crane A shoe that is not clean might slip off a control pedal during operation Do not make modifications or additions to the crane s access system that have not been evaluated and approved by Manitowoc e Donotuse top of mast boom or jib as walkways unless they have optional catwalks NOTE Optional walkways catwalks are available for the boom and luffing jib sections but only for those
172. aterials and not personnel The ASME Standards have a retrofit statement that applies to existing cranes after the standards go into effect It is not the intent of the standards to require retrofitting of existing equipment If an item is being modified the performance requirement shall be reviewed relative to the current standard The standards contain more criteria than the current OSHA 1926 550 This new standard is consistent with the U S Department of Labor Occupational Safety and Health Administration OSHA regulations for Construction that state in 29CFR1926 550 g 2 General Requirements The use of a crane or derrick to hoist employees on a personnel platform is prohibited except when the erection use and dismantling of conventional means of reaching the work site such as a personnel hoist ladder stairway aerial lift elevating work platform or scaffold would be more hazardous or is not possible because of structural design or work site conditions Use of a Manitowoc crane to handle personnel is acceptable provided The crane user shall comply with the manufacturer s specifications and limitations for lifting accessories hooks slings personnel platforms etc e The requirements of the applicable national state and local regulations and safety codes are met determination has been made that use of a crane to handle personnel is the least hazardous means to perform the work e The crane operator sh
173. att Published 06 20 08 Control 033 07 2 9 C SAF 17 18 ETY INFORMATION and boom by reducing ratings reducing operating speeds or a combination of both Unless otherwise specified on Capacity Chart or in Operator s Manual stop operation under following wind conditions a If wind causes load to swing forward past allowable operating radius or sideways past either boom hinge pin land load and apply drum brakes b If wind exceeds 35 mph land all loads and apply drum brakes lower boom onto blocking at ground level or otherwise restrain it and apply swing and travel brakes and or locks Booms jibs or masts which are being assembled or disassembled on ground with or without support of boom rigging shall be securely blocked to prevent dropping of boom jib or mast sections Workers shall not go under boom jib or mast sections when removing connecting pins or bolts Each outrigger shall be visible to operator or signal person during extension and retraction Handling Load Size of Load 1 NOTE 2 10 Crane shall not be loaded beyond applicable static or dynamic ratings given on the capacity chart for the crane configuration Capacity charts for Manitowoc cranes show the total weight of freely suspended loads for various boom and jib lengths and operating radii To determine actual weight of load which can be lifted at a given radius working load operator must deduct weight of certain
174. b Figure 2 3 Attach the chain from the manual in use to the link behind the operator s seat Keep all other manuals provided with the crane in the crane owner s user s office so they are readily available when needed Operator Information Manual 431 Bookshelf Behind Operator s Seat FIGURE 2 3 than standard boom is located on the Crane Identification Label on the attachment m Published 06 20 08 Control 033 07 2 7 Manilow SAFETY INFORMATION SAFE OPERATING PRACTICES General The importance of safe operation cannot be over emphasized Carelessness and neglect on the part of operators supervisors and planners rigging personnel and job site personnel can result in their death or injury and costly damage to the crane or property The safety information in this publication is intended only as a guide to assist qualified operators in safe operation Manitowoc cannot foresee all hazards that will arise in the field therefore safety remains responsibility of crane operators and owner Local state and other governmental agencies may require stricter operating practices When a conflict in practices exists follow the strictest practice Read Operator s Manual Safe and efficient operation of this crane requires that it be maintained in proper working order and that its operators and maintenance personnel be familiar with the crane s functions and capabilities The Operator s Manual sup
175. b stop positioner 13 View G to lug 16a on boom top and to lug 16b on jib stop 17 Disconnect assist crane Tighten eyebolt until positioner safety latch spring is tensioned to approximately 9 in 229 mm long Figure 4 28 View F 2 Route cable 19 Figure 4 27 View G through cable sheaves 20 on jib stop and in boom butt and pin cable to jib stop 3 Connect other end of cable to cable from hand winch as shown in View F Prepare Jib Dolly See Figure 4 27 for following procedure Check following items each time dolly 22 View D is used 1 Tire pressure at inflation valve 24 View E Inflate to 112 psi 7 7 bar 2 Oil level in wheel hubs Fill if required to FULL ring in sight glass 23 View E Use same gear oil used in drum planetaries on crane Install Jib Dolly See Figure 4 27 for following procedure An assist crane capable of lifting half the weight of the jib is required for the following procedure A fork lift truck is required to handle the upper jib point 1 Attach slings from assist crane to end of jib top 2 Liftjib top with assist crane 3 Install upper jib point a Using a fork lift truck lift upper jib point 25 View C into position at jib top b Pin upper jib point to jib top with pins 26 four places c Remove fork lift truck 4 Position dolly 22 View D under upper jib point 25 with the longest guide forward and to the right View H 5 Lower jib top so u
176. b strap 8 and remove connecting pin 7 Set strap on pin 9 in strap support bracket 1 Remove equalizer 2 Rotate strap bracket forward View C Lower inside strap 8 into inside strap bracket Store strap support brackets 1 View C a Remove connecting pin 11 b Rotate support bracket 1 180 c Repin bracket 1 to jib butt with pin 11 and pin to storage lug with pin 9 Remove strap retaining pin 10 View C and store support bracket Store inside strap 8 in inside strap bracket with retaining pin 10 Store connecting pins 7 in holes on jib straps Store strap support bracket on jib butt Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Remove Butt and First Two inserts See Figure 4 32 for following procedure 1 2 Raise jib strut to approximately 70 Store jib stop positioner cylinders View F NOTE Disconnecting hydraulic hoses is not necessary a Support cylinder 13 to prevent its dropping when pins are removed b Remove pin 12 from lug on jib stop and store in clevis on positioner top Remove pin 17 View E from lug 20 d Rotate positioner so pin 12 slides into bracket 18 View F e Using pin 17 connect bottom of positioner to lug 18 as shown in View F 3 Using nylon slings from assist crane hook onto butt and first two inserts Wrap slings around chords only Do not use lifting lugs on butt or inserts and do
177. b strut top with shackles and suitable slings 12 View D Minimum capacity required for slings is 25 000 Ib 11 340 kg per side d Connect counterweight boxes with tie links as shown in Figure 4 21 View G four places WARNING Falling Strut Hazard Do not disconnect crane counterweight 11 from jib strut until all remaining steps are performed Counterweight is required to prevent jib strut from rising when main strut is lowered If counterweight is not connected to jib strut jib strut will rise part way and then both struts could fall forward violently Luff down until luffing hoist wire rope is slack Unpin handling pendants and links from lugs on main strut butt Attach 55 USt 50 t shackle 14 View 1 and hook from assist crane to links 15 Connect Drum 3 load line 19 View 1 to link 16 with load line socket 17 18000 LUFFING JIB OPERATOR S MANUAL e Use same socket used to anchor load line to boom or jib point e sure Drum 3 load line passes under Drum 3 guide sheave in mast sure Drum 3 load line passes through center of boom hoist wire rope and over top of boom hoist equalizer Pin strut handling pendants 10 View 1 to link 16 Slowly pull main strut back until Holes A in strut stop are aligned CAUTION Strut Damage Pull strut back only until holes are aligned Pulling strut further back may damage strut to strut stops 8 9 10 11 12
178. be installed in operator s or machinery cab of crane 2 Operator and all maintenance personnel shall be thoroughly familiar with location use and care of fire extinguisher s provided ACCIDENTS If this crane becomes involved in a property damage and or personal injury accident immediately contact Crane Care Customer Service or the Product Safety and Reliability Manager at the following address Published 06 20 08 Control 033 07 2 15 SAFETY INFORMATION 18000 LUFFING JIB OPERATOR S MANUAL Manitowoc Cranes 2401 So 30th St Manitowoc WI 54220 1 888 499 7278 or 920 683 6390 Phone Fax Provide a complete description of the accident including the crane model and serial number SAFE MAINTENANCE PRACTICES WARNING Importance of safe maintenance cannot be over emphasized Carelessness and neglect on part of maintenance personnel can result in their death or injury and costly damage to the crane or property Safety information in this publication is intended only as a guide to assist qualified maintenance personnel in safe maintenance Manitowoc cannot foresee all hazards that will arise in field therefore safety remains responsibility of maintenance personnel and crane owner Maintenance Instructions To ensure safe and proper operation of Manitowoc cranes they must be maintained according to the instructions contained in this manual and the Service Manual provided with the crane Crane maintena
179. boom and jib the RCL the block level sensor and the wind See Figure 6 11 for following procedure speed indicator will be inactive Terminating plug 2 Views A and B is provided so the block 1 Unscrew sealing cap 1 View A from terminating plug up limit control can be disconnected for the following 2 reasons 3 5 2 Disconnect electric cable 3 View from cable 4 e Crane setup and rigging 3 Connect sealing cap 1 View to electric cable 4 e Maintenance C mm Published 06 20 08 Control 4 033 07 6 17 MAINTENANCE 4 Connect terminating plug 2 View B to electric cable 2 Failing to perform this step will prevent load drums from hoisting and boom from lowering Operating limits alert will come on Reverse above steps to reconnect the block up limits the RCL the block level sensor and the wind speed indicator Removing Upper Boom Point or Jib Point Failing to perform following steps will prevent load drums from hoisting and boom or luffing jib from lowering Also operating limits alert will come on Remove terminating plugs and reconnect electric cables to proper receptacles when corresponding attachment is reinstalled See Figure 6 9 for following procedures If Upper Boom Point Upper Luffing Jib Point or Fixed Jib is Removed 1 Disconnect cable from receptacle 14 View C 2 Unscrew sealing cap 6 View C from terminating plug 7 and attach to receptacle 14 3 Conne
180. by using weld studs at approximately 1 to 2 ft intervals For Receptacles Equipped With Shorting Plugs Shorting plugs must be plugged in whenever receptacle is not being used Electrical enclosures are to be mounted as shown in view G G View H H View K K and view L L Torque the KEPS nuts tight to establish less than 01 ohms between frame and enclosure receptacle shells All enclosure mounting bolts must be electrically common to one another less than o1 ohms A05580 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 18 of 20 MODEL 18000 CONTROL WIRING Boom amp Limits DESCRIPTION OF PART Note 10 The basic bill of material contains one wired load link item 9 and one wireless load link item 8 The wired load link item 9 is typically used on the lower point even multi parts of line and the wireless load link item 8 is typically used on the upper point single or two part line One additional wired load link 1 item 189 is required and used on the lower boom point or lower jib point for tandem drum operation Note 11 Transceiver item 11 and cable WBMJ8 item 12 are mounted on the jib top for luffing jib or fixed jib applications PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER A05580 19 of 20 CONTROL WIRING Boom amp Limits ITEM DESCRIPTION OF PART A05580 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 20 of 20 Ol Ol ez FURNISHED ACTUATOR LIMIT CONTROL
181. cessary to ensure proper operation 8 After boom and jib are raised check operation of MAX UP 1 limit See instructions under Operational Checks As MAINTENANCE Max Up 2 Limit Adjustment See Figure 6 1 for following procedure 1 Loosen screws in limit switch 4a 2 Rotate actuator 2 so roller on limit switch 4a is between cams 4b and 5b 3 Slide limit switch 4a toward actuator 2 until roller just touches actuator and hold Switch must not click open Securely tighten screws in limit switch After boom and jib are raised check operation of MAX UP 2 limit following instructions under Operational Checks Max Down Limit Adjustment See Figure 6 1 for following procedure 1 Loosen screws in limit switch 5 2 Rotate actuator 2 counterclockwise until Hole B in actuator lines up with hole in boom top 3 Insert alignment pin 6 through Hole B in actuator and into hole in boom top Make sure shoulder of pin rests squarely against actuator to ensure proper alignment for adjustment 4 Slide limit switch 5a against cam 5b until limit switch just clicks open and hold Securely tighten screws in limit switch Remove alignment pin 6 Check MAX DOWN limit setting as follows a Rotate actuator 2 clockwise away from limit switch and then counterclockwise so MAX DOWN limit Switch roller contacts cam 5b b Limit switch must click open when Hole B in actuator lines up with hole in boo
182. ck against boom stops boom hoist reeving between boom and mast will go slack and load block will swing in toward boom if minimum load is not used Table 6 1 DIMENSION A for MAX Boom Angle DIMENSION A at 83 Boom Length 55 or 55A Boom 55 79 Boom or 55 79A Boom ft m ftin m 120 36 6 185 5 60 140 42 7 20 10 6 34 160 48 8 234 7 09 180 54 9 258 7 83 200 61 0 28 1 8 57 220 67 1 307 9 32 240 73 2 330 10 06 260 79 2 356 10 81 280 85 8 37 11 11 55 300 91 4 404 12 29 320 97 5 42 10 13 04 340 103 6 452 13 78 360 109 7 47 8 14 52 380 115 8 50 1 15 27 400 121 9 526 16 01 420 128 0 550 16 75 1 Dimension A is measured from front of rotating bed to centerline of load block suspended freely from lower boom point NOTE2 If a single part line is used over lower boom point add 14 in 0 35 m to dimensions in table and measure to centerline of freely suspended single part line Published 06 20 08 Control 4 033 07 6 9 MAINTENANCE Actuator Rod Replacement See Figure 6 4 View A for following procedure 1 2 5 6 Remove defective actuator rod Slide spring washers and spring over new actuator rod while sliding new actuator rod into bracket assembly Position actuator rod so that tapered end just touches limit switch roller Actuator rod should not be pressing limit switch roller down Drill 0 25 6 35 mm hole through spring washer
183. countries that authorize their use Two ladders stored in insert next to boom butt are available for boom assembly and disassembly See Boom Ladder Assembly in Section 4 of crane Operator s Manual for instructions Getting On or Off Crane Personnel getting on and off the crane shall do so only at the steps provided and only while crane is parked Never climb onto or off a moving crane Climb onto and off crane only when it is parked and only with operator s permission When personnel use ladders to get on or off the crane their hands shall be free of any objects Objects which cannot be carried in pockets or tool belts shall be lifted into place with a hand line or hoist Personnel Fall Protection Anchors Manitowoc has provided fourteen anchors on the upperworks Figure 2 2 to which workers can attach their personnel fall protection equipment A WARNING Fall Hazard Anchors are designed to handle only one person at a time Dot use anchors for lifting or pulling loads Published 06 20 08 Control 033 07 2 5 SAFETY INFORMATION 18000 LUFFING JIB OPERATOR S MANUAL Anchors for personnel fall protection equipment 4 Places Front of Rotating Bed 8 Places on Engine Covers 3 Places on Rear of Rotating Bed under mast 2 Places Each Upper Counterweight Tray Counterweight Boxes Have Non Ladder Skip Surfaces Steps Both Sides of Both Carbody Counterweights
184. ct sealing cap to end of cable and store on upper boom point or upper jib point If Luffing Jib Is Removed 1 Unscrew sealing cap 1 View C from terminating plug 2 Disconnect cable from receptacle 15 View C Connect terminating plug 2 View C to receptacle 15 Connect sealing cap to end of cable and coil cable onto cable reel luffing jib butt 5 Remove sealing caps 7 View C from terminating plugs 6 and connect terminating plugs to jib stop receptacles 16 17 and 18 Storing Electric Cable See Figure 6 9 for following procedure The electric cables for the boom and jib are long enough to accommodate the maximum length of each attachment Store excess electric cable for the boom and luffing jib by winding it onto the reel on mounted on the respective butt The reel is equipped with a locking pin Disengage the locking pin to allow the reel to be wound Engage the locking pin to lock the reel in position The electric cable from the crane to the reel must be disconnected before the reel can be wound 6 18 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Store excess electric cable for the fixed jib by winding it around the brackets on the fixed jib Maintenance CAUTION Prevent Damage To prevent two blocking from occurring do not operate crane until cause for improper operation and all hazardous conditions have been found and corrected Inspect and test the block up li
185. d 6 to 8 Strand Wire Rope Minimum of 6 rope diameters Torque ft Ibs 225 225 KN m 0 30 0 30 225 360 0 30 0 49 but not less than 6 in 152 mm Rotation Resistant Wire Rope Tightening torque values shown are based on threads being clean dry and free of lubrication Seizing Dead End Ib Rope Clip 4 6 to 9 Rope Diameters for Conventional Rope OR 20 Rope Diameters for Rotation Resistant Rope Live Endin 7 Straight Line Socket c Method A D Wedge gi q Do not reinstall any shipping material bolt plastic strap or wire in hole of wedge or socket after assembling Minimum of 20 rope diameters but not less than 6 in 152 mm Clip Short Piece of Wire Rope Terminator Wedge Right Method B Method C ALL ARE DANGEROUS AND PROHIBITED WRONG Rope Backward Rope Backward Breaking in Wire Rope After installing a new wire rope break it in by operating it several times under light load and at reduced speed This practice allows the wire rope to form its natural lay and the strands to seat properly NOTE Wire rope will stretch during the break in period reducing the wire rope s diameter as the strands compact around the core 4 78 Published 06 20 08 Control 033 07 Dead End Clipped to Live End Dead End Clipped to Live End Wedge Backward FIGURE
186. d other items removed from boom and jib All blocking tools and other items removed from jib point roller path area Published 06 20 08 Control 033 07 4 23 4 24 SETUP AND INSTALLATION All safety devices installed electric cords connected and limits adjusted see appropriate adjustments sections in this manual e Rated Capacity Indicator Limiter Boom jib angle indicators Automatic boom stop must be reset for luffing jib operation after boom and jib are raised e Automatic jib stops e Jib and boom block up limits Luffing Jib Raising Procedure Chart reviewed and following operations determined Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Raising method in line or jack knife Required boom to jib angle for jack knife raising method Raising procedure in this section read and thoroughly understood Proper amount of crane counterweight installed Wind within allowable limits for raising boom and jib see charts in Luffing Jib Operator s Manual All lube points greased see Lubrication Guide in Luffing Jib Operator s Manual LUFFING JIB mode selected and confirmed Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION ITEM NUMBERS CORRESPOND TO IN 2 N LINE RAISING PROCEDURE STEPS da 7 View D 4431 7 y V
187. d to the bypass position to allow the jib to be raised an additional 1 2 to 2 to LUFFING JIB MAX UP 2 limit e Luffing Jib Max Up 2 maximum angle which automatically stops the luffing hoist when the boom to luffing jib angle is 169 2 to 170 This limit can be bypassed with the limit bypass switch only when the attachment is lowered to ground boom below 50 Luffing Jib Max Down minimum angle 70 boom to luffing jib angle This limit cannot be bypassed A minimum limit switch is provided as a backup to stop the jib if the programmed minimum limit fails Maintenance At least once weekly and each time the attachment is erected check that the luffing jib stops at the specified angles Pre Erection Checks To insure proper operation of the luffing jib stops e The jib stop cables must be connected to receptacles 7 and 8 Figure 6 11 View A e luffing jib angles must be properly calibrated See Rated Capacity Indicator Limiter Operation Guide for instructions The jib stop limit switches must be mounted properly Jib Maximum Up 1 and 2 Limit Checks See Figure 6 1 for following procedure Perform the following steps with the boom and luffing jib on the ground 1 Check Dimension D1 View A If necessary adjust position of limit switch housing to obtain deactivated dimension Perform remaining steps with engine running and appropriate Luffing Jib Capacity Chart selected 2 Depress limit s
188. diameters can cause rope distortion If the proper tail length is used a welded end is acceptable D s Er Tapered and welded end BRIDON AMERICAN HANDLING INSTALLATION Rotation Resistant Ropes must have properly seized or welded ends They must be installed without inducing twist or turn They must not be kinked and they must have the proper tail length at the wedge socket WEDGE SOCKETS All Rotation Resistant Ropes can be used with standard wedge sockets Certain precautions must be taken Rotation Resistant Ropes should be tightly seized with wire strand or tape or welded to prevent loss of rope lay at the dead end Loss of rope lay will change the operating characteristics of the ropes and can cause high strands and rope distortion The dead end should be a minimum length of 20 rope diameters for all Rotation Resistant Ropes with either welded or seized ends A wire rope clip may be attached to the dead end LIVE END NES 25 ENTERING 95 WRONG 5 zu m SWIVELS recommends that Endurance 19 Endurance 8RR and Endurance Dyform 18 not be dead ended into a swivel unless used under specific conditions and with specific limitations Endurance Dyform 34LR and Endurance 35LS be used with a swivel in any application but when used in multiple part reeving a swivel is not necessary therefore not recommended All Rotation Resistant Ropes will rotate to some extent under
189. ding Wire Rope onto 4 76 Anchoring Wire Rope to Wedge 4 77 Anchoring Wire Rope to Button 4 77 Breaking in Wire 4 78 Pad Eye Usage for Wire Rope Reeving 4 79 General MIR a RI e RR M MR Eo 4 79 4 79 Rigging Winch 4 80 Load Line Reeving 44 Luffing 4 80 Load BIOCKS 5 2 5 Rn rn dentur eer denied a 4 80 Guide 1 4 80 Duplex Hook rather RR REED ORG OE REA Ron avai AUR pura 4 80 Wire Rope Specifications 4 80 Wire Rope 4 80 Reeving Diagrams 4 80 Load Line Reeving 79A Luffing 4 86 Load Block 4 86 Load Block 0 4 86 D plex Hook eoe erede eet doeet e eed ett has s 4
190. e 1 The most be operated Whined and B be rtv Y pottus and 86 suey hazar s meshed operator mist be wd merta to operate aans Operator vara n sole rengomataty of crane Dune or user 2 The crane must te operated in F Gormphance with a conditions Given on Pa appic Sountarweighl eic Use cor by Aro stamped with the laminated with plaste Using any of program of continuing improvement in prod e Mi reserves to change the contained in the Operator s arce Manos gt any Vna without you have questions fs crane or its Operator s Service Mangal please contact your Manitowoc distributor fy up b date OPERATOR S OR SERVICE MANUAL AND CAPACITY CHARTS MUST KEPT IN OPERATOR S AT ALL TIMES weight of the load which cas te ified en radas Eel mun Sn f cuam ing sagrari Wom Wa V 5 E NN Capacity Chart for your crane for a The tan of wind h 5464 load ttvently side load maq Bene freely suspended load to move ovt Published 06 20 08 Control 033 07 FIGURE 1 1 1 1 INTRODUCTION 18000 LUFFING JIB OPERATOR S MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS Description 55 79A Boom 55 or 55A Boom Luffing Hoist Drum 6 Model 18000 without MAX
