Manitowoc 2000 Operator's Manual
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Manitowoc 2000 Operator's Manual

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Manitowoc
2000
Operator Manual

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  • Page 1 Manitowoc 2000 Operator Manual...
  • Page 3 Avoid unsafe operation and maintenance. • This crane and attachment must be operated and maintained by trained and experienced personnel. Manitowoc is not responsible for qualifying these personnel. • Do not operate or work on this crane or attachment without first reading and understanding Operator’s Manuals and Capacity...
  • Page 4 BLANK PAGE...

  • Page 5: Table Of Contents

    Manitowoc Distributors ........
  • Page 6 TABLE OF CONTENTS 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Disassembly Precaution ..........2-25 Personnel Handling Policy .
  • Page 7 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL TABLE OF CONTENTS Breaking in Wire Rope ..........4-35 Anchoring Wire Rope to Button Socket .
  • Page 8 TABLE OF CONTENTS 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Storing Electric Cord ..........6-12 Disconnecting Block-Up Limit Control .

  • Page 9: Section 1

    Manitowoc Distributors ........

  • Page 11: General Description

    Nameplates and Decals The instructions in this manual apply only to the Model 2250 Drawing in Section 2 of this manual. MAX-ER™ 2000 with a #44 Luffing Jib on a #79 Boom. CRANE ORIENTATION CRANE DATA...
  • Page 12 INTRODUCTION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1152 Wire Rope Upper Guide Jib Point Adjustable Straps Strap Strut Lower Jib Point Load Lines Luffing Hoist Wire Rope Hook and Stop Weight Ball Wire Rope Guides Load #44 Luffing Jib...

  • Page 13: Weights Of Components

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL INTRODUCTION WEIGHTS OF COMPONENTS NOTE: Weights may fluctuate ±3% due to manufacturing tolerances Weight Description Pounds Kilograms LIFTCRANE: Upperworks and lowerworks complete, 2 swing drives, counterweight, gantry, backhitch, MAX-ER equipped with 462,000 lb (209 560 kg) wheeled counterweight, 130 ft (39,6 m)
  • Page 14 INTRODUCTION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Weight Description Pounds Kilograms 34 ft 5-3/4 in (10,5 m) counterweight strap (each) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 15 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL INTRODUCTION Weight Description Pounds Kilograms BLOCK OPTIONS: 300 USt (272 t) load block with swivel hook - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...

  • Page 16: English And Metric Conversions

    INTRODUCTION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL ENGLISH AND METRIC CONVERSIONS Inverse Conversion DIVIDE ( ÷ ) known value by conversion factor to obtain Direct Conversion equivalent value in desired units. For example, 3,6576 m is MULTIPLY ( x ) known value by conversion factor to obtain converted to feet, as follows: equivalent value in desired units.

  • Page 17: Manitowoc Distributors

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL INTRODUCTION To Convert Symbol Application Symbol Multiply By VOLUME (LIQUID) Ounce Milliliter 29.5735 Pint Liter 0.4732 Fluid Capacities Quart Liter 0.9464 Gallon Liter 3.7854 Gallon Per Minute Pump Flow Liters Per Minute L/min 3.7854...
  • Page 18 THIS PAGE BLANK...
  • Page 19 Pedestal Mounted Crane ..........2-29 Manitowoc...
  • Page 20 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Definition ........... . 2-29 Examples .

  • Page 21: Diesel Engine Exhaust

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION SECTION 2 SAFETY INFORMATION DIESEL ENGINE EXHAUST Safety Alert Symbol WARNING This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety...
  • Page 22 SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Crush Hazards Cut or Crush Hazards Electrocution Hazard Cut Hazard Explosion Hazard Fall Hazard FIGURE 2-1 Published 4-19-2011, Control # 072-04...
  • Page 23 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION Engine Diesel Coolant Fuel Engine Hydraulic Coolant Filter Vent Fall Hazards Engine Hydraulic Oil Level Pump Drive Oil Fluid Symbols Level Flying Object Hazards Falling Boom Hazards (Crush Hazard) Overhead Obstruction Hazard...
  • Page 24 SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Sound Power Level Personal Fall Protection Read Manual Pressure Cleaning Tire Pressure (if applicable) Pressure Release Hazard FIGURE 2-1 continued Published 4-19-2011, Control # 072-04...

  • Page 25: Safety And Information Signs

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION SAFETY AND INFORMATION SIGNS When ordering a sign, give the crane model number, the crane serial number, and the name and part number of the Maintaining Signs sign (Figure 2-2). If the sign has a figure number, it can be used if the drawing number is missing.