191. e Installation and Maintenance in this section Wire rope must spool off bottom of luffing hoist drum Tightly wind excess wire rope onto luffing hoist drum Anchor other end of luffing hoist wire rope to right side of main strut with socket and wedge provided see Wire Rope Installation and Maintenance in this section 4 13 SETUP AND INSTALLATION To Assist Crane u po a Backstay Basic Strap Erection Pendant with Shackle Erection Pendant Storage Bar inside strut ET DIVA 18000 LUFFING JIB OPERATOR S MANUAL Storage Pin in Shipping Holes Backstay Strap View Storage Holes Attach Tag View A Line Here 5 Assist Crane Main Erection et Perdant Erection Pendant Strut disconnected Erection Pendant to Assist Crane Erection Pendant 6 to Drum 1 AF 355 Led Load Line From Drum 1 Basic Backstay Straps Tagline Strap Storage Pin Removed TN from Top Holes and Stored in Boom Top Main Wire Rope Strut Backstay Strap on Boom Insert Backstay Link on Boom Butt Backstay Strap stored on boom Strap Bracket Connecting Pin with Collar and Retaining Pin Published 06 20 08 Control 4 033 07 4 14 Bottom Holes Link N Stop Basic 4 117 y Backstay Strap View G stored on strut Connecti
192. e S3 22 24 Volts DC 6 100 S3 2 Black S3 21 MAX DOWN 1 wwug Boom Top Adapter Frame Left Side of Boom Typical for 44 Luffing Jib and 79 Luffing Jib T3 Jib Butt 76 101 Description Description 1 Boom Node Controller Receptacles 2 Actuator R1 MAX DOWN 3a Limit Switch MAX UP 1 R2 MAX UP 1 maximum working 3b Cam MAX UP 1 R3 MAX UP 2 maximum 4a Limit Switch MAX UP 2 R4 ToLuffing Jib Cable Reel 4b Cam MAX UP 2 Terminating Plugs Limit Switch DOWN T1 MAX DOWN 5b Cam MAX DOWN T2 MAX UP 1 maximum working 6 Alignment Pin TS MAX UP 2 maximum 7 Spacer each limit switch T4 To Luffing Jib Cable Reel 8 Mounting Bracket FIGURE 6 1 6 2 Published 06 20 08 Control 033 07 r c Crane Care 18000 LUFFING JIB OPERATOR S MANUAL Maintenance At least once weekly check that the limit switches stop the luffing jib at the specified angles if not replace any defective parts and or adjust jib stop limit switches Adjustment The jib stop limit switches must be installed adjusted and sealed at initial assembly of the attachment Limit switch adjustments must be checked and
193. e securely fasten boom from movement by wind or other outside forces e Move all controls to off f Apply all drum brakes and pawls Operational aids accessories such as rated capacity g indicator or limiter boom and jib angle indicator or limiter anti two block device level indicator swing limiter proximity device etc may be installed on your crane Disengage master clutch if equipped h Stop engine 13 Operator shall perform following operations if power or a Such devices are to be used only as AIDS TO ASSIST OPERATOR their presence on crane in no way substitutes for or lessens requirement that operator knowledge experience and judgment are required to ensure safe operation of crane Crane shall not be loaded beyond applicable static or dynamic ratings given on capacity chart for crane See Size of Load later in this section See Section 3 of this manual and Operation Aids topic in this section for purpose of each operational aid 14 15 control function fails during operation a Land all suspended loads if possible under brake or power control b Apply all brakes and locking devices c Move all controls to off If crane will be operated at night operator shall make sure that there is sufficient lighting for safe operation Load and landing area shall be illuminated Operator shall not operate crane during periods of bad weather if his or her ability to see load or signal person
194. e bottom and top pins Figure 4 20 View H connecting strut top to strut butt 3 Move strut top slowly forward while hauling in luffing hoist wire rope so that wire rope between struts pays out smoothly without kinking or binding 4 Rotate strut supports C 5 View D to working position View C and pin main strut top to jib strut top with shipping pins 6 5 Lower butt end of main strut top and pin to jib strut top with pins 7 View A Store Luffing Hoist Wire Rope 1 Disconnect wire rope from socket 20 Figure 4 20 View G in end of main strut Store socket with main strut 2 Spoolluffing hoist wire rope onto Drum 3 for storage If desired a sucker line can be attached to end of luffing hoist wire rope and spooled through sheaves in struts as luffing hoist wire rope is removed This practice will make it easier to install the luffing hoist wire rope next time Remove Main and Jib Strut Tops Main strut top and jib strut top are shipped together as shown in Figure 4 20 View H Reverse assembly steps under Install Jib Strut Top topic to remove strut tops Remove Jib and Main Strut Butts Main strut butt and jib strut butt are shipped together as shown in Figure 4 20 View A Reverse assembly steps under Install Jib and Main Strut Butts topic to remove strut butts 4 72 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Changing Boom and Jib Length A DANGER Crushing Injury
195. e off jib butt during remainin from storage bar in base of main strut J g g steps shackles to pendants 13 Continue to slowly pay out luffing hoist wire rope to lower 4 Connect chain sling from assist crane to shackle on one main strut Keep load line from Drum 1 slack erection pendant View A 14 Have ground personnel use taglines to guide jib 5 Hoist and swing with assist crane so erection pendant is backstay straps so they do not hit boom lacings extended vertically above top of main strut 15 Stop lowering main strut when stops on strut are against 6 Connect shackle on other erection pendant to load line side plates of boom top wire rope guide View G from Drum T View G 16 Pay out load line from Drum 1 so erection pendant hangs vertically View D and disconnect load line View CAUTION O Strut Damage Connect Backstay Straps Donot attempt to raise main strut with load line from Drum 1 until step 7 is performed Structural damage to strut will occur 1 Remove strap storage pins from shipping position and store and in bottom holes in strap brackets See Figure 4 9 Views E and F for following procedure Keep load line from assist crane centered over main strut while raising strut Structural damage can occur 2 Remove retaining pins collars and connecting pins if strut is side loaded from end of each basic backstay strap 3 Rotate links from storage position to w
196. ead obstructions Level 1 of grade or 1 ft 0 03 m in 100 ft 30 5 m The area selected must be large enough to accommodate the crane selected boom and jib length and movement of an assist crane For 44 Jib The maximum combined boom and jib length is 520 ft 158 5 m The minimum boom length for use with the jib is 140 ft 42 7 m See the capacity chart for boom and jib length limitations For 79A Jib e The maximum combined boom and jib length is 650 ft 198 1 m The minimum boom length for use with the jib is 160 ft 48 8 m See the capacity chart for boom and jib length limitations To allow movement of aerial work platforms and an assist crane there must be a minimum of 35 ft 6 1 m clearance on both sides of the boom and jib CRANE ORIENTATION The terms RIGHT LEFT FRONT REAR used in this section see the operator s right left front and rear sides when seated in the operator s cab looking forward with the crawler motors to the rear ACCESSING PARTS Some parts of the crane boom and jib cannot be reached from the ground Take necessary precautions to prevent falling off the crane boom or jib during assembly and disassembly Falling from any elevation could result in serious injury or death Owner user shall provide approved ladders or aerial work platforms so workers can safely access those areas of crane boom and jib that cannot be reached from ground Published 06 20 08 Con
197. eavy components by hand Use a hoist jacks or blocking to lift components Use care while welding or burning on crane Cover all hoses and components with non flammable shields or blankets to prevent a fire or other damage To prevent damage to crane parts bearings cylinders Swivels slewing ring computers etc perform following steps before welding on crane Disconnect all cables from batteries 26 27 28 29 30 31 32 33 Published 06 20 08 Control 033 07 SAFETY INFORMATION e Disconnect output cables at engine junction box Attach ground cable welder directly to part being welded and as close to weld as possible Do not weld on engine or engine mounted parts per engine manufacturer Disconnect and lock power supply switch before attempting to service high voltage electrical components and before entering tight areas such as carbody openings containing high voltage components When assembling and disassembling booms jibs or masts on ground with or without support of boom rigging pendants or straps securely block each section to provide adequate support and alignment Do not go under boom jib or mast sections while connecting bolts or pins are being removed Unless authorized in writing by Manitowoc do not alter crane in any way that affects crane s performance to include welding cutting or burning of structural members or changing pressures and f
198. ed in such a manner that it has limited resistance to rotation has no more than nine outer strands and comprising an assembly of two layers of strands laid helically over a center in two operations the direction of lay of the outer strands being opposite to that of the underlying layer i e Endurance 8RR While this properly defines the ropes it does not tell the complete story about a commonly misunderstood and often misused product All of these ropes have specific operating and performance characteristics and some have limitations An overview of certain operating characteristics shows the following Endurance Endurance Endurance Endurance 19 8RR Dyform 18 Dyform 34LR amp 35LS Multiple Part Reeving No Yes Yes Yes Single Part Reeving Yes Yes Yes Yes Swivels No No No Yes Strength Low Low High Highest Preformed Yes Yes Partially No Multiple Layer Winding Yes Yes Yes Yes Prevention of Block Spinning N A Good Much Better Best More detail and further explanation of these characteristics and limitations will be covered in the following discussions These ropes should be limited to a maximum fall of 150 times the rope diameter i e 1 2 rope x 150 75 when used single part or rope distortion and damage may occur AE B C D E 2 A Endurance 19 B Endurance 8RR C Dyform 18 D Dyform 34LR E Endurance 35LS DIAGRAMATIC ILLUSTRATION OF ROTATION VARIOUS ROPE CONSTRUCTIONS 6 X 3
199. ee Crane Assembly in Crane Operator s Manual for detailed instructions and capacity limitations The jib butt jib strut and main strut are shipped from Manitowoc as an assembled unit The assembly weighs approximately 23 250 Ib 10 500 kg and is the heaviest load to be lifted Size assist crane accordingly Instructions in this section assume an assist crane will be used To allow for the set up of an assist crane there should be a minimum of 35 ft 10 7 m clearance on one side of the boom Installing 44 Luffing Jib Lower Boom 1 If specified in raising procedure chart travel front crawler rollers onto blocking 2 Swing upper slightly to either side and lower load block and weight ball onto ground 3 Swing boom in line with crawlers and lower boom point onto blocking approximately 54 in 1 4 m high as shown in Figure 4 5 View A This will allow you to assemble jib on blocking approximately 6 in 152 mm high Prepare Boom and Jib 1 Remove load block from boom point 2 Remove upper boom point if equipped SETUP AND INSTALLATION Change boom requirements Note that 40 ft 12 2 m insert with luffing hoist guide sheaves must be installed next to 10 ft 3 1 m insert which is next to boom butt length as necessary to meet job Check that all boom inserts and straps are assembled in proper sequence according to rigging drawing A WARNING Tipping Hazard Crane can tip if step 5 is not performed if req
200. emain extended Removing 79A Jib Remove Jib Load Line Jib load line will be used to lower main strut later in the removal procedure Haul in load line on Drum 3 until end of line is near boom hoist equalizer Remove Jib Dolly Reverse installation steps to remove jib dolly Figure 4 27 Do not lower jib onto ground Remove Upper Jib Point 1 Support upper point with fork lift truck 2 Remove connecting pins 7 Figure 4 27 View E 3 Lower jib onto blocking approximately 6 in 150 mm high Boom down as required so jib sections are parallel to ground Remove Jib Jib removal is identical to boom removal The following instructions assume that assembly personnel already know how to disassemble the boom jib sections If in doubt see Boom Rigging Guide in Crane Operator s Manual WARNING Tipping Hazard Crushing Injury Hazard Jib sections can collapse when connecting pins are removed Block both ends of each jib insert before removing connecting pins Never work under or inside jib sections that are not securely blocked Disassemble Jib NOTE Do not disassemble butt and first two inserts at this time 1 Remove jib top and all but two inserts next to jib butt 2 Disconnect jib straps Store links as shown Figure 4 21 View J 3 Store straps on jib sections er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 4 Remove wind speed indicator from jib top to prevent b Remove n
201. ement of the hoisting equipment in the case of a system failure Manitowoc offers upgrade packages for friction controlled models to install anti two block dead man control and automatic hoist system control requirements to satisfy other codes and standards Manitowoc continues to recommend that cranes be properly maintained regularly inspected and repaired as necessary Manitowoc reminds crane owners that all safety decals must be in place and legible Manitowoc continues to urge Manitowoc crane owners to upgrade their cranes with rated capacity indicator limiter systems for all lifting operations Should you have any questions about this subject or other product safety matters relating to the operation and use of a Manitowoc crane please contact Crane Care Customer Service or the Product Safety and Reliability Manager at the following address Manitowoc Cranes 2401 So 30th St Manitowoc WI 54220 Phone 1 888 499 7278 Fax 920 683 6390 PEDESTAL BARGE MOUNTED CRANES A WARNING Crane owner user must verify that method used to fasten or restrain crane to foundation barge ship or floating platform is strong enough under all operating conditions to prevent crane from breaking off foundation or moving on barge Manitowoc does not permit use of a truck crane on a barge ship or floating platform Pedestal Mounted Crane Also see ASME publication B30 8 2004 Floating Cranes and Derricks SAFETY INFORMATION A WARNI
202. endants are lying over strut Interpolate as Required backstay straps S 30 F 1 C 230 5 psi 15 8 0 3 bar Verify that top of jib strut is properly anchored to counterweight Figure 4 21 Views E F G 50 F 10 C 240 5 psi 16 5 0 3 bar Check strut stop cylinder to verify the following 70 F 21 250 S BSi 1 2 e Strut stops 1 are fully retracted and retaining pins 90 F 32 260 5 psi 17 9 0 3 bar 2 View A are installed e Strut stops are pinned to strut butt Do not remove pin 7 View D If difference in strut stop cylinder pressure is greater than 5 psi 0 3 bar or pressures are not within limits specified in the preceding table contact factory for assistance View C WARNING Cylinder Movement Hazard Strut cylinder will extend forcefully if cylinder rod retaining pin 7 View D is removed and cause personal injury Extending cylinder will damage strut by twisting 4 46 Description Strut Stop Cylinder Retaining Pin with Cotter Pin Pressure Gauge Strap Shipping Pin stored Strap Shipping Pin working Storage Hole for Shipping Pin 5 Cylinder Rod Retaining Pin with Snap Pin Main Strut FIGURE 4 23 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION POSITION POSITION D POSITION B NX EN POSITI
203. entification of the load drums and guide sheaves Once wire rope is routed through the guide sheaves be sure to install rope guard pins bars and rollers to retain the wire rope on the sheaves Wire rope and sheaves can be damaged if rope is not properly retained on sheaves Reeving See Figure 4 55 and Figure 4 56 for load block reeving Reeving the load block in any manner other than shown can result in excessive block twist CAUTION Wire Rope Damage Do not hoist load block closer to boom point than shown on Load Block Reeving charts Improper fleet angle or contact with other parts can damage wire rope er 18000 LUFFING JIB OPERATOR S MANUAL Lifting Lugs Shackle optional View B Reeving Position SETUP AND INSTALLATION A WARNING Avoid Death or Serious injury Exercise care when block is standing in vertical position as the potential for tipping exists Potential causes of tipping are unstable work area boom movement and the reeving process If work area is unstable lay block flat on side plate FIGURE 4 50 FIGURE 4 51 mm Published 06 20 08 Control 033 07 4 87 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL One Drum Two Drum 1 1 8 in 28 mm Rope 1 1 8 in 28
204. ers Boom to Boom to Boom Luffing Jib Luffing Jib Length Luffing Jib No 44 Angle Luffing Jib No 44 Angle Feet Meters Feet Meters Degrees Feet Meters Degrees 220 240 67 1 73 2 220 240 67 1 73 2 190 240 57 9 73 2 180 240 54 9 73 2 160 240 48 8 73 2 130 240 39 6 73 2 120 240 36 6 73 2 90 240 27 4 73 2 70 240 21 3 73 2 70 240 21 3 73 2 Load blocks hook and weight ball on ground until boom and luffing jib are erected Remove lower boom point 8542 A 4 14 04 GA 5 18005910 MANITOWOC CRANES INC Upper Luffing Jib Point Lower Luffing Jib Point 79A Luffing Jib Lower Luffing Jib Point Eng Rev 06 19 08 Group F ower ower X ower 00 gt lt oin 55 Or 55A Boom Top 79 Boom CONTROL WIRING amp LIMITS MANITOWOC CRANES INC Location Of Load Link Item 9 489 Boom Point Lower Assy With 12 Or More Parts Of Line Boom 79A Ref Location Of Load Link Item 9 Over Lower Boom Point And Switch Asm Item 32 With 2 4 6 8 Or 10 Parts Of Line Over Lower Boom Point 81 Far 71 68 Near 63 Side 52 50 Side Upper Boom Point View 1 Note Direction Of Load Link Location Of Load Link Over Upper Boom Point Assembly Ref 73 55 9 Sab 55 Wired 70K 77 iver 3 73 59 4
205. ersonnel and their personal belongings clothing water coolers lunch buckets etc away from crane if it is being operated near electrical power lines or equipment Before operating crane in the vicinity of electrical power lines or equipment notify the power utility company Obtain positive and absolute assurance that the power has been turned off The crane is NOT INSULATED Always consider all parts of the load and the crane including the wire rope pendants or straps and tag lines as conductors Most overhead power lines ARE NOT insulated Treat all overhead power lines as being energized unless you have reliable information to the contrary from the utility company or owner The rules in this section must be followed at all times even if the electrical power lines or equipment have been de energized Crane operation is dangerous when close to an energized electrical power source Exercise extreme caution and prudent judgement Operate slowly and cautiously when in the vicinity of power lines If the load wire rope boom or any portion of the crane contacts or comes too close to an electrical power source everyone in on and around the crane can be seriously injured or killed The safest way to avoid electrocution is to stay away from electrical power lines and electrical power sources The operator is responsible for alerting all personnel of dangers associated with electrical power lines and equipment The crane is
206. es c Pin jib strut to adapter frame and install keeper plates View A As pins are installed install washers to limit side play of jib strut to 1 8 in 3 2 d Disconnect slings from jib strut Install main strut as follows a Connect chain slings from assist crane to four lifting lugs on main strut View D Adjust length of rear chain slings so rear end of strut hangs at least 8 ft 2 4 m lower than top end of strut b Lift main strut into position at end of adapter frame and align connecting holes c Pin main strut to adapter frame and install keeper plates View C SETUP AND INSTALLATION As pins are installed install washers to limit side play of main strut to 1 8 in 3 mm d Disconnect slings from main strut Install Luffing Hoist Wire Rope 1 2 Published 06 20 08 Control 033 07 Select and confirm LUFFING JIB mode Place reel of luffing hoist wire rope on ground along right side of jib near sheave end of struts Attach wire rope to sucker line if installed in strut sheaves If sucker line is not installed reeve free end of luffing hoist wire rope through strut sheaves and under guide sheave right side on boom top as shown in reeving diagram on rigging drawing Route free end of luffing hoist wire rope through guide sheaves in 40 ft 12 2 m insert nearest boom butt Securely anchor free end of luffing hoist wire rope to luffing hoist drum with wedge provided see Wire Rop
207. essure is not within specified range contact Manitowoc Service Department for assistance Make sure all safety devices block up limits boom and jib angle indicators boom and jib stops rated capacity indicator limiter are installed and operating properly See Section 6 of this manual Make sure proper luffing jib capacity chart is selected to turn on luffing jib mode Raise and lower attachment as instructed in Section 4 of this manual Perform all operations with crane on a firm level uniformly supporting surface Crane must be level to within 1 ft 0 3 m in 100 ft 3 1 m Pressure Gauge FIGURE 3 7 10 Operate all crane functions slowly and smoothly Avoid sudden starts and stops which could side load or shock load attachment 11 Do not operate if wind exceeds allowable limits given in Capacity Charts provided with crane and luffing jib WIND CONDITIONS Wind adversely affects lifting capacity and stability The result could be loss of control over the load and crane even if the load is within the crane s capacity A WARNING Tipping Crane Hazard Judgment and experience of qualified operators job planners and supervisors must be used to compensate for affect of wind on lifted load and boom by reducing ratings or operating speeds or a combination of both Failing to observe this precaution can cause crane to tip or boom jib to collapse Death or serious injury to personnel can resul
208. f down and haul in Drum 3 load line 1 while following with assist crane to lower main strut until backstay straps can be connected POSITION E Watch closely as strut lowers so that load line does become tangled in boom hoist equalizer Signal operator as required 14 Connect backstay straps 11 to connecting links 10 using pins 12 View F 15 Connect rear tie links 9 Figure 4 21 View E between two crane counterweight boxes at jib strut top 16 Slowly luff up to raise main strut to POSITION F 17 Remove retaining pins 15 View D from strut stops 14 Support strut stops when removing pins Strut stops will swing away from main strut 18 Store pins 15 in lugs on main strut 13 View C Continued On Next Page Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION View A View B P2132 P2131 P2133 working 8 shipping 8 stored Description Luffing Hoist Line Drum 6 Cylinder Rod Retaining Pin 2 Main Strut Lug 3 Strut Stop Tube Retaining Pin 4 Top Strut Locking Pin 5 Pin with 2 Cotter Pins Handling Pendants FIGURE 4 25 ad Published 06 20 08 Control 033 07 4 49 SETUP AND INSTALLATION Raise Main Strut continued See Figure 4 25 for following procedure 19 Slowly luff down to lower main strut 2 to rear POSITION G View C Stop when strut stops 3 are just above boom top 4 as