  • Page 26: Crane Access Points

    SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL CRANE ACCESS POINTS • Do not allow ground personnel to store their personal belongings (clothing, lunch boxes, water coolers, and the like) on the crane. This practice will prevent ground personnel from being...
  • Page 27 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION P824 Catwalks Boom Butt View E Catwalk P823 Gantry View D P821 Catwalk Tube View A Standard Cab Shown Steps (2 places) (4 places) A1048 Rear Load Drums View C...
  • Page 28 SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A03893 Elevated Cab Catwalk/ Back-Up Catwalk/ Shown Platform Power Plant Platform Operator’s Stairs Enter/ Exit Catwalk/Platform Between Drums Enter/ Exit Catwalk/ View E Platform Elevated Cab FIGURE 2-3 continued Published 4-19-2011, Control # 072-04...

  • Page 29: Operator's Manual/Capacity Chart Storage

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION OPERATOR’S MANUAL/CAPACITY CHART If the serial numbers of your manuals and Capacity Charts do not match the serial numbers of the crane or attachment, STORAGE contact your Manitowoc distributor for the proper manuals or Manitowoc provides the following manuals and other Capacity Charts.

  • Page 30: Safe Operating Practices

    SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFE OPERATING PRACTICES inspection or to verify the crane’s performance after maintenance procedures. General No personnel shall be allowed to climb onto the crane or enter the crane cab unless performance of...
  • Page 31 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION The operator shall be thoroughly familiar with the 10. The operator shall verify that the Capacity Chart being operation of the crane and its proper care. If adjustments used is the correct one for how the crane is equipped or repairs are necessary or if there are known defects (boom length, load line reeving, counterweight, etc.).

  • Page 32: Handling Load

    SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Land all suspended loads, if possible, under brake boom rigging) shall be securely blocked to prevent or power control. dropping of boom, jib, or mast sections. b. Apply all brakes and locking devices.

  • Page 33: Lifting/Moving Load

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION Only use slings and other rigging that are in safe Unused load drums are parked (working and operating condition and have a rating equal to or greater parking brakes applied; if equipped, drum pawls than the load to be lifted.
  • Page 34 SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Free of defects. Sound the signal horn before traveling and intermittently while traveling, especially when Strong enough to prevent crushing, bending, or approaching personnel. shear failure. If equipped, the automatic travel alarm will sound Of sufficient thickness, width, and length to when the crane is traveled.

  • Page 35: Signals

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION Multiple Load Line Operation • The load lines must hang as near vertical as possible to minimize side and forward loads. The distance between the load points and the hook...

  • Page 36: Safety Devices

    SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL When it is necessary to give instructions to the operator Crane level indicator: either electronic (viewable in (other than those established by signal system), all crane’s electronic display) or mechanical (viewable from crane motions shall be stopped.

  • Page 37: Category 2 Operational Aids

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION occurrence of the deficiency, the repair must be completed deficiency occurs. Exception: If the employer documents that within 7 calendar days of receiving the parts. it has ordered the necessary parts within 7 calendar days of...

  • Page 38: Assembling, Disassembling, Or Operating Crane Near Electric Power And Transmission Lines

    SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL OPTIONAL Drum Spooling Limiter (maximum or minimum bail limit) Temporary alternative measures if inoperative or WARNING malfunctioning: Electrocution Hazard! The qualified person directing the lift, the operator, or a Manitowoc cranes are not equipped with all features designated signal person shall watch the drum and required to operate within OSHA 29CFR1926.1408, Table...

  • Page 39: Set-Up And Operation

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION the load, load line, or crane boom if it comes too close to stops does not assure that electrical contact will not an electrical power source. Low voltages can also be occur.

  • Page 40: Electrical Contact

    SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Sometimes the sensing portion of the proximity FIRE EXTINGUISHERS devices becomes confused by complex or differing A portable fire extinguisher with a minimum rating of arrays of power lines and power sources.

  • Page 41: Safe Maintenance Practices

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION crane’s operation and required maintenance as well as the Do not remove cylinders until working unit has been hazards involved in performing these tasks. securely restrained against movement. Training and qualification of maintenance and repair Pinch points are impossible to eliminate;...

  • Page 42: Environmental Protection

    28. Unless authorized in writing by Manitowoc, do not alter Handle and dispose of waste according to local, state, and the crane in any way that affects the crane’s federal environmental regulations.
  • Page 43 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION THIS PAGE BLANK Manitowoc 2-23 Published 4-19-2011, Control # 072-04...

  • Page 44: Boom Disassembly Safety

    SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL BOOM DISASSEMBLY SAFETY General Safety decals (Figure 2-5) are placed near the connectors on the boom sections as shown on the Boom Disassembly Decal Drawing at the end of this section.

  • Page 45: Pin Removal

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SAFETY INFORMATION Pin Removal When removing pins from boom sections, stand clear of pins being removed. Even though the boom is resting on blocking, individual pin connections may still be under load.
  • Page 46 SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1301 View A WRONG – DANGEROUS! and there is No Blocking If Boom is Off Ground Under Boom Sections... and Supported by Straps... Boom will COLLAPSE when Lower Pins are Removed! View B WRONG –...