209. f wind speed mounting bracket Set Up Jib Stop Positioners See Figure 4 28 for following procedure 1 Pump hand pump 11 View until pressure gauge 12 reads 2500 psi 172 3 bar 2 Using hand winch 3 View D in jib top disengage safety latch 7 View F in jib butt 3 Adjust safety latch spring tension if necessary View F 4 Signal crane operator in operator s cab to retract positioner cylinders Weight of jib stops retracts cylinders 9 View E A WARNING Structural Damage Raising boom and jib with jib stop positioner cylinders extended will result in structural damage Be sure cylinders are retracted 5 Using hand winch 3 View D in jib top release tension on safety latch cable 4 6 Pay out additional cable and pull cable through jib as needed to provide at least 12 in 305 mm slack at safety latch Slack is needed to allow latch engagement when cylinders are extended Pre Raising Checks Make the following checks and correct any defects before raising the attachment Q All installation steps given in this section performed 0 Boom and jib inserts installed proper sequence according to Rigging Drawings Q Boom jib and backstay straps installed in proper sequence and unpinned from storage positions Q All connecting pins installed and properly retained i Boom and luffing hoist wire rope anchored properly to drums spooled tightly onto drums and engaged with proper sheave
210. fault will go off once the boom and luffing jib are raised and the load lines block up limit chains are hanging freely MAX UP 1 and MAX UP 2 these faults will go off once the boom to jib angle is less than 1682 1 Disengage swing lock and release swing brake 2 Slowly luff up until jib straps lift out of strap brackets on jib and stop 3 Slowly boom up Jib point rollers will roll along ground as boom and jib are jack knifed into position A WARNING Tipping Hazard Structural Damage Do not allow jib or backstay straps to become too tight during raising steps Crane will tip or structural damage will result Do not allow jib and backstay straps to become too slack during raising steps Jib strut could fall onto jib butt 4 Payoutload lines as boom and jib are raised 4 28 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL 5 Jib straps and backstay straps will tighten as boom and jib rise OPERATOR AND SIGNAL PERSON watch backstay straps and jib straps along left side of boom and jib as boom and jib rise Pay out luffing hoist wire rope luff down so jib straps remain slack e Allow backstay straps to float up and down 3 6 in 76 162 mm above strap brackets at top end of boom butt Allow jib straps to float up and down 3 6 in 76 162 mm above strap brackets at end of jib top It will be necessary to use limit bypass switch to luff down if BLOCK UP limit is on
211. fing Jib Capacity Chart selected 2 Depress limit switch 2 actuator rod to activated Dimension D2 and hold Listen for limit switch to click open LED OFF Turn limit bypass key clockwise and hold 4 Push luffing jib handle forward Luffing hoist must not turn in down direction and JIB MAXIMUM DOWN fault should come on Operational Checks Make the following operational checks after the boom and jib are raised 1 Travel crane onto a firm level surface or level crane by blocking under crawlers Raise boom and luffing jib until boom is at 80 Monitor BOOM TO LUFFING JIB ANGLE on main display information screen while performing remaining steps SLOWLY raise luffing jib Luffing hoist must stop and be inoperable in up direction when boom to luffing jib angle is 168 6 Fault alarm should come on indicating JIB MAXIMUM UP 1 limit has been reached 6 6 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL 7 Turn limit bypass key clockwise to bypass MAXIMUM UP 1 limit 8 SLOWLY raise luffing jib past MAXIMUM UP LIMIT 1 9 Luffing hoist must stop and be inoperable in up direction when boom to luffing jib angle is 170 10 Fault alarm should come on indicating JIB MAXIMUM UP 2 limit has been reached If maximum stops do not operate properly troubleshoot system 11 SLOWLY lower luffing jib 12 Luffing hoist must stop and be inoperable when boom to luffing jib angle is 70 Turn
212. for Aux Drum Sheave View T T View U U Boom Butt INSERT ASSEMBLIES REQUIRED FOR VARIOUS BOOM LENGTHS ITEM NO R107 R120 R130 R138 R153 R167 BOOM LENGTH INSERT INSERT INSERT INSERT INSERT INSERT ASSEMBLY ASSEMBLY ASSEMBLY ASSEMBLY ASSEMBLY ASSEMBLY METERS 55 BOOM 55 BOOM 55 BOOM 55 BOOM 79 BOOM 79 BOOM 10 0 3 05 W SHEAVES 20 0 6 10 TRANSITION 20 0 6 10 40 0 12 19 m ITEM R106 40 0 12 19 ITEM R129 55 79 ITEM R152 ITEM R166 ITEM R119 40 0 12 19 m ITEM R139 90 0 12 0122 0 EL A18WN3SSV NOISIA3H JIB LENGTH FEET METERS INSERT 10 0 3 05 m ITEM 29 ADDITIONAL PARTS REQUIRED FOR VARIOUS JIB LENGTHS INSERT 200 6 10 31 INSERT 40 0 12 19 m ITEM 33 STRAP 9 4 3 4 2 86 m ITEM 27 STRAP 19 4 3 4 5 91 m ITEM 30 STRAP 39 4 3 4 12 00 m ITEM 32 TIMBER ITEM 7 BOOM SUPPORT LINK ITEM 28 COLLAR ITEM 9 PIN ITEM 10 PIN ITEM 12 ADJUSTABLE STRAP LENGTHS POSITION STRAP LENGTH o Oo Se 1 1 1 1 On 10 Onplalalo2 Sss oss eps oss eo E kod bai kad kad kad ked o o o o o o o o
213. front of chest with thumb tapping chest Published 06 20 08 Control 033 07 ightly raised hand in front of body make pushing motion in direction EXTEND BOOM Telescoping Booms Both fists in front of body with thumbs pointing RETRACT BOOM Telescoping Boom One hand signal One fist in front of chest thumb pointing outward and heel of fist tapping chest Oommen 18000 LUFFING JIB OPERATOR S MANUAL OPERATION THIS PAGE BLANK mm Published 06 20 08 Control 033 07 3 3 OPERATION Left Side of Boom Identification Crane Mode Select Confirm Switch Drum 4 Boom Hoist Park Switch Drum 6 Luffing Hoist Park Switch Boom Hoist Control Luffing Hoist and Swing Control Limit Bypass Switch Digital Display Mechanical Boom Angle Indicator Mechanical Level See Figure 3 4 for drum identification OAND OQ GENERAL OPERATION The instructions in this section supplement the operating control instructions in the Crane Operator s Manual This section has two purposes e To familiarize qualified operators with the location of the controls used for luffing jib operation e Toalert operators to important safety information WARNING Prevent death or serious injury to personnel Luffing jib attachment must be installed and operated by experienced personnel trained in erection and operation of construction cranes These personnel shall read understand and
214. g jib chart in Rated Capacity Indicator Limiter 2 Select and confirm luffing jib mode After confirming this mode top line of display should read see Figure 3 3 Crane Mode LUFFING JIB ON 3 To retract jib stop positioner cylinders select and confirm LJIB STOP mode After confirming this mode top line of display should read Crane Mode LUFFING JIB ON SP SP in this line means that jib stop positioner cylinders should be retracting power applied to solenoid 4 To extend jib stop positioner cylinders select and confirm mode LJIB STOP again After confirming this mode top line should now read Crane Mode LUFFING JIB ON SP is gone and power is removed from solenoid Cylinders should extend fully OPERATION Luffing Jib LJIB SP Mode Mode ON ON Crane Mode LUFFING JIB ON SP FIGURE 3 3 A WARNING Moving Part Hazard If retracted jib stop positioner cylinders will extend jib stops rise when engine is stopped 2 Drum 4 Boom Hoist Park Switch 3 Drum 6 Luffing Hoist Park Switch 4 Boom Hoist and Whip Hoist Control 5 Luffing Hoist and Swing Control See Operating Controls in Section 3 of crane Operator s Manual for operation of above controls 6 Normal Limit Bypass Switch This switch bypasses the limits identified in Table 3 1 A WARNING When bypassing a limit carefully follow instructions under Limit Devices topic in this section Insert key Turn CLOCKWISE and HOLD t
215. ge pins in boom top 12 Slowly luff up until jib straps start to go into tension and stop er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 13 Apply swing brake boom up to raise jib point clear of dolly and remove dolly Y 14 Install load blocks or weight ball see Load Block B WARNING Reeving in this section Falling Load Hazard Load lines going up boom can overhaul load lines going down jib Do not untie load lines from jib until load blocks A or weight balls have been installed Load lines can fall off WARNING boom if this precaution is not followed Falling Load Hazard Do not lift load blocks or weight balls off ground until boom 15 Slowly raise boom and jib to desired boom angle see has been raised to desired operating angle and jib has capacity chart for boom angles been positioned at required operating radius for load to be 16 Pay out load line as boom and jib are raised handled Structural damage can occur and attachment ae can collapse if this precaution is not observed 17 Position jib at required operating radius 18 Travel forward until load blocks and or weight balls are directly below jib point 19 Lift load blocks and or weight balls to desired position 16 4 185 View View View C Figure 4 30 mm Published 06 20 08 Control 4 033 07 4 61 SETUP AND INSTALLATION Lowering Boom and 279A Luffing Jib General ALL boom and jib combinations must be raised
216. guage DECAL Warning Boom Ladder Korean Language 8 Black Letters 4 White Letters 5 Clear Letters W white Outline Refer to boom and jib rigging drawing for part number Not Shown See 175916 for quanities and placement Position decal by safety harness anchor PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER SECTION 3 OPERATING CONTROLS AND PROCEDURES TABLE OF CONTENTS Standard Hand Signals for Controlling Crane 3 1 General Operation sese ke Er RR arc ch Ek Rr UR A eR Rm RR dn 3 4 Luffing Jib Operating 8 3 4 1 Crane Mode Select Confirm 3 4 2 Drum 4 Boom Hoist Park Switch 3 5 3 Drum 6 Luffing Hoist Park 3 5 4 Boom Hoist and Whip Hoist 3 5 5 Luffing Hoist and Swing 3 5 6 Normal Limit Bypass 3 5 7 Digital Display ema e dee erbe v dete 3 6 8 Mechanical Boom Angle Indicator 3 7 9 Mechanical Level 3 7 Automatic Jib Stop not shown 3 7 Operating
217. h Language A10487 DECAL Warning Pinch Point Hazard Chinese Language A12557 DECAL Warning Pinch Point Hazard Spanish Language N N N N N G G G G G N N N N N HH A11644 DECAL Warning Pinch Point Hazard Italian Language 81001118 DECAL Warning Pinch Point Hazard Korean 386567 DECAL Manitowoc 539090 DECAL Manitowoc Logo 40 Red Ball or DECAL Manitowoc Logo 40 Red Ball 539091 DECAL Manitowoc Logo 40 Clear Ball A07883 DECAL Caution Jacking Cylinder Damage English Language A10489 DECAL Caution Jacking Cylinder Damage Chinese Language A12569 DECAL Caution Jacking Cylinder Damage Spanish Language A11646 DECAL Caution Jacking Cylinder Damage Italian Language 81001120 DECAL Caution Jacking Cylinder Damage Korean A08167 DECAL Warning Burn Hazard English Language A10490 DECAL Warning Burn Hazard Chinese Language A12570 DECAL Warning Burn Hazard Spanish Language A11647 DECAL Warning Burn Hazard Italian Language 81001121 DECAL Warning Burn Hazard Korean A10544 DECAL Manitowoc Crane Group A06767 DECAL 18000 Model No see Note1 A06768 DECAL Manitowoc 18000 see Note1 A06702 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 6 of 8 N Q Q Q QO NN N m N MODEL 18000 55 11450 13350 11451 13351 11449 13349 13807 14199 81000744 15213 81001530 386206 386207 1159
218. h an anti two block device 7 Manitowoc s Capacity Charts are based on freely suspended loads To prevent side load damage to boom jib and sheaves e Load lines must hang as near vertical as possible to minimize side and forward loads 2 12 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL e must remain centered on boom and jib point shafts unless special lift approval is granted by Manitowoc e Load lines should be located over load s center of gravity as it is supported on a trailer barge or ground 8 Crane operator must be familiar with operational characteristic of crane as it relates to multiple drum operation simultaneous operation same or opposite direction or individual operation 9 When using tandem drums maximum operating layers may be limited depending on whether crane was initially designed for tandem drum operation or not A WARNING Avoid Over Load and Side Load Damage to Crane Manitowoc highly recommends that you contact your Manitowoc Crane Care distributor for lift planning assistance and approval Holding Load When a load is suspended operator shall take following precautions 1 Not leave his her position at controls 2 Not allow personnel to stand or pass under load 3 Move all controls to off apply all drum brakes engage boom hoist pawl and apply swing and travel brakes or locks Signals 1 Continuous communication shall be maintai
219. h one leg of sling Lifting Moving Load 1 Before lifting or moving load operator or qualified person directing lift shall make following checks a Crane has a firm uniformly supporting foundation under both crawlers all tires or each outrigger jack pad or float Unless otherwise specified on capacity chart foundation shall be level to within 1 1 ft 0 3 m rise or fall in 100 ft 30 5 m distance When such a surface is not available it shall be provided with timbers cribbing or other structural members to distribute load such that allowable bearing capacity of underlying member is not exceeded Contact Manitowoc Crane Care Customer Service at Manitowoc for ground bearing data b Load is secured and properly balanced in slings or lifting device before lifting the load more than 3 6 in 76 152 mm c Lift and swing paths are clear of personnel and obstructions d Loadis free to be lifted e Load line is not kinked or otherwise damaged f Multiple part load lines are not twisted around each other in such a manner that lines will not separate when load is lifted g Hook is brought over load in a manner that will minimize twisting or swinging Canrrowoc 18000 LUFFING JIB OPERATOR S MANUAL Load line and boom hoist ropes are properly spooled on drums and seated in sheaves Load drum brakes are in proper working order Operator shall test load drum brakes each time a load approaching rated lo
220. h or serious injury if the message is ignored A CAUTION Identifies potential hazards that could result in minor or moderate injury if the message is ignored CAUTION Without the safety alert symbol identifies potential hazards that could result in property damage if the message is ignored NOTE Highlights operation or maintenance procedures Safety Symbols Safety symbols used in the decals on this crane are identified in Figure 2 1 Published 06 20 08 Control 033 07 2 1 SAFETY INFORMATION 18000 LUFFING JIB OPERATOR S MANUAL Crush Hazards Cut or Crush Hazards Electrocution Hazard Cut Hazard Explosion Hazard Fall Hazard FIGURE 2 1 2 2 Published 06 20 08 Control 033 07 r c Crane Care 18000 LUFFING JIB OPERATOR S MANUAL SAFETY INFORMATION Engine Diesel Coolant Fuel Engine d Hydraulic Vent Filter eF Fall Hazards T Hydraulic Oil Oil Level 0 Pump Drive Fluid Symbols Flying Object Hazards Falling Boom Hazards Overhead Obstruction Hazard Falling Load Hazards Crush Hazard Power Line Hazard Electrocution Fire Extinguisher gt PLY anto FIGURE 2 1 continued mm Published 06 20 08 Control 033 07 2 3 SAFETY INFORMATION 18000 LUFFING JIB OPERATOR S MANUAL Personal Fall Protection Sound Power Level Read Manual Pressure Cleaning Tire Pressure Pressu
221. hackles hooks slings blocks has been properly maintained and is safe for use All lifting equipment has a capacity equal to or greater than load to be lifted GENERAL SETUP AND INSTALLATION This section contains installation and removal instructions for the luffing jib attachments available for the Model 18000 44 and 479A For the remainder of this section luffing jib attachment is referred to as jib or attachment The instructions in this section assume that the crane required length of boom and mast and MAX ER attachment if required are already installed and ready for luffing jib installation For 44 Jib the crane must be rigged as follows e 55 79 boom e 100ft 30 5 m mast e MAX ER attachment For 479A Jib the crane must be rigged as follows 55 or 55A boom e 1008 30 5 mast without MAX ER attachment e 1408 42 7 m mast with MAX ER attachment mm The attachment shall be installed operated and removed by experienced personnel trained in the operation and erection of construction cranes These personnel shall read understand and comply with the instructions in this section in the Luffing Jib Rigging Drawing and in the Liftcrane Luffing Jib Capacity Charts provided with the attachment Contact your Manitowoc Crane Care distributor for a detailed explanation of any procedure not fully understood The installation removal area must be firm level and free of ground and overh
222. horoughly familiar with operation of crane and its proper care If adjustments or repairs are necessary or if there are known defects that impair safe operation crane shall not be operated until unsafe conditions have been corrected er 18000 LUFFING JIB OPERATOR S MANUAL If there is a warning sign at start controls operator shall not start engine until warning sign has been removed by person who installed it Before starting engine operator shall make sure that a All daily inspection and maintenance services have been performed b All controls are in off position and all brakes and locking devices are applied or engaged C All personnel are clear of crane Deploy a swing radius barrier Operator shall test controls limits communication systems at start of each shift Any defects found shall be corrected before operation is begun A WARNING 12 SAFETY INFORMATION b The counterweight to include applicable auxiliary counterweight is in place and of proper weight Maximum required counterweight shall not be exceeded Operator shall perform the following operations before leaving operator s cab for any reason a Park crane if mobile and position upperworks so the crane does not interfere with operation of other equipment b Apply travel and swing brakes or locking devices Land any attached load d Lower boom onto blocking at ground level or onto a boom rest if possible otherwis
223. ib stops can be damaged 14 Jib straps will slacken as boom and jib lower View D Signal person watch jib straps along left side of jib as boom and jib are lowered Do not allow straps to become too slack or they will bounce against jib inserts Signal operator to haul in luffing hoist wire rope luff up so jib straps remain 2 1 2 3 1 2 ft 0 76 1 07 m above strap supports at end of jib top Do not allow jib straps to go into tension It will be necessary to use limit bypass switch to luff down if BLOCK UP limit is on WARNING Tipping Hazard Do not allow jib straps to become too tight during lowering steps Crane will tip or structural damage will result Do not allow jib straps to become too slack during lowering steps Strap connectors will bounce against jib inserts possibly resulting in damage 15 Continue to boom down approximate boom to luffing jib angle shown in View D and stop booming down and luffing up Luff up or down as required to position jib straps 2 1 2 3 1 2 ft 0 76 1 07 m above strap supports at end of jib top 4 64 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL 16 Boom down until connectors between jib butt and first jib insert are approximately 6 in 150 mm from ground 17 Make sure jib straps lower into strap supports at ends of inserts 18 Signal crane operator to extend cylinders with the mode switch Cylinders will extend View F and r
224. ide is against Place free end of seizing wire in valley between two stands WATORO Then wind seizing wire over free end as shown Finally twist Install wedge so end of wire rope extends past end of and pull two ends of seizing wire together until seizing is tight wedge but not out of drum socket Make sure seizing is not under wedge Remove seizing if it interferes with assembly Straight Wedge Outside Drum Wire Seizing Rope N Hole in Don t Allow End of Drum Flange Wire Rope to Extend Out of Socket Opening T Anchoring Wire Rope to Drum S Wind seizing wire around wire rope as shown Then twist two ends of seizing wire together at center of seizing Alternately twist and pull ends until seizing is tight View B Rope Diameter Smaller than 1 in 26 mm FIGURE 4 40 See Figure 4 41 for following procedure Use the correct wedge part number for the size of wire rope Straight Wedge e being used see parts drawing for the boom hoist drums or Inside Drum for the load drum shaft to obtain the correct part number 1 Assemble wire rope and wedge to drum socket 2 Tighten wedge rapping back of wedge with a brass drift and hammer FIGURE 4 41 mm Published 06 20 08 Control 033 07 4 75 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL Winding Wire Rope onto Drum Wraps of First Layer Tight Against Drum and Agains
225. iew C When steps 4 and 5 are performed If steps 4 and 5 are not performed jib jib stop will swing past adapter frame View E stop will not swing past boom top into proper operating position Damage could occur Jib stop will not operate into proper operating position 2 Greater Than 160 yA 60 or p fe More ni Z FIGURE 4 14 M A de Published 06 20 08 Control 033 07 4 25 SETUP AND INSTALLATION Raising Boom and 44 Luffing Jib General WARNING Falling Boom And Jib Hazard Select and confirm LUFFING JIB mode Operating in any other mode with luffing jib attached is prohibited Luffing jib limits are disabled when LUFFING JIB mode is off Boom and jib could be pulled over backwards A WARNING Moving Part Hazard Warn all personnel to stand clear of jib point rollers while raising boom and jib Use digital display in operator s cab to monitor boom angle and boom to luffing jib angle while raising boom and jib In Line Raising Procedure See Figure 4 14 for following procedure NOTE t is normal for the following limits to come during the raising procedure BLOCK UP this fault will go off once the boom and luffing jib are raised and the load lines block up limit chains are hanging freely MAX UP 1 and MAX UP 2 these faults will go off once the boom to luffing jib angle is less than 1682 A WARNING Tipping Crane Hazard When using in line method
226. imit switch goes out e Tighten jam nut If boom reaches Dimension A before it stops See Figure 6 4 a Loosen jam nut at adjusting rod coupling View b Turn adjusting rod out against boom butt until actuator rod clicks limit switch open and LED on limit switch goes out c Tighten jam nut Check that actuator rod over travels limit switch as shown in Figure 6 4 View B Boom down and then back up Boom must stop at specified Dimension A If boom fails to stop repeat steps 4 8 Cansrowoc 18000 LUFFING JIB OPERATOR S MANUAL Adjustment with luffing jib Unless otherwise specified see Figure 6 5 for following procedure 1 Travel crane onto a firm level surface or level crane by blocking under crawlers Make sure 3 in 76 mm long adjusting rod is installed See to Table A in to determine required jib angle for boom length in use 4 Use an accurate digital protractor level held against underside of right bottom boom chord to measure Protractor Angle Table B during remaining steps 5 Boom up slowly Carefully monitor angle on protractor level while booming up 6 Stop booming up when boom Protractor Angle reaches specified If boom stops automatically at specified Protractor Angle further adjustment is not needed If boom stops automatically before reaching specified Protractor Angle perform step 7 If boom reaches specified Protractor Angle before it automatically stops perfor
227. ing 4 62 ECCE 4 62 Jack Knife Lowering Procedure 4 62 Jack Knife Lowering Procedure continued 4 64 Removing 79A 4 64 Remove Jib Load 4 64 Remove Jib 4 64 Remove Upper Jib Point 4 64 Remove guide serbe Se RENS 4 64 Disassemble 4 64 Remove Jib Strap 2 4 66 Remove Butt and First Two inserts 4 66 Lower Jib Strut cose ek Red eA A 4 66 Lower Main Strut 4 68 Lower Main Strut continued 4 70 Store Main Strut Top 4 72 Store Luffing Hoist Wire Rope 4 72 Remove Main and Jib Strut 4 72 Remove Jib and Main Strut Butts 4 72 Changing Boom and Jib 4 72 Wire Rope Installation 1 4 74 Wire Rope Storage 4 74 Removing W
228. ing vertically between backstay straps Pendants will lie against cross brace between straps c Disconnect Drum 3 hoist line from links and lay hoist line on top of boom d Disconnect one handling pendant from links and allow to pendant to hang vertically e Use assist crane to lift other pendant with links back up and outside of jib backstay straps Lower pendant to vertical and disconnect assist crane from links f Repeat step 29e for other pendant g Reconnect pendant to links and pin links with handling pendants to jib strut butt h Use assist crane to lift Drum 3 hoist line into position behind boom hoist equalizer Haul in excess line on Drum 3 i If Drum hoist will not be used store it on Drum 3 30 Disconnect crane counterweight from jib strut top Figure 4 21 View F 31 Disconnect tie links from counterweight boxes Figure 4 21 Views E and G 32 Remove boxes one at a time and install Place one box on each side of crane counterweight 33 Reinstall wire rope guide bars Figure 4 20 View I 19a and 19b Canrrowoc 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 24 Operating Position 23 22 23 Stored J gt 4 173 24 View H Shipping Position gt S 14 13 16 and 16a View E FIGURE 4 26 ad Published 06 20 08 Control 033 07 4 51 SETUP AND INSTALLATION Raise Jib Strut See Figure 4 26 Views A
229. ing Hoist Wire 4 42 Install Main Strut 4 44 Install Backstay Straps on Main Strut 4 45 Raise Main Strut cute ete n eet ach RIEN RC REN UAR A ed 4 46 Raise Main Strut continued 4 48 Raise Main Strut continued 4 50 Raise Jib Str t ccc cate Ie paci ecl s Rn 4 52 Install tes ette RU naque t teneant creda gud expand 4 52 Install Jib Strap 2 4 54 Connect Jib Strut Straps to Equalizers 4 54 Complete Jib Assembly 4 54 Prepare Jib Dolly 4 54 Install Jib Dolly ec RU Reg 4 54 Install Jib Load 4 56 Connect Electric Cords Adjust Electronic 4 56 Install Wind Speed Indicator Assembly 4 56 Set Up Jib Stop Positioners 4 56 Pre Raising Checks 4 56 Raising Boom and 79A Luffing 4 57 General D 4 57 Jack Knife Raising Procedure 4 60 Lowering Boom and 479A Luff
230. int Point Drum Reeving Wiring Interconnect Diagram 55 Or 79A Boom Top With Upper Boom Point A15368 Q Load Sensor Link WIRELESS 07389 ITRANSCEIVER Limit Switch Assembly Boom Node Block Up INTERFACE Controller CONTROLLER eine 08627 pica 9 WBM150440 WBMJ8 WN12 81000194 81000201 81000202 MABE 81000199 515946 agis 06154 Cable Reel On Boom Butt eur Mio 1 06 54 2 e TOR 391121 Extended Upper Extended Upper Boom Point Boom Point Lower Sheaves Upper Sheave Wiring Interconnect Diagram 79A Boom Top With Extended Upper Boom Point Load Sensor Link 15368 WIRELESS imi Limit Switch Assembly 2407389 TRANSCEIVER OOOO Boom Node x Block Up BUS Controller INTERFACE sa Terminator C A08627 Adapter Plug 572384 I Ref T T E 163 V WBM150440 WBMJ8 WN12 81000194 81000201 81000156 E WNBE 81000196 L A15346 15488 15488 4 GL i a 81000200 52 81000200 yu NA et x 591121 06154 N U er Boom Lower Boom With Tandum Point Drum Reeving Wiring Interconnect Diagram 55 55 Or 79A Boom Top With Existing Upper Boom Point 170419 Ref From 777 888 M250 Or 2250 REVISION A05580 11 of 20 ASSEMBLY MANITOWOC CRANES INC Luffing Jib 3 17580 02 Maximum Angle e Lo
231. ire Rope from Shipping 4 74 Seizing and Cutting Wire 4 74 Anchoring Wire Rope to 4 75 Winding Wire Rope onto 4 76 4 1 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Anchoring Wire Rope to Wedge 4 77 Anchoring Wire Rope to Button 4 77 Breaking in Wire 4 78 Pad Eye Usage for Wire Rope Reeving 4 79 General uode eut petes apama t eed Rewer esq 4 79 Safety reti densae b nica eee Sut pe Peg uu UM ER 4 79 Rigging Winch 4 80 Load Line Reeving 44 Luffing 4 80 Load BIOCKS gt metr Reed eI MTM PANE 4 80 Guide 2 4 80 Duplex HOOK sinora REED ES putet pub tior e ee c 4 80 Wire Rope Specifications 4 80 Wire Rope 4 80 Reeving Diagrams 4 80 Load Line Reeving 79A Luffing 4
232. is 8 Operator shall not start crane movement if the load or impaired by darkness fog rain snow etc designated signal person is not within his her range of Never operate crane during an electrical thunderstorm vision or communication When local weather storm warning exists Manitowoc 9 Operator shall understand and respond to signals from recommends that operation be stopped and the crane the person directing the lift or from the designated signal secured See step 12 under Operator Conduct topic person When a signal person or crane follower is not required operator is responsible for lift Operator shall DO NOT depend on grounding Grounding of obey a stop signal at all times no matter who gives crane affords little or no protection from electrical it hazards The effectiveness of grounding is limited by size of conductor wire used condition of 10 Operator shall verify that the capacity chart being used ground magnitude of voltage and current present is the correct one for how the crane is equipped boom and numerous other factors length load line reeving counterweight etc 16 Wind can cause crane to tip or boom and other 11 Operator shall verify that attachments to collapse Operator or qualified person a All attachments are properly assembled and directing lift shall compensate for effect of wind on load attached to the crane according to the rigging drawings called for on the capacity chart
233. ised CAUTION Structural Damage Avoid possible structural damage to boom and jib from side loading as boom and jib are raised Disengage swing lock and release swing brake until boom and jib have been raised to required boom to luffing jib angle Retract jib stop positioner cylinders before beginning to raise boom and jib NOTE t is normal for the following limits to come on during the raising procedure BLOCK UP this fault will go off once the boom and luffing jib are raised and the load lines block up limit chains are hanging freely UP 1 and MAX UP 2 these faults go off once boom to luffing jib angle is less than 169 2 to 170 See Figure 4 29 for following procedure 1 Determine boom to luffing jib angle that boom and jib must be raised to before jib can be raised see Liftcrane Luffing Jib Capacities Chart 2 Signal crane operator to retract positioner cylinders with mode switch 3 Disengage swing lock release swing brake and slowly boom up Jib point dolly will roll along ground as boom and jib are jack knifed into position 4 60 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL 4 Pay out load line as boom jib are raised 5 Jib and backstay straps will tighten as boom and jib rise Signal person watch jib straps and jib point dolly along left side of jib as boom and jib are raised Do not allow jib point to rise off dolly A WARNING Tipping Hazard Do
234. ist crane from jib strut until all of following steps are performed Boom length changed Boom straps connected to boom hoist equalizer and equalizer unpinned from rails e Backstay straps pinned to main strut Main strut fully raised Perform Raise Main Strut steps 16 28 er 18000 LUFFING JIB OPERATOR S MANUAL Jib See Figure 4 36 for following procedure It is okay to change the jib length with the struts positioned as follows Main strut fully raised Do not disconnect backstay pendants Jib straps disconnected from jib strut straps Jib strut raised and lowered as required to provide clearance Do not raise strut above 70 or lower strut to point that it contacts jib butt Slings from Assist Crane SETUP AND INSTALLATION To prevent parts from collapsing and possible death or serious injury to personnel observe following safety precautions when changing jib length Know weight of what you are lifting and size assist crane and all lifting slings accordingly Handle jib only with nylon slings securely attached to chords as close to end of inserts as possible Do not lift against lacings or lifting lugs on inserts Do not cantilever more than 40 ft 12 2 m of insert from end of inserts being lifted Attach nylon slings to both inserts as shown in Figure 4 37 Boom Insert Handling Shown Jib Insert Handling Similar 5 4 196
235. k sheaves Attach load to duplex hook so load hangs straight Load block can fail if overloaded allowing load to fall Load Block Handling Each load block as two lifting lugs as shown in Figure 4 50 View A The load blocks can be stood up for reeving as shown in Figure 4 50 View B Duplex Hook Attach the load so it is balanced equally on the hook Lifting slings must be within angles given in Figure 4 51 to achieve maximum hook capacity The duplex hook has a hole to which an optional shackle can be attached as shown in Figure 4 51 WARNING Falling Load Hazard Limit load to be handled with shackle to capacity of load block or shackle whichever is less Load block or shackle can fail if overloaded allowing load to fall 4 86 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Wire Rope Specifications See Wire Rope Specifications chart in Capacity Chart Manual for the following load block reeving information e Parts of line required to handle desired load Wire rope length required for various boom lengths and parts of line Maximum spooling capacity of load hoists Wire Rope Installation See Wire Rope Installation in this section for instructions e Installing wire rope on drums e Anchoring wire rope to drums See Figure 4 52 and Figure 4 53 for dead end locations and components in the lower and upper boom points Guide Sheaves and Drums See Figure 4 54 for id
236. l unsecured wire rope on jib side This could cause personnel injuries and damage to equipment Securely tie off load lines to jib before raising attachment 4 22 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL FIGURE 4 13 Connect Electric Cords Connect electric cords to respective junction boxes and switches See Boom Wiring and Limits Diagram at end of this section e Jib stop limit switches on jib adapter e Block up limit switches Load sensors for attachments without wireless RCL Install Wind Speed Indicator Assembly Install wind speed indicator if removed for shipping Use star washers to attach mounting bracket to jib top to provide good a ground see Wind Speed Assembly drawing at end of this section Connect electrical cable at base of wind speed mounting bracket Adjust Electronic Devices Adjust electronic devices according to instructions in Section 6 of this manual e Jib stop limit switches stop limit switch to 85 or 87 depending on boom length after boom and jib are raised e Block up limit switches Pre Raising Checks Make the following checks and correct any defects before raising the attachment J Lower boom point removed from boom top if required by raising procedure chart Rigging winch and wire rope guides removed from jib butt if required by raising
237. le This limit cannot be bypassed The luffing jib can be raised after the limit is contacted A WARNING FIGURES Falling Boom Jib Hazard 8 Mechanical Boom Angle Indicator Do not lower luffing jib below down limit Structural damage will occur possibly causing boom and luffing jib Shows the angle of the boom in degrees above horizontal to collapse The boom and luffing jib angles can also be viewed in display Screen mm Published 06 20 08 Control 033 07 3 7 C OPERATING PRECAUTIONS 1 Read and comply with instructions in Liftcrane Luffing Jib Capacity Charts provided with luffing jib attachment Do not operate beyond limits given in capacity charts Make sure proper counterweight is installed on crane and MAX ER if equipped Read and comply with instructions in this manual and in Crane Operator s Manual Read and comply with Maximum Allowable Travel Specifications in Luffing Jib Capacity Chart Manual Make sure luffing jib attachment is installed properly Read and comply with instructions in Section 4 of this manual Before raising boom and jib verify that pressure in jib stop positioner hydraulic system see Figure 3 6 is at proper setting For detailed instructions see Section 4 in this manual Pressure Gauge FIGURE 3 6 Before raising boom and jib verify that pressure in main strut stop cylinders Figure 3 7 is at proper setting For detailed instructions see Section 4 of this manual If pr
238. lent value in desired units For example 3 6576 m is converted to feet as follows 3 6576 m 0 3048 12 To Convert Application To Symbol Multiply By FORCE Square Inch in Filter Area Square Centimeter cm 6 4516 Clutch Contact Square Foot ft Ground Contact Square Meter m 0 0929 Pound Force Ib Pedal Effort KiloNewton kN 0 00445 Newton N 4 4482 Pound Force Ib Line Pull KiloNewton kN 0 00445 Pound Force Per Inch Ib in Newton per millimeter Nmm 0 1751 Spring Force Pound Force Per Foot Ib ft Newton per meter Nm 14 5939 Horsepower Pound Sq In Degrees Fahrenheit hp psi Degrees Centigrade Engine Hydraulic amp Air TEMPERATURE Cil Air Etc Kilowatt Bar Degrees Centigrade kW Inch in Adjustments Millimeter mm 25 4000 Foot ft Outline Dimensions Meter m 0 3048 Mile miles Travel Distance Kilometer km 1 6093 0 7457 0 0689 F 32 1 8 Degrees Fahrenheit C x 1 8 32 pre stele Inch Pound in Newton Meter Nm 0 1129 Bolt Torque Foot Pound ft Ib Newton Meter Nm 1 3558 VELOCITY Miles Per Hour mph Vehicle Speed Kilometers Per Hour km h 1 6093 Miles Per Hour mph Wind Speed Meters Per Second m s 0 4470 Feet Per Minute fpm Line Speed Meters Per Minute m min 0 3048 VOLUME Cubic Yard yd Cubic Meter m 0 7646 Bucket Capacity Cubic Foot ft Cubic Meter m
239. lete Upper Jib Point Roller Installation 4 11 Connect Jib Straps assess crees eR e Rn Sa 4 11 Install Struts 4 11 Install Luffing Hoist Wire Rope 4 13 Raise Main Struts cde kee ES 4 15 Connect Backstay Straps 4 15 Connect Hydraulic Hoses 4 17 Set Up Adjustable Straps 4 19 Raise JID STIUt u a susu e ERE TREE QUE ERRARE RR ned 4 21 Install Load Lines 4 22 Connect Electric Cords 4 22 Install Wind Speed Indicator 4 22 Adjust Electronic Devices 4 22 Pre Raising Checks iis ee eem qu eese e iR gee RR 4 22 Raising Boom and 44 Luffing 4 26 General QU asa usu amas asas S ole 4 26 In Line Raising 4 26 Jack Knife Raising 4 28 Lowering Boom and 44 Luffing 4 30 General 2 T 4 30 In Line Lowering Procedure 4 30
240. lified person directing lift shall establish procedures to furnish equivalent protection i e assign an additional signal person to observe distance between boom or load and job site obstructions to include power lines 9 When drum spooling limiter maximum or minimum bail limit is inoperative or malfunctioning qualified person directing lift operator or designated signal person shall watch drum and make sure it is not over spooled rope does not jump off drum and that there are never less than 2 full wraps of wire rope on load drum or boom hoist or as otherwise indicated in local state or federal regulations OPERATING NEAR ELECTRIC POWER LINES AND TRANSMISSION LINES Electrocution Hazard Thoroughly read understand and abide by all applicable federal state and local regulations regarding operation of cranes near electric power lines or equipment United States federal law prohibits the use of cranes closer than 10 ft 3 m to power sources up to 50 000 volts and greater distances for higher voltages 29CFR1910 180 and 29CFR1926 550 Published 06 20 08 Control 033 07 2 13 SAFETY INFORMATION To avoid death or serious injury Manitowoc recommends that all parts of crane boom and load be kept at least 20 ft 6 m away from all electrical power lines and equipment NOTE For detailed guidelines on operating near power lines refer to current edition of ASME B30 5 American National Standard Keep all p
241. lifting equipment from total weight given on chart See specific capacity chart for your crane for a list of lifting equipment which must be deducted Operator s judgment must be used to further reduce total weight to allow for dynamic effects of swinging hoisting or lowering and adverse weather conditions to include wind Operator or other designated person directing the lift shall verify that weight of load is within static or dynamic rating for radius at which load will be lifted Verified weights and measured radii shall take priority over RCI RCL readings Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Attaching Load 1 Attach hook to load with slings or other suitable rigging Each hook shall have a latch that is in proper working order Hook latches shall not be wired open a Inspect each hook and latch before using b Never use a hook or latch that is distorted or bent c Make sure spring will force latch against tip of hook d Make sure hook supports load Latch must never support load Latches are only intended to retain loose slings under slack conditions 2 Only use slings and other rigging that are in safe operating condition and have a rating equal to or greater than the load to be lifted 3 Do wrap load line around load 4 Use suitable protection between slings and any sharp edges on load 5 Secure unused legs of a multi leg sling before handling a load wit
242. ll against wedge and live end of wire rope enough to tighten wedge in socket Use a brass hammer to seat wedge and wire rope as deep into socket as possible 5 Attach a wire clip to dead end of wire rope using one of the RIGHT methods shown Rope clip will aid in preventing wire rope from being pulled out of socket Published 06 20 08 Control 033 07 SETUP AND INSTALLATION NOTE Use Right Method A only if wire rope clip is small enough to be securely tightened to dead end Right Method C is only for a Terminator wedge socket 6 After socket is pinned in place hoist load slowly so wedge seats tight Do not shock load socket and wedge warnine Falling Load Hazard Wire rope can break if following precaution is not observed Do not attach dead end of wire rope to live end of wire rope with wire rope clip Wire rope clip will transfer load from live side of wire rope to dead end seriously weakening attachment Anchoring Wire Rope to Button Socket See Figure 4 43 for following procedure 1 Remove pin from socket 2 Install button end of load line in socket 3 Pin socket to anchor point 4 Securely tighten locking screw Button 1 Locking Screw behind Button Socket Button Socket Assembly FIGURE 4 43 4 77 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL Wire Rope Clip 0 875 1 0 Size inch mm 22 23 25 4 1 125 1 25 28 58 31 75 Standar
243. lows of air hydraulic components Doing so will invalidate all warranties and capacity charts and make crane owner user liable for any resultant accidents Keep crane clean Accumulations of dirt grease oil rags paper and other waste will not only interfere with safe operation and maintenance but also create a fire hazard Store tools oil cans spare parts and other necessary equipment in tool boxes Do not allow these items to lie around loose in operators cab or on walkways and stairs Do not store flammable materials on crane Do not return crane to service at completion of maintenance or repair procedures until all guards and covers have been reinstalled trapped air has been bled from hydraulic systems safety devices have been reactivated and all maintenance equipment has been removed Perform a function check to ensure proper operation at completion of maintenance or repair SAFETY INFORMATION BOOM DISASSEMBLY SAFETY NOTE The term boom used in the following instructions applies to all lattice attachments fixed jib luffing jib mast etc DANGER Collapsing Boom Hazard Prevent death or serious injury when disassembling boom sections read and adhere to following instructions Safe handling of lattice booms during disassembly is a primary concern for preventing serious or fatal injuries A boom can collapse during disassembly if workers fail to observe safe working practices Accidents
244. m Point Upper Assembly Ref 73 9 ft Lg 55 55 WOR Transceiver 59 6 Ya Relief 48 67 Part Of Item 6 66 49 Single Must Be Looped Over 2 Part Part Hook On Boom Top Line 47 Line 65 4 Of See Note6 12 ft Lg 27 2 Pat ped Wedge 18 27 12 ft Lg H 25 18 55 Or 455A J 25 8 Load Link See Note 4 Location Of Weight Item 25 And Actuator Wireless 70K With 2 4 6 8 Or 10 2h Parts Of Line Over Lower Boom Point v Node 23 ERN Controller TN Bracket Assy ock Angle i Transmitter Ref a Single Part Line 0 55 Or 55A Boom Top Transceiver Strain Relief Out To Boom Top Part Of Item 6 Node Controller Must Be 12 Looped Over Hook On 6 TENIS Boom Top WBM150440 From Cable Reel Boom Top Left Side 7 of 20 MANITOWOC CRANES INC 62 62 58 58 51 57 _ l 50 1 59 viii 9ftlg 55 1 lI H 59 59 49 Single Part Line View 4 Upper Boom Point 170419 Ref Dead End On Upper Boom Point 26 44 9 Load Link Wired 70K Luffing Jib Angle Min Ref 12ftLg 27 See Note 8 View P P Location Of Load Link Item 9 And Switch Asm Item 26 With 2 4 6 8 Or 10 Parts Of Line Over Lower Boom Point Load Pin 1 Can In Mounting Bracket On Boom Top Luffing Jib Angle Max
245. m step 8 MAINTENANCE 7 If boom stops before reaching specified Protractor Angle See Figure 6 1 a Loosen jam nut at adjusting rod coupling View A b Turn adjusting rod all the way into coupling Boom up slowly until boom reaches specified Protractor Angle d Turn adjusting rod out against boom butt until actuator rod clicks limit switch open and LED on limit switch goes out e Tighten jam nut 8 If boom reaches specified Protractor Angle before it stops See Figure 6 4 a Loosen jam nut at adjusting rod coupling View A b Turn adjusting rod out against boom butt until actuator rod clicks limit switch open and LED on limit switch goes out c Tighten jam nut 9 Check that actuator rod over travels limit switch as shown in Figure 6 1 View B 10 Boom down and then back up Boom must stop at specified Protractor Angle If boom fails to stop repeat steps 4 9 Table A Boom Length 140 180 200 340 42 7 54 9 61 0 103 6 87 Table B Boom Angle 85 Protractor Angle 72 7 87 74 7 Digital Protractor Level Against Bottom Chord on Right Side of Crane Q FIGURE 6 5 Published 06 20 08 Control 033 07 6 11 MAINTENANCE PHYSICAL BOOM STOP A WARNING Falling Attachment Hazard Physical boom stops must be installed and pinned in working position for all crane operations Physical boom stops do not automatically stop
246. m top step 3 c With LUFFING JIB mode selected push luffing jib handle forward Luffing hoist must not turn and LUFFING JIB MAX DOWN operating limit should come on d Readjust limit switch if necessary to ensure proper operation Final Adjustment Steps 1 Securely fasten actuator 2 to jib butt with screws and lock washers provided 2 Once limit switches are properly adjusted drill and seal limit switch spacers 7 Figure 6 1 to mounting bracket 8 with roll pins and lead wire seals 3 Make sure boom and luffing jib angle indicators are properly adjusted before raising boom and luffing jib See instructions in this section Published 06 20 08 Control 033 07 6 3 MAINTENANCE Operational Checks Make the following operational checks after the boom and jib are raised 1 Raise boom and luffing jib until boom is at 80 2 Monitor BOOM TO LUFFING JIB ANGLE on digital display while performing remaining steps SLOWLY raise luffing jib Luffing hoist must stop and be inoperable when boom to luffing jib angle is 168 maximum working angle 5 Operating limit alert should come on indicating LUFFING JIB MAX UP 1 limit has been reached Stop raising luffing jib immediately if limit switch fails to stop luffing hoist Lower boom and jib to ground and readjust MAX UP 1 limit switch 6 Turn limit bypass key clockwise to bypass MAX UP 1 limit SLOWLY raise luffing jib past MAX UP LIMIT 1 Luffing hoist must stop
247. may be on a common shaft each with different parts of line or on multiple shafts boom and upper point boom and fixed jib point etc Manitowoc authorizes multiple load line operation for those applications requiring it provided following steps are performed 1 Aqualified lift planner and crane operator shall read and become thoroughly familiar with appropriate Capacity Charts and Wire Rope Specification Charts 2 Lift planner and crane operator shall make sure total load does not exceed rated capacity given in Capacity Chart and Wire Rope Specification Chart for given boom point or jib point EXAMPLE If one of load line is lifting from jib point proper jib chart applies 3 Crane shall be thoroughly inspected by a qualified person prior to setup 4 Crane shall be thoroughly inspected for load line interference caused by routing and reeving of multiple load lines If interference is found it shall be eliminated 5 For cranes produced before 2003 Rated Capacity Indicators Limiters were not required by ASME B30 5 for non personnel lifting To aid operator in staying within crane s capacity chart with total applied load Manitowoc recommends that its cranes be equipped with Rated Capacity Indicators Limiters to monitor load on each load line Operator is still responsible knowing load and radius whether or not crane is equipped with load indicator s 6 Manitowoc also recommends that each load line be equipped wit
248. mit controls weekly or every 40 hours of operation as follows 1 Lower the boom onto blocking at ground level and carefully inspect the following items a Inspect each limit switch lever and actuating lever Figure 6 10 for freedom of movement Apply one half shot of grease to the fitting on the actuating lever Wipe away any excess grease b Inspect each weight Figure 6 9 for freedom of movement on the load line Inspect each weight each chain each shackle and each connecting pin Figure 6 9 for excessive or abnormal wear Make sure cotter pins for shackles are installed and spread d Inspect the entire length of electric cables for damage e Checkthat the electric cables are clear of all moving parts on the boom and jib and that the cables are securely fastened to the boom and jib with clips or nylon straps f Check that all cables and terminating plugs Figure 6 9 are securely fastened 2 Test the block up limit controls for proper operation using either of the following methods a BOOM LOWERED Manually lift each weight one at a time while the engine is running The load drum should not operate in the hoist direction and the boom luffing hoist should not operate in the lower direction b BOOM RAISED Slowly hoist each load block and weight ball one at a time against the weight When the chain goes slack the corresponding load drum should stop hoisting and the boom luffing hoist sho
249. mm Rope 1 Jo Item Description on LII 2 1 Pin with Cotter Pin Load Cell 70 k Link ll Wedge Socket 1 1 8 in 29 mm _ with Pin and Cotter Pin del 4 Bushing 3 inch OD x 2 9 32 inch ID 4 76 mm OD x 56 mm ID WWW LP WH Button Socket 1 1 4 in 32 mm with Dead End Dead Ends Pin and Cotter Pin Dead End Lug Optional One Drum Two Drum 1 1 4 in 32 mm Rope n H 55 i 4322 TI sere TH UH C Dead Ends H HH d k 4 20 Dead End 179A LOWER JIB POINT FIGURE 4 52 1 1 8 in 28 mm Wire Rope 179A UPPER JIB POINT Item Description 1 Pin with Cotter Pin Link Pin with Cotter Pin Load Cell 70 000 Ib 31 751 kg Link Pin with Cotter Pin Swivel 25 USt Button Socket 1 1 8 28 mm or 1 1 4 in 32 mm Wire Rope with Pin Wedge Socket 1 1 8 in 28 mm Link Pin with Cotter Pin Swivel Weight Ball 1 1 4 in 32 mm Wire Rope FIGURE 4 53 4 88 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL A08237 9 1 5s OQ I mm Published 06 20 08 Control 4 033 07 SETUP AND INSTALLATION 11 179A Luffing Jib Item Description Drum 1 Hoist in boom insert Drum 2 Hoist in boom butt Drum 3 Whip in crane Guide Sheaves in Boom Guide Sheaves in Ma
250. mounted on a carbody crawlers removed which is securely fastened to foundation Figure 2 7 Carbody Foundation 2 Crawler mounted crane working on timbered area of barge ship or floating platform with crawlers restrained by curbing and end stops Figure 2 9 When not working crane carbody is anchored with tie downs to foundation Traveling with load is not permitted 2 105 If bolting carbody to foundation contact your Manitowoc Crane Care distributor for recommended bolt pattern and for type and quantity of bolts to be used FIGURE 2 7 Barge Mounted Crane Definition A barge mounted crane is a crane that is anchored or Tie Downs End Stop restrained in a work area of the barge ship or floating Required Front and platform and is subjected to tipping forces When Parked Lf Carbody Rear a Examples Curbing N 5 PEN NOTE The foundation is the deck of the barge ship or floating platform 2 107 NOTE Manitowoc does not permit traveling with load 1 Crawler mounted crane with carbody anchored with tie downs to foundation Figure 2 8 FIGURE 2 9 3 RINGER crawler mounted carbody mounted supported on blocking screw jacks or steel pedestals which are braced and fastened to foundation in such a manner as to prevent movement Figure 2 10 4 RINGER platform mou
251. mph Rating Reduction Above 35 mph OPERATION NOT PERMITTED 16 m s Wind speed to be measured at or above boom point elevation See Luffing Jib Capacity Chart for specific backward stability conditions 3 10 Published 06 20 08 Control 033 07 er 18000 LUFFING JIB OPERATOR S MANUAL 79A Luffing Jib on 55 or 55A Boom with MAX ER Attachment Operation Permitted Operation is permitted in steady winds or wind gusts up to the maximum speed given in Table 3 4 provided ratings are reduced the specified amount Operation Not Permitted Operation is not permitted in the areas indicated in Table 3 4 Observe the following options Boom with 90 150 ft 27 4 45 7 m Luffing Jib with MAX ER Attachment Upto 50 mph 22 m s Park crane upper in line with crawlers with load block on ground or secured and position boom at 75 and luffing jib at 45 50 22 m s and Above Lower boom and luffing jib onto blocking at ground level Table 3 4 Rating Reductions for Various Wind Speeds and Wind Gusts OPERATION Boom with 170 230 ft 51 8 70 1 m Luffing Jib with MAX ER Attachment Up to 40 mph 18 m s Park crane upper in line with crawlers with load block on ground or secured and position boom at 75 and luffing jib at 55 40 mph 18 m s and Above Lower boom and luffing jib onto blocking at ground level Boom with 250 310 ft 76 2 94 5 m Luffi
252. namerican com Dyform is a registered trademark of Bridon American Corporation NATIONAL ACCREDITATION OF CERTIFICATION BODIES WARNING Any warranties expressed or implied concerning the use of this product apply only to the nominal strength of new unused wire rope All equipment using this product must be properly used and maintained Wire rope must be properly stored handled used and maintained Most importantly wire rope must be regularly inspected during use Damage abuse or improper maintenance can cause rope failure Consult the AISI Wire Rope Users Manual ASME or ANSI Standards or Bridon American Corporation before usage Wire rope removal criteria are based on the use of steel sheaves If synthetic sheaves are used consult the sheave equipment manufacturer WARNING 12 00 1M WEDGE SOCKET WARNINGS AND APPLICATION INSTRUCTIONS Extended Wedge Socket Assembly U S Patent No 5 553 360 2200 EP 5 421 US 422T TERMINATOR NOTE Existing Crosby S 421 Wedge Sockets can be retrofitted with the New Terminator Wedge The only existing US 422 Wedge Sockets that can be retrofitted with terminator wedges are US4 US6 and US8 See the Crosby Catalog for additional information New QUIC CHECK Go and QUIC CHECK features cast into wedge The proper size a wire rope is determined when the following criteria are met 1 The wire rope shall pass thru the Go hole in the wedge 2 The wire
253. nce and repair must be performed by personnel who by reason of training and experience are thoroughly familiar with the crane s operation and required maintenance These personnel must read Operator s Manual and Service Manual before attempting any maintenance procedure there is any question regarding maintenance procedures or specifications contact your Manitowoc Crane Care distributor for assistance Training qualification of maintenance personnel is responsibility of crane owner Safe Maintenance Practices 1 Perform following steps as applicable before starting a maintenance procedure a Park crane where it will not interfere with other equipment or operations b Lower all loads to ground or otherwise secure them against movement c Lower boom onto blocking at ground level if possible or otherwise secure boom against dropping 2 16 10 Published 06 20 08 Control 033 07 d Move all controls to off and secure all functions against movement by applying or engaging all brakes pawls or other locking devices e Stop engine and render starting means inoperative f Place a warning sign at start controls alerting other personnel that crane is being serviced and engine must not be started Do not remove sign until it is safe to return crane to service Do not attempt to maintain or repair any part of crane while engine is running unless absolutely necessary If engine must be run keep your clothing and
254. nds or wind gusts up to the maximum speed given in Table 3 3 provided ratings are reduced the specified amount Operation Not Permitted Operation is not permitted in the areas indicated in Table 3 3 Observe the following options Boom with 90 230 ft 27 4 70 1 m Luffing Jib without MAX ER Upto 50 mph 22 m s Park crane upper in line with crawlers with load block on ground or secured and position boom at 85 and luffing jib at 55 50 mph 22 m s and Above Lower attachment onto blocking at ground level Table 3 3 Rating Reductions for Various Wind Speeds and Wind Gusts Luffing Jib Length ft 90 150 18000 LUFFING JIB OPERATOR S MANUAL Boom with 250 310 ft 76 2 94 5 m Luffing Jib without MAX ER Upto 40 mph 18 m s Park crane upper in line with crawlers with load block on ground or secured and position boom at 85 and luffing jib at 60 40 mph 18 m s and Above Lower attachment onto blocking at ground level Mast Above 50 mph 22 m s Haul in boom hoist wire rope just enough to tension mast straps Do not raise boom off blocking Wind can cause mast stops to collapse if this step is not performed Above 75 mph 34 m s Lower mast onto blocking at ground level 170 230 250 310 m 27 4 45 7 51 8 70 1 76 2 94 5 160 200 160 200 160 180 eee ft 48 8 61 0 48 8 61 0 48 9 54 9 Maximum Wind Speed Percent
255. ned between operator and signal person during all crane movements If communication is disrupted operator shall stop all crane movements 2 Signals to operator shall be in accordance with standard signals shown in Section 3 unless communications equipment telephone radio etc is used 3 signals shall be easily understood by operator at all times Operator shall not respond to any signal which is not clearly understood 4 For operations not covered in standard signals or for special situations or emergencies additional signals may be required In those cases signals used shall be agreed upon in advance by operator and signal person Signals used shall not conflict with or have potential to be confused with standard signals Canrrowoc 18000 LUFFING JIB OPERATOR S MANUAL 5 When it is necessary to give instructions to operator other than those established by signal system all crane motions shall be stopped 6 Signal person shall a Betested by a designated person and show that he or she has a basic understanding of crane operations and limitations and is thoroughly familiar with the standard hand signals and voice signals if used b Be positioned in clear view of operator Signal person s position should give him or her a clear view of load crane and operating area Direct load so it does not pass over personnel Keep unnecessary personnel out of crane s operating area 7 When moving crane foll
256. ners topic in this manual 4 Signal crane operator to retract cylinders with mode switch 5 Release tension on safety latch cable allowing enough slack for engagement when cylinders are extended Slack must be at safety latch Raise boom to where boom to jib angle is 140 Signal operator to extend cylinders with mode switch Cylinders will extend and remain pressurized 8 Verify safety latches are latched to prevent cylinders from retracting 9 Continue raising boom and jib to working position Procedure For Lowering Boom And Jib 1 Lower boom and jib With jib in dolly boom down until boom to jib angle is 140 2 Release jib safety latch with hand winch in jib top 3 Signal crane operator to retract cylinders with mode switch 4 Release tension on safety latch cable allowing enough slack for engagement when cylinders are extended 5 Continue lowering boom slowly verifying that stops do not engage pins in boom top Continue to lower boom and jib to ground Signal crane operator to extend cylinders with mode switch If cylinders do not extend automatically manually pump cylinders to extended position Periodic Check Of Oil Level See Section 5 of this manual for oil change interval and instructions er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 7 stored P2112 10 working FIGURE 4
257. ng Jib with MAX ER Attachment Up to 30 mph 13 m s Park crane upper in line with crawlers with load block on ground or secured and position boom at 75 and luffing jib at 55 30 mph 13 m s and Above Lower boom and luffing jib onto blocking at ground level Mast Above 50 mph 22 m s Haul in boom hoist wire rope just enough to tension mast straps Do not raise boom off blocking Wind can cause mast stops to collapse if this step is not performed Above 75 mph 34 m s Lower mast onto blocking at ground level 90 150 170 230 250 310 t 27 4 45 7 51 8 70 1 76 2 94 5 Boom 160 220 240 280 300 340 160 220 240 280 300 340 160 220 240 280 300 340 ij 48 8 67 1 73 2 85 3 91 4 103 6 48 8 67 1 73 2 85 3 91 4 103 6 48 8 67 1 73 2 85 3 91 4 103 6 Maximum Wind Speed Percent Rating Reduction mph m s Above 35 mph 16 m s OPERATION NOT PERMITTED Wind speed to be measured at or above boom point elevation See Luffing Jib Capacity Chart for specific backward stability conditions Published 06 20 08 Control 033 07 SECTION 4 SET UP AND INSTALLATION TABLE OF CONTENTS General Setup and Installation 4 1 Grane Orientation sk ket n dem enm hua 4 1 Accessing Parts d hasse
258. ng Pin with Collar and FIGURE 4 9 Retaining Pin Crane Care 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION Raise Main Strut 10 Lower erection pendant from assist crane to vertical and See Figure 4 9 for following procedure disconnect sse Grano 11 Slowly haul in load line from Drum 1 to raise jib strut Continue to pay out luffing jib hoist wire rope A WARNING Operator must carefully match rate of speed that luffing hoist wire is payed out with speed that load line is Moving Part Hazard hauled in Do not stand on boom top or jib butt while main strut is being raised or lowered Wait until main strut is stopped and supported by assist crane or luffing hoist line before climbing onto boom top or Luffing hoist wire rope must remain slack until strut is raised to vertical jib butt CAUTION Strut Damage 1 Remove backstay strap storage pins from shipping Too much tension in luffing hoist wire rope can cause holes View B and install in storage holes structural damage to strut Keep luffing hoist wire rope Allow straps to rest in storage brackets slack until strut nears vertical 2 Attach taglines to backstay basic straps Taglines should 12 As strut nears vertical haul in luffing hoist wire rope just be at least 20 ft 6 m long 9 enough so main strut moves smoothly past vertical 3 Disconnect shackles on ends of strut erection pendants Jib strut should not ris
259. ng jib to collapse 4 Position boom at 70 or higher boom angle 5 Slowly luff down to position jib at required boom to luffing jib angle see Raising Procedure Chart for angle 4 32 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Monitor angle on digital display It will be necessary to use limit bypass switch to luff down if BLOCK UP limit is on CAUTION Structural Damage Avoid side loading as boom and jib are lowered Disengage swing lock and release swing brake when jib point rollers contact ground 6 Slowly boom down until jib point rollers contact ground Depending on boom and jib combination jib may be hanging vertical when rollers contact ground If this happens raise jib luff up until jib is a few degrees forward of vertical It will be necessary to use limit bypass switch to boom down if BLOCK UP limit is on 7 Release swing brake disengage swing lock and continue to lower boom slowly Jib point rollers will roll along ground as boom and jib unfold Pay out load lines as boom and jib lower Jib straps and backstay straps will as boom jib lower OPERATOR AND SIGNAL PERSON watch backstay straps and jib straps along left side of boom jib as boom and jib lower Do not allow straps to become to slack e Allow backstay straps to float up and down 3 6 in 76 162 mm above strap brackets at top end of boom butt e Allow jib
260. nly never against lacings Nylon slings should be used to handle components If wire rope or chain slings are used protective covering such as sections of rubber tire must be used between the slings and the component er 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION RETAINING CONNECTING PINS That all trailer loads comply with local state and federal i transportation requirements Connecting pins are retained in various ways That all crane components are properly blocked and Snap pins secured so they cannot shift or fall off trailers Quick release pins To avoid damage to components Cotter pins Use nylon tie downs to secure components as shown in Keeper plates with cap screws and lock washers Figure 4 2 View A Do not operate crane until all connecting pins are installed If chain tie downs are used install protective covering and properly retained sections of rubber tire between chain and component being secured as shown in Figure 4 2 View B SHIPPING CRANE COMPONENTS When securing boom sections wrap tie downs over chords never over lacings Keep tie downs as close to blocking as possible View A to prevent bending of chords It is the owner user s responsibility to ensure the following Chain Tie Down Wrapped Over Boom Chord Nylon Tie Down Protective Wrapped Over Covering Boom Chord section of rubber tire FIGURE 4 2 REMOVABLE LACINGS 44
261. not allow jib straps to become too tight during raising steps Crane will tip or structural damage will result Do not allow jib straps to become too slack during raising steps Straps will bounce against jib inserts possibly resulting in damage Signal operator to pay out luffing hoist wire rope luff down so jib straps remain slack Do not allow straps to become too slack or they will bounce against jib inserts Keep jib straps 2 1 2 3 1 2 ft 0 76 1 07 m above strap supports at end of jib top It will be necessary to use limit bypass switch to luff down if BLOCK UP limit is on 6 Continue slowly with Jack Knife Raising Procedure 7 Stop raising boom when boom to jib angle is 140 Monitor this angle on digital display 8 Signal crane operator to extend positioner cylinders with mode switch Cylinders will extend and remain pressurized 9 Verify that safety latches are in position and will prevent cylinders from retracting 10 Continue slowly with Jack Knife Raising Procedure 11 Stop raising boom when boom and jib have been positioned at required boom to luffing jib angle Monitor this angle on digital display WARNING Falling Jib Hazard Do not position boom and jib at any boom to luffing jib angle less than minimum stop 70 Structural damage to jib butt will occur possibly causing jib to collapse When boom and jib are at proper angle jib stop saddles will be in position to automatically enga
262. nted which has ring braced and fastened directly to foundation in such a manner as to prevent movement 2 22 Published 06 20 08 Control 033 07 c Crane Care 18000 LUFFING JIB OPERATOR S MANUAL SAFETY INFORMATION Ringers must be equipped with hook rollers on boom and counterweight carriers Bracing Asc J d hs Ring Support Ring Assembly Foundation FIGURE 2 10 AXIS TRANSITIONAL ROTATIONAL SYMBOL NAME STATIC DYNAMIC STATIC DYNAMIC Longitudinal Surge Heel List Roll Vertical Heave Yaw Lateral Sway FIGURE 2 11 Capacity Charts referred to as DYNAMICS Figure 2 11 illustrates the dynamic conditions of the barge which influence crane Manitowoc provides two types of capacity charts fora crane capacity mounted on a barge or other supporting structure under static conditions 1 A capacity chart based on tipping when crane is CAUTION anchored only to prevent shifting Structural Damage Hazard If crane boom or structure is shock loaded during 2 capacity chart based on structural competence when 2 operation or there is indication of shock loading all crane is securely fastened for use as a pedestal I ounted Crane structural components of crane shall be inspected to detect cracks and other damage Nondestructive test NOTE Unless otherwise specified on a machine list
263. o BYPASS disable reached operating limits This position allows functions to be operated beyond the limits RELEASE to ENABLE operating limits This position allows limits to stop functions in the normal manner Remove key to prevent unauthorized operation Published 06 20 08 Control 033 07 3 5 OPERATION 18000 LUFFING JIB OPERATOR S MANUAL Table 3 1 Bypassable Limit Identification Non European European Limit Standard By pass Standard By pass Momentary Key Switch Momentary Key Switch past production with quadrant style jib stop Boom Up Limit Yes Boom Down Limit Yes Yes Block Up Limit each drum Yes Yes Bail Limits Max and Min each drum Yes Yes Rated Capacity Indicator Limiter Yes Yes Luffing Jib Maximum Up 1 Yes Yes Luffing Jib Maximum UP 21 Yes Yes Luffing Jib Down Yes Yes 1 Only when boom is below 502 current production without quadrant style jib stop Boom Up Limit YES Boom Down Limit Yes Yes Block Up Limit each drum Yes Yes Bail Limits Max and Min each drum Yes Yes Rated Capacity Indicator Limiter Yes Yes Luffing Jib Maximum Up 1 Yes Yes Luffing Jib Maximum UP 21 Yes Yes Luffing Jib Down 1 Yes Yes Luffing Jib Down 2 2 N A N A 7 1 Only when boom is below 50 2 Cannot be by passed Digital Display Displays boom angle luffing jib angle and boom to luffing jib angle See Figure 3 5 for identification of each angle 3 6 B
264. o loosen pins d Lift main strut slightly so that it just lifts off jib strut at hook and latch View D e Swing boom and hoist assist crane as required to disengage latch on main strut from hook on jib strut Use care not to hit strut stop cylinders with main strut f Place main strut on blocking and disconnect slings SETUP AND INSTALLATION From Assist Crane 8 Y a Jib Strut Adapter Frame 18000 LUFFING JIB OPERATOR S MANUAL Slings 20 Lifting Lug Keeper Hinge View EN 4 each Jib Plate Pin 5 Strut f M 5 dee zs o e 7 E V T a DTE Adapter Jib Jib Strut Frame Butt Support Hinge Adapter Pron Pin Frame P1385 Crane M X Main fs Strut Slings View End Lug Plate 4 each Jib Adapter Frame 4 12 Published 06 20 08 Control 4 033 07 FIGURE 4 8 Q anitowoc Crane Care 18000 LUFFING JIB OPERATOR S MANUAL See Figure 4 8 for following procedure Install jib strut as follows a Connect chain slings from assist crane to four lifting lugs on main strut View B Adjust length of rear chain slings so rear end of strut hangs at least 8 ft 2 4 m lower than top end of strut b Liftjib strut into position at end of adapter frame and align connecting hol
265. of Jib Stop Positioner Hydraulic Oil 5 6 Personnel Handling 2 20 Physical Boom Stop sis peces tempe uo have RA usaq 6 12 Published 06 20 08 Control 033 07 Index i Index ii 18000 LUFFING JIB OPERATOR S MANUAL Refueling eem 2 15 Removable Lacings 44 Jib 4 3 Retaining Connecting 4 3 Rigging 08 4 2 Rigging Winch Operation 4 80 Safe Maintenance 2 16 Safe Operating 2 2 8 Safety and Information 0 2 25 Safely Messages ioi eue uk ERE RR E RR DR RR RR 2 1 Shipping Crane 4 3 Standard Hand Signals for Controlling Crane Operations 3 1 Wind Z m ss hu ae BR ea e Qha 3 8 Wire Rope Installation 4 74 Wire Rope Lubrication 20 5 1 Published 06 20 08 Control 033 07 Canrro
266. of the hoist block to a maximum of 90 degrees When the operating conditions for a particular installation give a resultant above the appropriate band then cabling of the falls will most likely occur If the operating conditions give a resultant below any particular band the cabling of the falls will most likely not occur If the operating conditions for any particular installation fall within the band cabling is unpredictable ENDURANCE DYFORM 3418 ENDURANCE 35LS BRIDON AMERICAN RETIREMENT CRITERIA Recommended retirement criteria for all Rotation Resistant Ropes are 2 broken wires in 6 rope diameters or 4 broken wires in 30 rope diameters i e 6 rope diameters for a 1 diameter rope 6 Distortion of Rotation Resistant Ropes as shown above can be caused by shock load sudden load release and or induced torque and is the reason for immediate removal from service RECOMMENDED MINIMUM SHEAVE AND DRUM DIAMETERS The minimum D d ratio allowed by applicable codes and standards covering equipment where Rotation Resistant Ropes are typically used is 18 1 RECOMMENDED MINIMUM DESIGN FACTOR The minimum design factor allowed by applicable codes and standards covering equipment where Rotation Resistant Ropes are typically used is 5 BRIDON AMERICAN 280 New Commerce Boulevard Wilkes Barre PA 18706 Telephone 570 822 3349 1 800 521 5555 FAX 1 800 233 8362 Website http www bridonamerican com E mail bridonGbrido
267. ol 033 07 18000 LUFFING JIB OPERATOR S MANUAL Connect chain slings from assist crane to four lifting lugs on main strut Lift strut so it is level Lift main strut into position over jib strut Swing boom and hoist assist crane as required to engage latch on main strut with hook on jib strut View D Use care not to hit strut stop cylinders with main Strut Remove retaining pins from jib strut holes View E Align holes in end of main strut with holes in end of jib strut and install retaining pins View E Lift strut assembly onto transport trailer and disconnect slings Removing Jib Attachment A WARNING Collapsing Boom Jib Hazard Improper disassembly of boom and jib sections can cause boom or jib to collapse onto personnel removing connecting pins Death or serious injury can result if precautions listed below are not taken Lower boom jib so boom and jib points are supported on blocking or ground Slacken rigging do not attempt to remove connecting pins while boom or jib is supported by rigging Block below both ends of each boom or jib section before removing connecting pins Stand on outside of boom or jib sections when removing connecting pins Never work under or inside boom or jib sections Use care not to damage lacings and chords as pins are knocked out Remove jib in opposite sequence of installing jib Automatic boom stop must be reset to 85 for MAX ER operation without jib
268. om has been positioned at minimum angle of 85 and jib has been positioned at specified boom to luffing jib angle Crane will tip or structural damage will occur possibly causing attachment to collapse 2 Raise boom to a minimum angle of 85 3 Position jib at required boom to luffing jib angle see Liftcrane Luffing Jib Capacities Chart Monitor angles given in following procedure on digital display A WARNING Tipping Crane Hazard Do not allow boom to luffing jib angle to become less than 70 Structural damage to jib can occur CAUTION Structural Damage Side loading can cause structural damage to boom and jib as boom and jib are lowered Disengage swing lock and release swing brake when jib point rollers contact ground CAUTION Jib Point Damage Do not allow upper jib point to contact ground while lowering luffing jib Damage will occur 4 Slowly lower boom until upper jib point is approximately 6 ft 1 8 m off ground It will be necessary to use limit bypass switch to lower boom if BLOCK UP limit is on 5 Remove load blocks or weight balls a Remove block up limit weights and chains and connect block up limit electric cords to terminating plugs on junction boxes b Securely fasten load lines to jib point so load lines cannot fall off boom and jib er SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL A WARNING Falling Wire Rope Hazard For long boom and short jib combination
269. onto blocking approximately 8 in 203 mm high 2 Assemble remaining jib inserts and jib top in proper sequence as shown on Luffing Jib Rigging Drawing 3 Unpin jib straps from stored position on inserts and connect links between straps 4 Raise jib top wire rope guide See Figure 4 26 View H for following procedure boom jib sections If in doubt see Boom Rigging a Remove links 22 and pins 23 from storage Guide In Crane Operators Manual b Support wire rope guide 24 with slings from assist See Luffing Jib Assembly drawing at end of this crane section for proper positioning of jib sections Remove pins 23 from lugs 25 puan First Two Ingeris d Raise wire rope guide 24 to operating position a D 2 two inserts 19 21 Pin links 22 to wire rope guide 24 and to lugs 25 9 with pins 23 Wire rope will rub on jib point if b Using nylon slings and a four point hookup from links are not installed assist crane hook onto butt and first two inserts f Store extra two pins 23 in link storage lugs Component Identification for Figure 4 26 Item Description Description 1 Links 4 14 Jib Strut 1 2 Pin w Collar and Retaining Pin 2 15 Keeper Plate 2 3 Link Storage Pin 2 16 Pin 2 4 Link 2 16a End Plate with Cap Screws 4 5 w Collar and Retaining Pin 4 17 Jib Stop 6 Strap 4 18 Jib Stop Support 7 Spreader 2 19 20 ft 6 1 Jib Insert with Br
270. ontrols which are likely to remain functional 4 Stay in the crane until the power company has been contacted and the power source has been de energized NO ONE must attempt to come close to the crane or load until the power has been turned off Only as a last resort should an operator attempt to leave the crane upon contacting a power source If it is absolutely necessary to leave the cab JUMP COMPLETELY CLEAR OF CRANE DO NOT STEP OFF Hop away with both feet together DO NOT walk or run Following any contact with an energized electrical source your Manitowoc Crane Care distributor must be immediately advised of the incident and consulted on necessary inspections and repairs Thoroughly inspect the wire rope and all points of contact on the crane Should the distributor not be immediately available contact Crane Care Customer Service at the factory The crane must not be returned to service until it is thoroughly inspected for any evidence of damage and all damaged parts are repaired or replaced as authorized by your Manitowoc Crane Care distributor or the factory REFUELING 1 When using a portable container to refuel crane container shall be a safety type can equipped with an automatic closing cap and a flame arrester Engine shall be stopped before refueling crane 3 Smoking and open flames shall be prohibited in refueling area FIRE EXTINGUISHERS 1 A portable fire extinguisher with a minimum rating of 10 BC shall
271. oom Angle angle between center line of boom and horizontal Monitor this angle when raising boom to operating angle Adjust automatic boom stop to proper angle when operating with luffing jib See Automatic Boom Stop in Section 6 of this manual for adjustment procedure 85 for 44 or 79A Luffing Jib on 140 180 ft 42 7 54 9 m of 55 79A or 55 Boom Published 06 20 08 Control 033 07 The 87 for 44 or 79A Luffing Jib on 200 340 ft 61 0 103 6 m of 55 79A or 55 Boom Luffing Jib Angle angle between center line of jib and horizontal Monitor this angle when raising and lowering jib during operation Boom to Luffing Jib Angle angle between center line of boom and center line of jib Monitor this angle when raising boom and jib from ground and lowering boom and jib to ground digital display also displays system faults and operating limits for the luffing hoist and all other crane functions See Digital Display Readings in the Crane Operator s Manual for a complete list of operating conditions system faults and operating limits er 18000 LUFFING JIB OPERATOR S MANUAL OPERATION 9 Mechanical Level Indicates crane levelness from front to rear and from side to side Crane levelness can also be viewed in display screen Automatic Jib Stop not shown When an automatic jib stop is reached the luffing hoist stops automatically brake spring applies and is inoperable The operating limit alert
272. orking position 7 Slowly haul in load line from assist crane to raise main and pin to ends of basic backstay straps strut At same time pay out luffing hoist wire rope pay 9 P 4 Repeat above steps for backstay links between each 8 Raise strut to at least 45 with assist crane and stop boom section view D 5 See View E for connection of backstay link at boom butt 9 Slowly haul in load line from Drum 1 until load line is supporting strut manito ye Published 06 20 08 Control 033 07 4 15 C SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL Supply Line to Return Line from Manifold Jib Strut on Boom Butt 4 16 View A Front of Rotating Bed Accumulator Counterbalance Valve 2 400 psi 165 bar P1633a Pressure Control Pilot Valve 2 600 psi 179 bar Gauge Coupler Strut Stop Hydraulic Cylinder N Cylinder Coupler Relief Valves 2 100 psi 145 bar Jib Overflow Vent Strut Tank Line Return Line from Manifold on Boom Butt View D Overflow Tank Return Line to Manifold Couplers on Boom Butt Supply Lineto Jib Strut Three Hoses CI s m from Jib Strut Boom Insert Couplers 18 1623 Boom Top to Jib Strut Stop Couplers FIGURE 4 10 Published 06 20 08 Control 033 07 C 18000 LUFFING JIB OPERATOR S MANUAL Connect Hydraulic Hoses
273. owing audible signals shall be used STOP one short audible signal b GO AHEAD two short audible signals c BACK UP three short audible signals Operational Aids Verified weights measured radii and Manitowoc s Capacity Charts and instructions shall take precedence over operational aids when handling a load If it is necessary to temporarily override an operational aid crane user shall stay within limits of Manitowoc s Capacity Charts and instructions A designated qualified person responsible for directing the lift shall make sure load does not exceed capacity chart When operational aids are inoperative or malfunctioning the following steps shall be taken to ensure safe continued operation of the crane 1 Steps shall be taken to schedule repairs and calibration immediately Operational aids shall be put back into service as soon as replacement parts if required are available and repairs and calibration can be carried out Every reasonable effort must be made to expedite repairs and calibration 2 When rated capacity indicator limiter is inoperative or malfunctioning designated qualified person directing lift shall establish procedures for determining load weights and shall make sure that weight of load does not exceed crane rating at radius where load is handled 3 When boom angle or radius indicator is inoperative or malfunctioning radius or boom angle shall be determined by measurement i e measure radiu
274. ped see Note 8 44 562045 4 PIN Cotter 1 8 x 1 1 2 long 45 562105 PIN Cotter 1 8 x 1 1 2 long 46 A05198 STRAP 10 2 x 3 3 4 55 Boom 47 A06149 PIN 1 Hole w Hd 48 A06150 PIN 2 Hole 49 A06151 COLLAR 50 A06457 LINK 55 Boom 51 A07565 2 PIN 2 Hole 5 8 dia x 9 7 8 long INSERT 40 12 19 M 55 BOOM R119 A05387 1 INSERT ASSEMBLY 40 55 Boom see Note 9 R120 05451 1 INSERT 40 machining see 573 R121 194123 TIMBER R132 A07561 PIN 1 Hole w Hd R123 A06099 PIN 1 Hole w Hd R124 A06649 PIN Upper Male Connector Locking R125 548342 NUT Lock NE 3 8 16 R126 563640 PIN Safety 1 4 O D x 5 long R127 612480 SCREW Hex Cap 3 8 16 x 4 1 2 long grade 5 R128 709703 16 WASHER Flat 1 32 Luffing Jib Equipped see Note 8 52 171497 PLATE End 53 172169 SHEAVE 24 dia 54 563803 PIN Snap 3 8 x 2 1 4 long 55 612657 SCREW Hex Cap 5 8 11 x 1 long grade 5 56 710307 WASHER Lock 5 8 57 A06399 WIRE ROPE GUARD ASSEMBLY Luffing Line 58 06586 GUARD Wire Rope 59 A06659 SHAFT 4 1 2 O D x 9 15 32 long 60 562045 PIN Cotter 1 8 x 1 1 2 long 61 532105 PIN Cotter 1 4 x 1 1 2 long ASSEMBLY REVISION A07766 PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER 18 of 22 N N N N N N N N MODEL 18000 LUFFING JIB RIGGING 44 Luffing Jib on 55 79A Boom with 100 Mast DESCRIPTION OF PART STRAP 40 2 x 3 3 4 55 Boom
275. plied with and considered part of your crane must be read and completely understood by each person responsible for operation and maintenance of the crane The Operator s Manual must be read to personnel who can not read or understand English or other language the manual is translated into Because of a program of continuing improvement in product design Manitowoc reserves the right to change the information and specifications contained in the Operator s Manual at any time without notice If you have any questions regarding the crane or its Operator s Manual please contact your Manitowoc Crane Care distributor Operator Qualifications The crane shall be operated only by the following qualified personnel 1 Designated operators 2 Trainees under direct supervision of a designated operator 3 Supervisors inspectors and maintenance or test personnel when necessary in performance of their duties Operation of the crane by these personnel shall be limited to the crane functions needed to perform the inspection or to verify the crane s performance after maintenance procedures No personnel shall be allowed to climb onto the crane or enter the crane cab unless performance of 2 8 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL their duties require them to do so and then only with knowledge of the operator or other qualified person Qualified person is defined as one who by reason of training and e
276. pper point engages saddles in dolly 6 Disconnect assist crane 4 54 Published 06 20 08 Control 033 07 Canrrowoc 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION View D 6 11 3 12 P2156 P2143 PANNIS 7 unlatched VIEW A 1 ft 305 mm 8 3 4 9 in 7 minimum 222 229 mm unlatcheg 5 4 8 4 9 View F 9 View E P2150 extended retracted Item Description Description 1 Jib Insert typical Safety Latch 2 Jib Top Spring 3 Hand Winch Hydraulic Cylinder 4 Cable Jib Stop 5 Cable Sheave Pump Handle 6 Junction Box Pressure Gauge FIGURE 4 28 Published 06 20 08 Control 4 033 07 4 55 SETUP AND INSTALLATION Install Jib Load Line Route load lines through proper guide sheaves on boom butt on boom top and in jib strut The position of the guide sheaves in the strut must match the guide sheaves on the boom top Pull load lines approximately 40 ft 12 19 m past end of jib and lay them on ground Securely fasten load lines to jib point Install load block after boom and jib have been jack knifed into position and dolly has been removed NOTE Load block s will be installed after boom and jib are jack knifed to required angle A WARNING Falling Wire Rope Hazard For long boom and short jib combinations wire rope on boom side of attachment can overhaul unsecured wire rope on jib side of attachment Wire rope could fall off
277. ps are rated for at least 4 45 KN line pull Sucker Bex 2 Pull Sucker Line with Line amp A Winch or Fork Lift Truck AN Wire Rope Pad from Drum Eye Boom Point Sheaves 2 Load Block Sheaves Ommoou r FIGURE 4 45 mm Published 06 20 08 Control 033 07 4 79 SETUP AND INSTALLATION RIGGING WINCH OPERATION If your crane is equipped with the optional rigging winch in the boom butt see Rigging Winch Operation topic in the Operator s Manual for the crane Also see drawing at the end of this section LOAD LINE REEVING 44 LUFFING JIB Load Blocks See the Luffing Jib Assembly Drawings at the end of this section for a complete list of load blocks and weight balls available for this crane WARNING Falling Load Hazard Use only a hook and weight ball or load block with a capacity equal to or greater than load to be handled Avoid overloading bearings in load block sheaves Attach load to duplex hook so load hangs straight Load block can fail if overloaded allowing load to fall Guide Sheaves See Figure 4 47 and 4 48 for guide sheave identification and location of components in the lower and upper boom points Once the wire rope is routed through the guide sheaves be sure to install rope guard pins bars and rollers to retain rope on guide sheaves Wire rope and sheaves can be damaged if rope is not properly retained on sheaves Duplex Hook At
278. r comes first 5 5 Each Time Boom and Luffing Jib are Lowered to Ground 5 5 Once Yearly n E Su wau DULCE dece 5 5 Periodic Check of Jib Stop Positioner Hydraulic Oil 5 6 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL LUBRICATION SECTION 5 LUBRICATION GENERAL LUBRICATION Depending on the options the crane or attachment is equipped with some lubrication points given in this section may not apply LUBRICATION INTERVALS The intervals listed in this Lubrication Guide are for average operating conditions based on experience gained by testing lubricants at the factory and on recommendations given by the lubricant suppliers Severe operating conditions excessively dusty or corrosive atmosphere unusually high or low outside temperature extreme loadings uncommonly frequent or long operating cycles may require shortening the lubrication intervals Follow the intervals given in this section until adequate experience is obtained to establish intervals which meet your operating conditions Bearings and bushings that are too warm excessive play in moving parts binding in moving parts excessive or abnormal wear in gears and chains and rust accumulation indicate a lack of lubrication If these conditions are found during regular inspection the lubrication interval for the faulty parts should be shortened
279. r lines Rider poles should be erected on each side of a crossing to assure sufficient clearance is maintained Appoint a reliable and qualified signal person equipped with a loud signal whistle or horn and voice communication equipment to warn the operator when any part of the crane or load moves near a power source This person should have no other duties while the crane is working Tag lines should always be made of non conductive materials Any tag line that is wet or dirty can conduct electricity DO NOT store materials under power lines or close to electrical power sources Prior to operating near transmitter towers where an electrical charge can be induced into the crane or load e The transmitter shall be deenergized OR e Tests shall be made to determine if an electrical charge will be induced into the crane or load Every precaution shall be taken to dissipate induced voltages Consult local state and federal codes and regulations Electrocution Hazard Devices The use of insulated links insulated boom cages guards proximity warning devices or mechanical limit stops does not assure that electrical contact will not occur Even if codes or regulations require the use of such devices failure to follow the rules in this section may result in serious injury or death Be aware that such devices have limitations and you should follow the rules and precautions outlined in this section at all times even if the crane is
280. ral ALL boom and jib combinations must be raised and lowered using Jack Knife Method See the Liftcrane Luffing Jib Capacities Chart to determine the following e Counterweight Requirements crane and MAX ER Boom to Luffing Jib Angle e Maximum Boom and Jib Lengths Raised or Lowered Over end of blocked crawlers Over endor side of unblocked crawlers Published 06 20 08 Control 033 07 4 57 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL THIS PAGE BLANK 4 58 Published 06 20 08 Control 033 07 Gan c Crane Care 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION CIRCLED NUMBERS CORRESPOND TO JACK KNIFE RAISING PROCEDURE STEPS View A View B 4 183 4 184 Figure 4 29 Published 06 20 08 Control 4 033 07 4 59 SETUP AND INSTALLATION Jack Knife Raising Procedure Circled numbers in Figure 4 29 correspond to numbered steps in the following procedure WARNING Moving Part Hazard Warn all personnel to stand clear of jib point dolly while raising boom and jib Death or severe crushing injuries will occur if personnel come into contact with dolly WARNING Tipping Hazard Determine BOOM TO LUFFING JIB ANGLE that boom and jib must be jack knifed to before jib can be raised see Raising Procedure Chart Crane will tip or structural damage will result if specified angle is not adhered to Monitor angle on digital display as boom and jib are ra
281. rap 3 Insert pin through access hole in outer strap at required pinning location 4 Depress plunger and slide load pin into narrow end of key hole Release plunger 5 Check that load is tightly locked against narrow end of key hole View B NOTE fload pin is not tightly locked in operating position remove load pin rotate it 180 and reinstall Make sure locking pin is installed as shown in View E Check that cable from hand winch is attached to adjustable strap View D 8 Check that cable between hand winch and adjustable strap is snug 9 Check that ratchets on hand winches are set to prevent winches from paying out line 10 Remove retaining pin connecting adjustable strap to jib strut Install retaining pin in storage hole View D Published 06 20 08 Control 033 07 4 19 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL 3 Strut Stop View B P1630 Main Strut Cylinder Rod End Cylinder Backstay 1 Mounting Straps Strut Stop Frame Lugs both Sides of Erection Strut Stop Pendants 7 NO Oylinder INTERFERENCE 1631 View Store Erection Jib Pendants Here Strut Stored 3 Hand Item Description 1 Washer 2 Shim 3 Shim 4 Support 5 Stop Block we 4 147 3 View E Strut Stop
282. re Release Hazard FIGURE 2 1 continued 2 4 Published 06 20 08 Control 033 07 Crane Care 18000 LUFFING JIB OPERATOR S MANUAL LUFFING JIB ATTACHMENT ACCESS POINTS A DANGER Crushing Injury Hazard Upperworks can swing into and crush personnel climbing on or off crane Moving crawlers can crush personnel climbing on or off crane To prevent death or serious injury Barricade all accessible areas to crane so personnel cannot be struck or crushed when upperworks is swung Do not climb or off crane while upperworks 15 being swung or crane is being traveled e Signaloperator that you need to climb on or off crane Operator do not swing or travel while personnel are climbing on or off crane Stop swing and travel motions Apply swing brake and turn on travel park Operator Always sound horn to alert personnel before you swing or travel General Take necessary precautions to prevent slipping and or falling off the crane during assembly disassembly maintenance or other work Falling from any height could result in serious injury or death Manitowoc has provided steps ladders catwalks and platforms at the locations shown in Figure 2 2 The owner user must provide workers with approved ladders or aerial work platform to access those areas of the crane that cannot be reached from the ground or from steps ladders catwalks and platforms provided by Manitowoc Adhere to local st
283. re at rear of lowerworks e Crawler pin handles on carbody are at front of lowerworks Application LIFT Liftcrane Model Number d e Read S Manual ines er oad and ground electrified d CLAM Clamshell DRAG Dragline energizes Greater cl arances ar Allow for way boom loa Operating Practices Sel ore operating near p Serial Number er lines up to 27 e required for higher voltages d lines and power lines in your Operator s ower lines en working near from crane wh epi dd re contacted a y if power lines pase a Made in U S J By MANITOWOC CRIANES INC me 999 SERIES 1 28 3 me REFER TC 5 F 15 IF IN DOUBT TACT SE PECIFICATIONS IN APACITY CHARTS THAT APPLY THIS CRANE RVICE DEPARTMENT AT MANITOWOC FOR ASSISTANCE 9991126 LIFT Berisi PERATOR S OR SERVICE MANUAL ate FOR se sainan NOTICE READ OPERATOR S OR SERVICE MANUAL stat tbe The Operator s or Service Manual supplied wih and con sidered part of thes mut be and completely by each penton Vor operation and maintenance of fs cane SAFE OPERATION or select on fe part of operators and job site personae can result i Saat and amp Mr many t promote vate und edicion paka thes crane P
284. re rope guide with assist crane as shown c Using pin 9 pin wire rope guide to Lug A Raise boom top wire guide a Support wire rope guide 12 View D with sling from assist crane b Remove connecting pins 13 View D Rotate wire rope guide to working position View E Pin wire rope guide to Lugs B View E with pins 13 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL e Do not install links and pins 14 View D for luffing jib configuration 9 Make sure removable strap brackets for luffing jib 18 Figure 4 21 View J are installed on main strut butt 10 If necessary add lugs 16 for counterweight tie links to top crane counterweight boxes 15 one on each side as shown in Figure 4 18 View H Install Backstay Straps on Boom See Figure 4 18 for following procedure Starting at butt end of boom install backstay straps in proper sequence on boom sections according to Luffing Jib Rigging Drawing This step is required only if straps are not stored on boom sections To prevent interference between pins heads of boom strap pins must face outboard sides of boom heads of backstay strap pins must face inboard as shown in View C If the straps are already installed proceed as follows 1 Remove storage pins from top hole 1A View A in brackets 2 2 Store pins in bottom holes 1B View B in brackets 2 3 Rotate links 3 forward and pin to adjacent straps 4 View B
285. readjusted if required each time the attachment is reassembled and when parts are replaced Seals must be removed to allow readjustment See Figure 6 1 for following procedures Preliminary Adjustment 1 Lower attachment to ground 2 Remove screws connecting actuator 2 to jib butt NOTE Check jib butt side to side position on pivot pin when attaching actuator Ensure switches remain on cam surface when jib butt shifts side to side Install shims at actuator attachment point or jib butt if necessary Max Up 1 Limit Adjustment 1 Loosen screws in limit switch 3a 2 Rotate actuator 2 clockwise until Hole A in actuator lines up with hole in boom top 3 Insert alignment pin 6 through Hole A in actuator and into hole in boom top Make sure shoulder of pin rests squarely against actuator to ensure proper alignment for adjustment 4 Slide limit switch 3a against cam 3b until limit switch just clicks open and hold 5 Securely tighten screws in limit switch 6 Remove alignment pin 6 7 Check MAX UP 1 limit setting as follows a Rotate actuator 2 counterclockwise and then clockwise so MAX UP 1 limit switch roller contacts cam 3b b Limit switch must click open when Hole A in actuator lines up with hole in boom top step 3 c With LUFFING JIB mode selected pull luffing jib handle back Luffing hoist must not turn and LUFFING JIB MAX UP 1 operating limit should come on d Readjust limit switch if ne
286. rs 1 View C and shims 2 View D until there is NO INTERFERENCE cylinders centered in frames 8 Disconnect cables from outer straps View H and b Install shims 3 View D under supports 4 so that connect cables to storage lugs at base of jib strut View when rollers bottom out in strut stop pockets on F boom top Figure 4 13 View gap is 1 8 in 3 mm Use hand winch to tighten cable as needed between supports 4 and underside of cylinders mm Published 06 20 08 Control 033 07 SETUP AND INSTALLATION c Reposition stop blocks 5 View E so distance between stop blocks and supports 4 is 5 in 127 mm CAUTION Structural Damage Do not raise jib strut above 70 during erection while boom is on ground Structural damage to jib strut or strut stop cylinders will occur At 70 strut angle cylinder rods will have approximately 5 in 127 mm travel remaining Figure 4 13 View B Connect adjustable straps to jib straps on jib insert a Using hand winch lower adjustable straps to vertical View G Raise or lower strut as needed b Raise or lower strut as needed to align connecting holes in inner straps with connecting holes in jib straps on jib insert c Pin adjustable straps to jib straps View J each adjustable strap straps CAUTION Structural Damage Inner straps will not extend to proper length if locking pins are not removed Structural damage will occur With jib straps resting in
287. rut supports B shipping pins 11 View E 14 Rotate strut supports B 10 View F to working position 15 While lowering main strut butt 1 guide saddles in strut supports B 10 to rest on pins 9 View C attached to lugs on jib strut butt 16 Disconnect assist crane from lifting slings Install Jib Strut Top See Figure 4 20 for following procedure 4 42 Component Identification for Figure 4 20 Description Main Strut Butt Jib Strut Butt Boom Top Connecting Pin Keeper Plate End Plate Strut Butt Support A Published 06 20 08 Control 033 07 Description Shipping Pin with Wire Lock Shipping Pin with Cotter Pins Strut Support B Storage Pin with 2 Cotter Pins Connecting Pin with 2 Cotter Pins Jib Strut Top Main Strut Top 18000 LUFFING JIB OPERATOR S MANUAL NOTE Main strut top and jib strut top are shipped together 4 5 as shown in View H Main strut top is above jib strut top Using appropriate slings attached to main strut top 14 View H lift jib strut main strut tops into position at jib strut butt 2 Adjust slings so butt end of top is higher than top end Position jib strut top 13 so bottom connecting holes in strut top line up with connecting holes in jib strut butt 2 Install connecting pins 15 View K and safety pins pin heads facing outboard side Lower jib strut top onto blocking 3 ft 0 9 m high Disconnect assist crane from slings Remove slings
288. s 2 places Grease each 7 Luffing Jib Hinge Pins 2 places Grease each 8 Jib Strut Hinge Pin 2 places Grease each 9 Main Strut Hinge Pin 2 places Grease each NOTE See Lubrication Guide in 18000 Crane Operator s Manual for lubrication of crane and boom 79A LUFFING JIB LUBRICATION Item Description Every 40 Hours or Weekly w Sheaves marked with an asterisk have sealed bearings and do not require periodic lubrication Repack sheave bearings with grease at overhaul Required 7 Description Required Service see 0 see NOTE whichever comes first Weight Ball Swivel Grease Load Block Sheaves Grease if equipped with fittings Load Block Trunnion Swivel Grease if equipped with fittings Bottom Wire Rope Guide Sheave Block Up Limit Switch 1 fitting inside each switch Grease Every 200 Hours of Operation or Monthly whichever comes first Grease each Each Time Boom and Luffing Jib are Lowered to Ground Jib Stop Positioner Cylinder Trunnion Grease 1 fitting 2 places Jib Hinge Pins 2 places Grease each in legs of butt Wheel Hub Sight Glass Check level o Wheel Hub Fill Plug Once Yearly 10 Jib Stop Positioner Hydraulic System NOTE See Lubrication Guides in 18000 Crane and MAX ER Operator s Manuals for lubrication of crane MAX ER and boom Fill to FULL ring in sight glass with same
289. s Make sure rope guard pins bars or rollers are installed to retain wire rope in sheaves Main strut raised and strut stop tubes pinned in operating position er 18000 LUFFING JIB OPERATOR S MANUAL Main strut cylinders pressurized Jib stop positioner cylinders retracted Load lines anchored properly to drums spooled tightly onto drums and engaged with proper sheaves Make sure rope guard pins bars or rollers are installed to retain wire rope on sheaves Load line going to jib point is securely attached to end of jib so load line cannot fall off jib and boom blocking tools and other items removed from boom and jib and from dolly travel path All safety devices installed electric cords connected and limits adjusted Raising instructions in this section read and thoroughly understood Proper amount of crane counterweight and if required MAX ER counterweight installed Wind within allowable limits for raising boom and jib All lubrication points greased SETUP AND INSTALLATION 9 LUFFING JIB mode selected and confirmed A WARNING Falling Boom And Jib Hazard Select and confirm LUFFING JIB mode Operating in any other mode with luffing jib attached is prohibited Jib stop positioner cylinders are extended and will cause structural damage Luffing jib limits are disabled when LUFFING JIB mode is off Boom and jib could be pulled over backwards Raising Boom and 279A Luffing Jib Gene
290. s misalignment will induce twist into the rope during operation by the rope climbing the flange or rolling into the sheaves of the traveling block during hoisting BRIDON THREE PART LINE FLOATING SHEAVE SMOOTH AMERICAN E FIVE PART LINE FLEET ANGLES Because Rotation Resistant Ropes develop less torque under load than a standard 6 strand rope there can be a problem with rope pileup poor spooling unless a proper fleet angle is maintained The fleet angle becomes even more important with the Rotation Resistant ropes such as Endurance Dyform 34LR and Endurance 35LS A fleet angle of 1 2 to 1 1 2 is recommended for all Rotation Resistant Ropes Rotation Resistant Ropes CABLING GRAPH Field research jointly conducted by the Wire Rope Technical Board and the Power Crane and Shovel Association has shown that cabling of the rope parts in a multiple part reeved hoisting arrangement is controlled by several factors The following calculations and graphs can be used to determine when and if cabling will occur on multiple part reeved hoisting arrangements The graph illustrates two dimensional ratios They are 1 L S Length of fall per unit rope spacing 2 D d Average pitch diameter of traveling and crown block sheave per unit rope diameter Various constructions of rope shown on the graph indicate the limited conditions for torsional stability with the angular displacement
291. s wire rope on boom side of attachment can overhaul unsecured wire rope on jib side of attachment Wire rope could fall off boom Securely fasten load lines to jib point before removing load blocks or weight balls Check dolly oil level and tire pressure Figure 4 27 View P Using a fork lift truck lift jib point dolly into position under jib top Lower boom and jib so upper jib point engages saddles in dolly see Figure 4 27 View F Figure 4 31 mm Published 06 20 08 Control 4 033 07 4 63 SETUP AND INSTALLATION Jack Knife Lowering Procedure continued See Figure 4 31 for following procedure 8 Release swing brake disengage swing lock and slowly boom down Jib point dolly will roll along ground as boom and jib are lowered 9 Boom down until boom to luffing jib angle is 140 View A Pay out load lines as boom and jib are lowered 10 Release jib safety latch with hand winch 3 Figure 4 27 View D in jib top 11 Signal crane operator to retract positioner cylinders with the mode switch Weight of jib struts will retract cylinders View C 12 Release tension on safety latch cable allowing enough slack for engagement when cylinders are extended 13 Continue to boom down slowly Pay out load lines as boom and jib are lowered Signal person watch jib stops to verify that stops do not engage pins in boom top CAUTION Jib Stop Damage Do not luff down if jib stops will engage pins in boom top J
292. s from assist crane to four lifting lugs on main strut View D Rear slings should be 6 8 ft 1 8 2 4 m longer than front slings Attach taglines to strut so that swing motion can be controlled when hinge pins are removed Remove keeper plate from both sides of adapter frame View C Lift main strut so slings are taut and hinge pins are loose Remove hinge pins Lift main strut away from adapter frame and jib strut and place main strut on blocking at ground level Disconnect slings from main strut Reinstall hinge pins and keeper plates in adapter frame for storage Remove jib strut as follows a Connect chain slings from assist crane to four lifting lugs on jib strut View Rear slings should be 6 8 ft 1 8 2 4 m longer than front slings Attach taglines to strut so that swing motion can be controlled when hinge pins are removed Remove keeper plate from both sides of adapter frame View A Lift jib strut so slings are taut and hinge pins are loose Remove hinge pins Lift jib strut away from adapter frame and place jib strut on ground Disconnect slings from jib strut Reinstall hinge pins and keeper plates in adapter frame for storage See Figure 4 14 for following procedure 3 The main strut jib strut and adjustable straps can be shipped as an assembled unit to reduce shipping space To assemble struts for shipping proceed as follows 4 34 Published 06 20 08 Contr
293. s with tape measure measure boom angle with a protractor level on centerline of boom mm SAFETY INFORMATION 4 When boom or jib angle limiter automatic boom or jib stop is inoperative or malfunctioning qualified person directing lift shall make sure maximum boom angle radius specified on capacity chart for load being handled is not exceeded Radius and boom angle shall be determined by measurement i e measure radius with tape measure measure angle with a protractor level on centerline of boom 5 When anti two block device is inoperative malfunctioning qualified person directing lift shall establish procedures to furnish equivalent protection i e assign an additional signal person to observe distance between load and boom or jib point This practice does not apply when lifting personnel in load line supported baskets Personnel shall not be lifted in load line supported baskets when anti two block devices are not functioning properly 6 When level indicator is inoperative or malfunctioning other means shall be used to level crane within limits specified on capacity chart i e level crane using a carpenter level on rotating bed 7 When boom length indicator is inoperative or malfunctioning qualified person directing lift shall establish boom length at which lift will be made by actual measurement and marking of boom 8 When swing limiter or other proximity device is inoperative or malfunctioning qua
294. secured and position Haul in boom hoist wire rope just enough to tension mast boom at 75 and luffing jib at 50 straps Do not raise boom off blocking Wind can cause mast stops to collapse if this step is not performed Above 75 mph 34 m s Lower mast onto blocking at ground level Table 3 2 Rating Reductions for Various Wind Speeds and Wind Gusts 190 240 57 9 73 2 140 180 200 240 260 280 42 7 54 9 61 0 73 2 79 2 85 3 70 120 21 3 36 6 200 240 61 0 73 2 130 180 39 6 54 9 200 240 61 0 73 2 Luffing Jib Length ft m Boom Length ft m Maximum Wind 140 180 42 7 54 9 260 280 79 2 85 3 140 180 42 7 54 9 260 280 79 2 85 3 Percent Speed mph m s Rating Reduction 15 0 10 25 11 30 13 35 16 Above 35 mph OPERATION NOT PERMITTED 16 m s For luffing jib operation in winds above 15 mph 7 m s with luffing jib positioned above 50 load block from luffing jib point must weigh at least 15 000 Ib 6804 kg Luffing jib may be blown over backwards if this precaution is not observed See luffing jib capacity chart for specific backward stability conditions mm Published 06 20 08 Control 033 07 3 9 OPERATION 179A Jib on 55 or 55 Boom without MAX ER Attachment Operation Permitted Operation is permitted in steady wi
295. sed limit switch assembly fastened at any or all of the following locations Lower boom point Upper boom point a b c Lower luffing jib point d Upper luffing jib point e Fixed jib point 2 Weight freely suspended by chain from each limit switch actuating lever weight encircles load line as shown in Figure 6 10 3 Lift block fastened to load line or lift plates fastened to load block See Figure 6 10 For detailed drawings of limit switch locations see Boom Wiring and Limits Drawing in Section 4 of this manual Block Up Limit Control Operation See Figure 6 8 through Figure 6 10 for following description During normal operation the weight overcomes spring force and rotates the actuating lever away from the limit switch lever This action allows the limit switch to close the load drum up and boom luffing jib down electric circuits The load can be hoisted and the boom luffing jib can be lowered When the weight is lifted by the lift block or lift plates spring force rotates the actuating lever against limit switch lever This action causes the corresponding limit switch to open the load drum up and boom luffing jib down electric circuits The load drum and boom hoist pumps stroke to off At the same time the load drum and boom luffing jib parking brakes apply to stop the load drum from hoisting and the boom luffing jib from lowering Crane Care 18000 LUFFING JIB OPERATOR S MANUAL MAINTENANCE 18000MOM60
296. sert into position and engage top connector holes in insert with fixed vertical pins in butt as shown in View C b Lower insert until bottom connector holes are aligned and install removable horizontal pins as shown in View E c Install blocking approximately 6 in 152 mm high under top end of insert Repeat steps 3c until all inserts and jib top have been installed Lift upper point roller assembly into position at end of boom top Pin top connecting holes in upper point to boom top View D mm Published 06 20 08 Control 033 07 4 9 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL Strap Storage Pin Link Link shipping holes each bracket stored J Ga working position Strap View Connecting Pins with Strap Storage Pin Collars and Retaining Pins storage holes each bracket Bottom From Assist Pin Crane Upper Jib Point Roller Nylon 4 10 Retaining Pin Latch From Assist Lifting Lug Strut Stop View F Cylinders FIGURE 4 7 4 10 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Complete Upper Jib Point Roller Installation See Figure 4 7 for following procedure 1 Attach nylon slings from assist crane to top chords at top end of jib top View A NOTE Assist crane must ha
297. single part hoisting However the limitations of single part hoisting must be understood Rotation Resistant Ropes will develop torque when a load is applied and rotation of the load can occur The amount of rotation depends on many factors Endurance 8RR Endurance 19 and Endurance Dyform 18 when used single part should be limited to a maximum fall of 150 x rope diameter i e 1 2 x 150 75 or distortion and damage may occur If the loads being handled under all operating conditions are within the recommended design factors the amount of rotation should not cause problems If the rope is shock loaded or loaded beyond the recommended design factor rotation of the rope will be a problem As stated previously when Rotation Resistant Ropes rotate the strength of the rope is reduced If the rotation is severe enough the rope can fail or rapidly develop broken wires and wear in the inner rope where it can be difficult to detect ODD PART REEVING Odd part reeving such as 3 5 or 7 part can cause problems if the traveling block is not properly aligned While a greater number of parts reeved in an even number will require slower hoisting speeds it can prevent problems If odd part reeving is necessary the dead end at the traveling block should be attached to the center of the block rather than at the side of the block see opposite top An odd part reeving system can cause the traveling block to be suspended and hang at an angle Thi
298. ssibly resulting in damage 4 70 Component Identification for Figure 4 34 Description Strut Stop Main Strut Pin with Cotter Pins Drum 3 Load Line Luffing Hoist Line Adjustable Link Pin with Collar and Retaining Pins Boom Backstay Strap Connecting Links gt 2 3 4 5 6 7 8 9 Published 06 20 08 Control 033 07 23 24 25 26 27 28 29 30 31 32 18000 LUFFING JIB OPERATOR S MANUAL As main strut nears vertical POSITION D tighten pendants 12 and Drum 3 load line 4 so main strut moves forward smoothly past vertical without dropping View B Continue to luff up while following with assist crane pay out load line and travel until main strut is at approximately 45 POSITION C Slacken Drum 3 load line 4 and raise pendants 12 to vertical POSITION B while luffing up Continue to lower main strut with assist crane while luffing up until main strut comes to rest on jib strut POSITION A Guide strut straps into strap brackets as strut comes to rest on jib strut Allow luffing hoist wire rope 5 to slacken as strut is lowered but do not allow wire rope to kink or jump off sheaves Lower pendants 10 Figure 4 25 View and links 15 Figure 4 25 View 1 to storage position on main strut butt Unpin socket 17 from link 16 and pins links 15 to main strut butt Remove counterweight 11 from end of jib strut one at a time
299. ssure before disconnecting air coolant and hydraulic lines and fittings er 18000 LUFFING JIB OPERATOR S MANUAL 11 12 13 14 15 16 17 18 19 20 Do not remove radiator cap while coolant is hot or under pressure Stop engine wait until pressure drops and coolant cools then slowly remove cap Avoid battery explosion do not smoke while performing battery maintenance do not short across battery terminals to check its charge Read safety information in battery manufacturer s instructions before attempting to charge a battery Avoid battery acid contact with skin and eyes If contact occurs flush area with water and immediately consult a doctor Stop engine before refueling crane Do not smoke or allow open flames in refueling area Use a safety type can with an automatic closing cap and flame arrestor for refueling Hydraulic oil can also be flammable Do not smoke or allow open flames in area when filling hydraulic tanks Never handle wire rope with bare hands Always wear heavy duty gloves to prevent being cut by broken wires Use extreme care when handling coiled pendants Stored energy can cause coiled pendants to uncoil quickly with considerable force When inflating tires use a tire cage a clip on inflator and an extension hose which permits standing well away from tire Only use cleaning solvents which are non volatile and non flammable Do not attempt to lift h
300. st Boom Top Wire Rope Guide For Luffing Hoist Only Guide Sheaves in Strut Jib Top Wire Rope Guide To Lower Jib Point Upper Jib Point FIGURE 4 54 4 89 SETUP AND INSTALLATION 4 211 18000 LUFFING JIB OPERATOR S MANUAL SINGLE HOIST DRUM REEVING 79A Lower Boom Point 99 Boom Wire Q 9 9 Rope Guide 9 9 9 9 9 9 9 9 9 9 9 9 9 9 Q ee 002 99 99 9 2 4 Part 9 Sheave Block 9 Sheave Block Q9 Q9 X See NOTE 6 Part 9 Sheave Block 10 Part 9 Sheave Block 4 90 Published 06 20 08 Control 4 033 07 N See NOTE 8 Part 9 Sheave Block Dead end wire rope at standard upper boom point dead end lug Standard upper boom point MCC 08516 is required for 1 1 8 in 28 mm and 1 1 4 in 32 mm wire rope e Dead End Socket Two Block Weight FIGURE 4 55 Q anitowoc Crane Care 18000 LUFFING JIB OPERATOR S MANUAL SETUP AND INSTALLATION 4 212 SINGLE HOIST DRUM REEVING 79 Q 9 Q Q Q 9 9 12 Part 14 9 9 O 9 I 08 16 Part 18 Part 20 Part 22 Part 13 Sheave Block 13 Sheave Block FIGURE 4 55 continued Zn Published 06 20 08 Control 033 07 4 91 prat SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL 4 213 SINGLE HOIST DRUM REEVING 79 24 Part 26 Part 13 Sheave Block 13 Sheave Block nu 28 Part Ne ere 30 P
301. strap 7 on top of strap storage pin 8 installed in strap support on insert 3 Rest inside strap 9 on top of pin 5 installed in strap support bracket Remove pins 11 from equalizer 10 Lift equalizer 10 into position at ends of straps 7 and 9 6 equalizer to straps 7 and 9 with pins 11 Connect Jib Strut Straps to Equalizers See Figure 4 27 for following procedure 1 Usingassist crane connected to slings on strut straps 3 View A pull jib strut forward and down until strut straps can be connected to equalizer links 2 Pay out luffing hoist wire rope as strut is pulled forward NOTE Jib strut is not heavy enough to overhaul luffing hoist wire rope Approximately 15 000 Ib 6 804 kg of pull is required 3 Pin strut straps 3 to equalizer links 12 View B with pin heads facing outside of jib Complete Jib Assembly 1 Install jib stop positioner one side at a time See Figure 4 26 View F for steps a in following procedure a Attach assist crane to lifting lug on jib stop 17 View F b Support jib stop with assist crane and unpin jib stop support 18 from jib butt c Pin support to jib stop for storage See Figure 4 27 for steps d h in following procedure d Loosen spring tension on positioner safety latch only enough to allow removal of pins 14 and 15 18000 LUFFING JIB OPERATOR S MANUAL e Remove jib stop positioner 13 from storage View H f Pin ji
302. t Wind speed to include wind gusts must be monitored by job planners and supervisors Wind speed at the boom or jib point can be greater than wind speed at ground level Also be aware that the larger the sail area of the load the greater the wind s affect on the load As a general rule ratings and operating speeds must be reduced when Wind causes load to swing forward past allowable operating radius or sideways past either boom hinge pin 18000 LUFFING JIB OPERATOR S MANUAL OPERATION 44 Luffing Jib on 55 79A Boom with 100 50 mph 22 m s and Above foot 30 5 m Mast Lower boom and luffing jib onto blocking at ground level Operation Permitted Boom with 190 240 ft 57 9 73 2 m Luffing Jib Operation is permitted in steady winds or wind gusts up to Upto 40 mph 18 m s the maximum speed given in Table 3 2 provided ratings are reduced the specified amount Park crane upper in line with crawlers with load blocks and weight balls on ground or secured and position Operation Not Permitted boom at 75 and luffing jib at 50 Operation is not permitted in the areas indicated in Table 3 2 40 mph 18 m s and Above Observe the following options Lower boom and luffing jib onto blocking at ground level Boom with 70 180 ft 21 3 54 9 m Luffing Jib Mast Upto 50 mph 22 m s Above 50 mph 22 m s Park crane upper in line with crawlers with load blocks EN and weight balls on ground or
303. t 6 1 m insert No 79 with straps 7 260 3 293 40 12 2 m insert No 79 with straps 12 130 5 502 40 ft 12 2 m transition insert No 55 79 with links 12 110 5 493 10 ft 3 0 m insert 55 7 680 3 483 20 ft 6 1 m insert 55 10 715 4 860 40 ft 12 2 m insert 55 with sheaves 19 640 8 908 28 ft 2 15 16 in 8 6 m basic strap each 355 161 20 ft 6 1 m strap with connector links each 290 131 40 ft 12 2 m strap with connector links each 525 238 Links attached to equalizer each set withpins 95 43 Equalizer with pins 3 675 1 666 Boom stop each tube 1 795 814 Drum 1 or 2 assembly load hoist without 9 970 4 522 BOOM NO 55 OR NO 55A 20 ft 6 1 m butt 18 440 8 364 30 ft 9 1 m top with straps upper and lower point and wire rope guide 40 700 18 461 10 ft 3 0 m insert 7 680 3 483 20 ft 6 1 insert 10 715 4 860 40 ft 12 2 insert
304. t Chord Members Not Shown CAT fa EN Rigging Winch Pendant Strap Stowage Typical on 10 20 or 40 Insert 44 Jib Adjustable Jib Top Allows Pendulum Stop Item 17 to Swing By Boom 20 0 Offset At Higher Jib Offset Angles The Stop Contacts Boom Top Here View R Correct Method Boom Inserts Warning Structural Damage If The Jib Offset Angle Is Not Increased to 20 After a 60 to 20 Boom Angle Then the Pendulum Stop Cannot Swing Past the Boom Top as Shown 12 Offset Boom Butt 5 Drum 2 mni e gt Component Identification View S Incorrect Method 9 of 22 CRANES INC 100 Jib Position 190 amp 110 Jib Position 200 amp Jib Position Approx Shipping Position Weight 23 245 Lb 70 Jib Position 80 Jib 120 Jib 2 Shipping Width 8 3 w Winch Handles Removed Es Position 220 230 240 Position 16 E dedii c 90 Jib 130 amp 140 Jib Position 170 amp 150 amp 180 Jib Position 160 Jib Position z SNA V SIS de Locked Operating Unlocked Adjustment Plunger Handle Shipping And Handlin Position Position To Be Removed After Box Section Removed For Clarity Pin Is In Place Slide Pin Load Pin Slide Pin Load Pin View P Shown In 160 Jib Position R
305. t Each Other Wedge See Drum and Lagging Chart in Capacity Chart Manual for correct size of drum laggings if used See Wire Rope Specifications Chart in Capacity Chart Manual for correct type size and amount of wire rope to be installed on load drums See Boom Rigging Drawing at end of this section for correct type size and amount of wire rope to be installed on boom hoist drums 1 Carefully inspect drums and all rope guides rollers and sheaves for wear or damage that can cause wire rope to wear or be cut If defects cannot be fixed replace faulty parts 3 T First Wrap Tight Against 2 2m tension to wire rope as it is wound slowly onto Flange for 3 4 of Diameter rum First wrap must be tight against drum flange for approximately three fourths of drum diameter see Voids and Loose Wraps in First Layer Figure 4 42 Cause Severe Wear of Wire Rope 3 Tap adjacent wraps against each other with a soft metal or wooden mallet Use extreme care not to put twists or turns in wire rope allow rope to assume its natural lay CAUTION Wire Rope Damage Voids or spaced wraps in first layer Figure 4 42 View B will permit movement and a wedging action with FIGURE 4 42 subsequent layers Wedging action will cause crushing and abrasion of wire rope Never allow wire rope to cross wind on drums 4 76 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MA
306. t load to fully seat the Wedge and Wire Rope in the socket This load should be of equal or greater weight than loads expected in use Efficiency rating of the Wedge Socket termination is based upon the catalog breaking strength of Wire Rope The efficiency of a properly assembled Wedge Socket is 80 During use do not strike the dead end section with any other elements of the rigging Called two blocking SECTION 5 LUBRICATION TABLE OF CONTENTS General 5 1 Lubrication Intervals eR ha Ee Rm den Rem Rn 5 1 e denk hinge oder ae a ca puru en alie Rn RU RR Re RN 5 1 Lubrication Rete het Re fem hir ER e 5 1 Oil Can ten etse itus Xa Nest x us ma 5 1 Wire Rope 5 1 Approved i ca tia ata od n Hace Eat dae dH etta de 5 1 44 Luffing Jib Lubrication RR 5 5 Every 40 Hours or Weekly whichever comes first 5 5 Every 200 Hours of Operation or Monthly whichever comes first 5 5 Each Time Boom and Luffing Jib are Lowered to Ground 5 5 79A Luffing Jib Lubrication 5 5 Every 40 Hours or Weekly whichever comes first 5 5 Every 200 Hours of Operation or Monthly whicheve
307. tach the load so it is balanced equally on the hook Lifting slings must be within angles given in Figure 4 46 to achieve maximum hook capacity The duplex hook has a hole to which an optional shackle can be attached as shown in Figure 4 46 WARNING Falling Load Hazard Limit load to be handled with shackle to capacity of load block or shackle whichever is less Load block or shackle can fail if overloaded allowing load to fall 4 80 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL FIGURE 4 46 Wire Rope Specifications See Wire Rope Specifications chart in Capacity Chart Manual for the following load block reeving information e Parts of line required to handle desired load Wire rope length required for various boom jib lengths and parts of line Maximum spooling capacity of load hoists Wire Rope Installation See Wire Rope Installation in this section for following instructions e Anchoring wire rope to drum e Installing wire on drum e Anchoring wire rope to wedge socket Reeving Diagrams See Figure 4 49 for 44 Luffing Jib reeving diagrams A WARNING Avoid Death or Serious injury Exercise care when block is standing in vertical position Figure 4 50 as the potential for tipping exists Potential causes of tipping are unstable work area boom movement and the reeving process If work area is unstable lay block flat on side plate
308. tay strap on the strut The inner strap is retained inside the outer strap The outer strap slides up or down over the inner strap The load pin must be installed in the proper key hole in the inner strap before the jib strut is raised The length of the jib dictates which key hole must be used The outer rims of the load pin have flanges that hold the pin in place in the key hole in the inner strap View B A slide pin mounted inside the load pin holds the load pin in place Depressing a spring loaded plunger in the load pin allows the slide pin to move through the load pin as long as the plunger is depressed When released the plunger engages one of two grooves in the slide pin to lock the slide pin in place Extending the slide pin holds the load pin in place in the key hole A DANGER Crane Collapse Install and lock load pins in proper holes of adjustable straps for jib length in use Figure 4 11 View A A WARNING Adjustable Strap Separation Make sure adjustable strap locking pin is installed Figure 4 11 View E before raising jib strut SETUP AND INSTALLATION Perform following steps at both adjustable straps 1 Determine correct pinning location for adjustable strap based on jib length See View A and table in Figure 4 11 2 Remove load pin from its stored position in adjustable strap by depressing plunger and sliding load pin toward wider end of key hole View B Remove pin through access hole in outer st
309. ted outside of the sensing area Reliance is placed upon the operator in selecting and properly setting the sensitivity of these devices Never rely solely on a device to protect you and your fellow workers from danger Some variables you must know and understand are e Proximity devices are supposed to detect the existence of electricity and not its distance quantity or magnitude Some proximity devices will detect only alternating current AC and not direct current DC Some proximity devices detect radio frequency energy and others do not Most proximity devices simply provide a signal audible visual or both for the operator and this signal must not be ignored Sometimes the sensing portion of the proximity devices becomes confused by complex or differing arrays of power lines and power sources DO NOT depend on grounding Grounding of a crane affords little or no protection from electrical hazards The effectiveness of grounding is limited by the size of the wire conductor used the condition of the ground the magnitude of the voltage and current present and numerous other factors Electrical Contact If the crane comes in contact with an energized power Source the operator must Vitus SAFETY INFORMATION 1 Stayinthe crane cab DON T PANIC 2 Immediately warn PERSONNEL in the vicinity to STAY AWAY 3 Attempt to move the crane away from the contacted power source using the crane s c
310. ther valves are preset to pressure settings given in Views B and C Published 06 20 08 Control 033 07 4 17 SETUP AND INSTALLATION 18000 LUFFING JIB OPERATOR S MANUAL Shown Pinned for 100 ft 30 5 m Jib Length Connectin Outer Inner Link 4 8 19 10 oe N 4 120 View A Hole Jib Length Hole Jib Length No feet meter No feet meter View B Slide 1 70 21 3 150 48 8 Load Pin Shown Locked Pin 2 80 24 4 160 48 8 in Operating Position 3 90 27 4 170 51 8 4 100 30 5 180 54 9 5 110 33 5 190 57 9 6 120 36 6 200 61 0 210 64 0 7 1130 39 6 220 67 1 70 1 73 2 140 42 7 230 70 1 240 73 2 1395 Strap Outer Strap Plunger Access and Cable Hole Winch to adjustable strap Jib Strut Retaining Pin Adjustable Strap Cable Jib Strut from hand Jib Strut Adjustable Strap Locking Pin 129 View F FIGURE 4 11 4 18 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Set Up Adjustable Straps See Figure 4 11 for following procedure The adjustable strap View A consists of four major parts a connecting link an inner strap an outer strap and a load pin The connecting link is pinned to the backs
311. trol 033 07 4 1 SETUP AND INSTALLATION Adhere to local state and federal regulations for handling personnel and for personnel fall protection Do not use top of boom or jib as walkways Optional boom ladders stored in boom butt are available from Manitowoc If your crane has ladders see Section 3 in Operator s Manual provided with crane CRANE WEIGHTS See Crane Weights in Section 1 of this manual for the weights of the individual boom and jib components OPERATING CONTROLS Become thoroughly familiar with the location and function of all operating controls provided for the crane and attachment Read and understand the instructions in Section 3 of this manual COUNTERWEIGHT REQUIREMENT See applicable Luffing Jib Capacity Charts and Raising Procedure Charts for counterweight requirements when operating with jib A WARNING Tipping Hazard Prevent crane from tipping Do not operate crane until proper counterweight is installed BLOCKED CRAWLERS To prevent crane from tipping or structural damage to attachment all boom jib combinations must be raised and lowered over blocked crawlers See Luffing Jib Capacity Charts and Raising Procedure Charts for blocked crawler requirements Also see Crawler Blocking Diagram in Luffing Jib Capacity Chart Manual for instructions A DANGER Tipping Hazard Prevent crane from tipping or structural damage to attachment Do not attempt to raise or lower boom and jib
312. ty pins NOTE Top connecting pins are 2 in 51 mm in diameter Bottom connecting pins are 2 1 2 in 64 mm in diameter 9 Raise insert until top connecting holes line up and install connecting pins and safety pins 10 Disconnect assist crane from slings Remove slings Connect Backstay Straps 1 Remove shipping pins 10 View H from strap brackets 11 and store in hole 12 2 Remove shipping pins 18 View J from straps on main strut butt Store in brackets 17 View L Component Identification for Figure 4 21 Item Description Main Strut Butt Jib Strut Butt Main Strut Top Jib Strut Top Strut Support C Pin with Wire Locks Pin with Wire Locks Crane Counterweight Boxes Counterweight Tie Links Strap Shipping Pin with Snap Pins Strap Bracket Storage Hole for Shipping Pin 4 44 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL 3 Rotate links 15 View L forward and pin to links 14 using pins 16 stored in links 15 pin heads facing outboard side Install collars retaining pins and cotter pins 4 Remove pins 23 View N securing adjustable straps 21 to shipping brackets 22 mounted on strut stop cylinders 20 Pins 23 will be used to attach adjustable links to backstay straps on boom butt 5 f necessary adjust length of adjustable links 21 for boom length View M Connect Jib Strut Top to Counterweight A WARNING Falling Equipment Hazard
313. type of wire rope the severity of duty and the type of corrosive elements the wire ropes is subjected to The wire rope must be properly protected at all times The lubricant must be fluid enough to fully penetrate the strands and rope core Use one of the methods shown in Figure 5 1 to lubricate the wire rope For maximum penetration apply lubricant where the wire rope opens up as it travels around a sheave or winds onto a drum The wire rope must be clean and dry before applying lubricant an air jet or wire brush are some cleaning methods Do not use grease to lubricate wire rope Grease will not penetrate rope properly and will buildup in valleys between wires and strands This buildup will inhibit rope inspection and could trap moisture in rope s interior APPROVED GREASE CraneLUBE E P 2 MCC 471197 for all grease points Published 06 20 08 Control 033 07 5 1 LUBRICATION Casing Filled with Swab and Lubricant RET Pouring onto Slow Moving Sheave Swabbing 5 2 18000 LUFFING JIB OPERATOR S MANUAL Moving Rope Hazard Take every precaution to protect hands from injury when rope is moving Wear heavy gloves and move rope as slowly as possible FIGURE 5 1 Published 06 20 08 Control 033 07 Q anitowoc Crane Care 18000 LUFFING JIB OPERATOR S MANUAL LUBRICATION THIS PAGE BLANK mm Published 06 20 08 Control 033 07 5 3 LUBRICATION 18000 LUFFING JIB OPERATOR S M
314. uired 5 If specified in raising procedure chart remove following items Lower boom point from 79A boom top Rigging winch and luffing jib wire rope guides from 44 butt 6 Add or remove crane counterweight to comply with applicable capacity chart 7 Remove boom stops lower catwalk and wire rope guide from 44 butt 8 Modify 44 butt for use as jib butt as shown on modification drawings 9 Attach jib stop assembly to lugs on jib butt with shafts and keepers plates Figure 4 5 View B a Support jib stops at point shown 50 Ib 23 kg b Remove pins from lower holes and install them in upper holes operating position Lower jib stops to operating position 10 Pin jib strut rest to lugs on jib butt Figure 4 5 View C 11 Attach hand winches to jib strut if necessary Figure 4 5 Published 06 20 08 Control 033 07 View D a If necessary install cables and attach to adjustable straps b Install handles if removed for shipping SETUP AND INSTALLATION O T Pin with Cotter Pins 179A Boom Top MAW Wo 18000 LUFFING JIB OPERATOR S MANUAL Adapter Frame Fixed 2 Vertical N View C m i 0 __2 5 SS 4 104 Typical Jib Sections Removable Lacing 2 each insert See Figure 4 3 30 ft 9 1 44 Jib Top Upper Point Roller Assembly AO ft 12 2 m 44 Jib Butt Typical Jib Inserts
315. uld not operate in the lower direction er 18000 LUFFING JIB OPERATOR S MANUAL MAINTENANCE 1 Adjust spring tension so there is enough force to lift weight of chain and rotate actuating lever when weight is CAUTION lifted Avoid Sheave Damage 2 Loosen setscrew in limit switch lever so lever is free to Use extreme care when testing block up limit controls rotate when boom is raised If block up limit control fails to stop load immediately stop load by moving drum control 3 Manually lift weight to allow actuating lever to rotate handle to off or by applying drum working brake upward otherwise two blocking may occur 4 Hold lever at Dimension A Hold roller on limit switch lever against actuating lever Adjustment while performing step 6 See Figure 6 12 for following procedure 6 Turn limit switch shaft CLOCKWISE only enough to Lower boom onto blocking at ground level and adjust each click limit switch open and hold Then securely tighten limit switch as follows setscrew in limit switch lever 7 Test limit switch for proper operation see Maintenance topic repeat adjustment steps until limit switch operates properly Description Item Description From Boom or Jib Node Grease Fitting Elbow with Cord Gripper Actuating Lever Limit Switch for Setscrew Roller Lower Boom Point Spring Limit Switch Lever nas 2 springs Enclosure Shaft Spring Tension Adjusting Cover Screw ani Z Limit Switch for
316. ure Control Wiring Boom amp Limits Load Block Conversion Bridon Tech Bull Rotation Resist Ropes Crosby Terminator Wedge Socket Warning and Application Instructions 2210 L 20 16 10 3 12109 6 1210928 AA 5 12109 j lt 12 10 9 28 12109 0 lt 105 lt S 1210928 or ashers 2 to Eac R67 R60 R59 dC AY n 106 Side to Center And Prevent Y Side Play In Boom Top Max Side Play Allowed 102 or 103 or 104 or 107 P 01 3 T a No Washers on Outboard 23 or 24 25 AIANWISSY NOISIA3H LUFFING JIB 44 LUFFING JIB SANVYO DOMOLINVIN 3 dnog MANITOWOC CRANES INC Jib Strut Sheaves 7 Man Strut 6 9 eaves LL 4 8 2 5 0 7 3 Main Strut Dead End Wire Rope Guide Assem on Boom Rigging Assem Wire Rope Guide Assem on Boom Rigging Assem Wire Rope Guide Assem on Boom Rigging Assem Luffing Jib Hoist Ref A04331 Luffing Jib Hoist Reeving Diagram For 14 Part Line 1700 500 m of 1 00 Constructex Part A14127 B S 125 000 R29 R21 H67 R18 R20 R60 R17 R19 Reo R59 AN 1 SIG AG FO C C69 Co 5 c R28 R61 R63 R58 R64 R66 R65 View A Rotated 23 49 CW 2 of 22 20105
317. user shall verify that correct capacity chart is being used pedestal mounted barge mounted 0 1 2 or 3 list or dynamic capacity chart Failing to use correct capacity chart can result in an accident Definitions 1 Machine List as defined by Manitowoc is crane s out of level condition from side to side as measured by angle between horizontal and a line drawn through centerline of crane s boom hinge pins Figure 2 12 This out of level condition creates side load and effects crane s lifting capacity 2 Barge List also referred to as heel or trim causes swing out of the load and may produce side load When Manitowoc provides a capacity chart showing capacities for a 2 degree machine list for example we are referring to maximum allowable lifting capacity for crane when experiencing an out of level condition side to side of 2 degrees as measured by angle between horizontal and a line drawn through centerline of crane s boom hinge pins Unless otherwise specified on capacity chart barge list heel or trim must not exceed machine list degrees given on the capacity chart 3 Barge List and Machine List are not same As machine rotates on barge barge list as defined above will change Worst machine list condition generally occurs when machine swings over corner of barge producing maximum side load 2 24 Published 06 20 08 Control 033 07 18000 LUFFING JIB OPERATOR S MANUAL Through Boom
318. uts star washers and bolts from base of damage during shipping wind speed mounting bracket a Disconnect electrical cable at base of wind speed Store indicator assembly in a safe place on crane inside boom 13 o Item Description Description stored gt Strap Support Bracket Equalizer Pin with Cotter Pins Jib Strut Straps Jib Stop Positioner Cylinder Link Jib Stop Jib Strap outside End Plate with Cap Screws Strap Retaining Pin outside strap Keeper Plate Pin with Cotter Pin Pin Jib Strap inside Bracket A Pin with Cotter Pin Lug B Strap Retaining Pin inside strap Lug C OMN E o Figure 4 32 mm Published 06 20 08 Control 4 033 07 4 65 SETUP AND INSTALLATION Remove Jib Strap Equalizers See Figure 4 32 for following procedure 1 2 10 11 12 13 14 15 16 4 66 Luff down to lower jib strut View A Guide strut strap equalizers 2 View B into strap support brackets 1 as jib strut is lowered Disconnect jib strut straps 3 View A from equalizer links 4 View B Strut straps will swing to rear Store connecting pins in holes of jib strut straps 3 Support outside jib strap b View B with assist crane and remove connecting pin 7 from strap bracket Remove strap retaining pin 6 Lower strap 5 into outside strap bracket Store strap in bracket with retaining pin 6 Support inside ji
319. ve sufficient capacity to lift weight of assembled jib 2 Slowly lift jib top until bottom holes in upper jib point roller are aligned with holes in jib top 3 Insert bottom pins to connect upper jib point roller to jib top View C 4 Lower jib top until rollers are on ground 5 Disconnect slings from jib top Connect Jib Straps See Figure 4 7 View B for following procedure Jib straps and links are stored on the inserts and jib top for shipping 1 Remove strap storage pins from shipping holes and install in storage holes 2 Remove retaining pins collars and connecting pins from end of straps on adjacent insert mm SETUP AND INSTALLATION 3 Rotate links from storage position to working position Install connecting pins collars and retaining pins to connect links to adjacent straps 5 Repeat steps at end of each insert Install Struts See Figure 4 7 for following procedure 1 Published 06 20 08 Control 033 07 The main strut jib strut and adjustable straps can be shipped as an assembled unit to reduce shipping space If struts are assembled proceed as follows a Connect chain slings from assist crane to four lifting lugs on main strut View F b Lift strut assembly off transport trailer and place assembly on ground c Remove retaining pins connecting main strut to jib strut View E Store pins in jib strut holes once main strut is removed If necessary lift main strut slightly t
320. w A View B 12 Straps Stored Operation 10 47 m d gt E M M 4 148 View G stored 8 9 working 8 working Lugs B 2 places 9 stored View F location not visible Description Storage Pin strap stored 9 Pin with Snap Pin 1B Storage Pin operation 10 40 ft 12 2 55 Insert with Drum 6 2 Strap Bracket typical Sheaves 3 Link typical 11 55 Boom Top 4 Strap typical 12 Wire Rope Guide 5 Connecting Pin typical 13 Connecting Pin with Snap Pins 6 Collar typical 14 Link with Pins and Snap Pins stored 7 Retaining Pin with cotter pins 15 Counterweight Box View H 8 Drum 6 Wire Rope Guide 16 FIGURE 4 18 mm Published 06 20 08 Control 4 033 07 4 37 SETUP AND INSTALLATION Preparing Crane Boom and Mast See Figure 4 18 for following procedure 1 4 38 Lower boom to ground level onto blocking approximately 4 ft 1 2 m high Remove load block If installed remove load block and upper boom point Boom point sheave assembly can be installed on boom point Connect unused block up limit electric cords to terminating plugs on boom point junction boxes If necessary remove 40 ft 12 2 m insert and install 40 ft 12 2 m insert with Drum 6 sheaves 10 View F Raise luffing hoist wire rope guide 8 View F on boom insert 10 a Remove stored pin 9 b Rotate wi
321. witch 1 actuator rod to activated Dimension D1 and hold Listen for limit switch to click open LED OFF Turn limit bypass key clockwise and hold er 18000 LUFFING JIB OPERATOR S MANUAL Description Edge of Actuator Rod to Edge of Jib Stop Tube Edge of Actuator Rod to Center of Pin D1 D2 D1 1b 124 6 2b 1 1a 4 t P M 1 3 _ 6 103 A1 Description 1 Limit Switch MAX UP 2 Actuator Rod Actuator Rod Bracket 2 Limit Switch MAX DOWN Actuator Rod Actuator Rod Bracket 3 Luffing Jib Butt 4 Jib Stop Mechanical 5 Boom Top Published 06 20 08 Control 033 07 Deactivated 1 44 in 36 7 mm 1 75 in 44 5 mm MAINTENANCE Activated 1 22 in 30 9 mm 1 79 in 45 4 mm 2a See Figure 6 11 Left Side of Boom and Luffing Jib Description Max Up 1 Angle 168 Max Down Angle 70 Item 1 2 FIGURE 6 2 MAINTENANCE 4 Pullluffing jib handle back Luffing hoist must not turn in up direction and JIB MAXIMUM UP 2 fault should come on Jib Maximum Down Limit Checks See Figure 6 1 for following procedure Perform the following steps with the boom and luffing jib on the ground 1 Check Dimension D2 View B If necessary adjust position of limit switch housing to obtain deactivated dimension Perform remaining steps with engine running and appropriate Luf
322. woc
323. xperience is thoroughly familiar with crane operations and the hazards involved Such a person shall meet the operator qualifications specified in OSHA Regulations United States Federal Law in ASME B30 5 American Nation Standard or in any other applicable federal state or local laws Operator training and qualification is crane owner s responsibility NOTE The regulations and standards mentioned above and latter in this section can be obtained from US DOL OSHA Rules and Regulations are available by mail from the Superintendent of Documents PO Box 371954 Pittsburgh PA 15250 7954 or by Phone 202 512 1899 e Fax 202 512 2250 e Electronically via GPO Access at docs or from www osha gov ASME formerly ANSI B30 Series American National Standards are available by mail from the ASME 22 Law Drive Fairfield New Jersey 0700 2900 or by e Phone US amp Canada 800 843 2763 e Phone Mexico 95 800 843 2763 e Phone Universal 973 882 1167 e Fax 973 882 1717 or 973 882 5155 E mail infocentral asme org Operator Conduct 1 Operator shall not engage in any practice which diverts his her attention while operating crane 2 Operator shall not operate crane when physically or mentally unfit 3 Operator shall be responsible for all operations under his her direct control When safety of an operation is in doubt operator shall consult with person supervising lift before lifting load 4 Operator shall be t
324. xtended place other hand motionless in finger closed thumb pointing fingers closed thumb pointing front of hand giving the motion downward signal hoist slowly shown as an RAISE BOOM amp LOWER LOAD LOWER BOOM amp RAISE LOAD SWING Arm extended point with With arm extended thumb With arm extended thumb finger in direction of swing of pointing up flex fingers in and pointing down flex fingers in and Boom out as long as load movement 15 out as long as load movement is desired desired da0108 A die Published 06 20 08 Control 033 07 3 1 Manilow OPERATION 3 2 STOP Arm extended palm EMERGENCY down move arm back and forth horizontally TRAVEL Both Tracks Use both fists in front of body making a circular motion about each other indicating direction of travel forward or backward For Land Cranes Only RETRACT BOOM Telescoping Boom Both fists in front of body with thumbs pointing toward each other da0109 18000 LUFFING JIB OPERATOR S MANUAL STOP Both arms TRAVEL Arm extended forward DOG EVERYTHING Clasp extended palms down move hand open and sl arms back and forth horizontally of travel TRAVEL One Track Lock the track on side indicated by raised fist Travel opposite track in direction indicated by circular motion of other fist rotated vertically in front of body For Land Cranes Only EXTEND BOOM Telescoping Boom One Hand Signal One fist in

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