  • Page 47: Personnel Handling Policy

    50 percent of the rated capacity conditions. for the radius and configuration of the crane. Use of a Manitowoc crane to handle personnel is acceptable • The crane is uniformly level within one percent of level provided: grade and located on a firm footing.
  • Page 48 All safety adverse weather conditions which could affect the decals must be in place and legible. We also urge Manitowoc safety of personnel . crane owners to upgrade their cranes with rated capacity •...

  • Page 49: Pedestal/Barge Mounted Cranes

    Carbody on barge. Foundation Manitowoc does not permit use of a truck crane on a barge, ship or floating platform. Pedestal Mounted Crane NOTE: If bolting carbody to foundation, contact your Manitowoc distributor for recommended bolt Also see ASME publication B30.8-2004, Floating Cranes...

  • Page 50: Barge Mounted Crane

    SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Barge Mounted Crane restrained by curbing and end stops (Figure 2-10). When not working, the crane carbody is anchored with Definition tie-downs to the foundation. Traveling with load is not permitted.

  • Page 51: Capacity Charts

    Trim Pitch FIGURE 2-12 Capacity Charts Operation On Barge Manitowoc provides two types of Capacity Charts for a crane General mounted on a barge or other supporting structure under Machine list and/or dynamics will be experienced when a static conditions.

  • Page 52: Crane Inspection

    SAFETY INFORMATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL between horizontal and a line drawn through the required. Correct each defect found before placing the crane centerline of the crane’s boom hinge pins. into service. Unless otherwise specified on the Capacity Chart, barge •...

  • Page 53: Section 3

    Operation Not Permitted ..........3-8 Manitowoc...

  • Page 55: Standard Hand Signals For Controlling Crane Operations

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5a - 2004 USE WHIPLINE. (Auxiliary LOWER. With arm extended HOIST.
  • Page 56 OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL STOP. Arm extended, palm EME RG ENCY STO P. Both T R AV E L . A r m e x t e n d e d DOG EVERYTHING. Clasp...
  • Page 57 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE BLANK Manitowoc Published 4-19-2011, Control # 072-04...
  • Page 58 OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1060 LOAD INDICATOR CONFIRM SELECT Crane Mode Selector Digital Display Drum 5 Park (Luffing Hoist) Has No Drum 3 Working Function Brake Pedal Drum 9 Park (Boom Butt Load Drum)

  • Page 59: General Operation

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES GENERAL OPERATION Boom/Luffing Hoist Park Switches The instructions in this section supplement the operating Enables and disables drum operation for the corresponding control instructions in the Crane Operator’s Manual. This...

  • Page 60: Automatic Jib Stop

    OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL The digital display also displays system faults and operating Select and confirm STANDARD MODE. limits for the luffing hoist and all other crane functions. See NOTE: The operating fault alarm (in operator’s cab) will Digital Displa y R eadings in Section 3 of the Crane come on if the luffing hoist is not parked.

  • Page 61: Wind Conditions - #44 Luffing Jib On #79 Boom

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Read and comply with instructions in Liftcrane Luffing 10. Operate all crane functions slowly and smoothly. Avoid Jib Capacity Charts provided with luffing jib attachment. sudden starts and stops which could side load or shock Do not operate beyond limits given in capacity charts.

  • Page 62: Operation Permitted

    OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Operation Permitted Operation Not Permitted Operation is permitted in steady winds or wind gusts up to 35 • Up to 50 mph (22 m/s) — Park crane (upper in line with mph (16 m/s).
  • Page 63 Wire Rope Storage ..........4-32 Manitowoc...
  • Page 64 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Removing Wire Rope from Shipping Reel ....... 4-32 Seizing and Cutting Wire Rope .

  • Page 65: General Installation And Removal

    KEEP UNAUTHORIZED PERSONNEL WELL CLEAR OF CRANE. Optional boom ladders (stored in boom butt) are available from Manitowoc. If your crane has ladders, see Section 3 in Falling Load Hazard! Operator’s Manual provided with crane. To prevent lifting equipment from failing and load from...

  • Page 66: Counterweight Requirement

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL COUNTERWEIGHT REQUIREMENT REMOVABLE LACINGS See applicable capacity charts and raising procedure charts The 20 ft (6,1 m) and standard 40 ft (12,2 m) #44 inserts are for counterweight requirements when operating with the jib.

  • Page 67: Identifying Straps

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION IDENTIFYING STRAPS A524 The backstay and jib straps are marked for identification as Manitowoc Boom or Jib shown in (Figure 4-2, View C). Part Number Number DRUMS ZZZZZZ-Z Connector...
  • Page 68 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1168 • Pins in Upper Holes for Operation Jib Stops in • Pins in Lower Holes for Shipping and Operating or Handling Jib Stop Assembly Position Support this End of Jib Stops (50 lb - 23 kg)

  • Page 69: Installing Jib

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION JIB RIGGING — #44 LUFFING JIB ON #79 BOOM CAUTION Tipping Crane Hazard! Installing Jib Crane can tip if step 6 is not performed when required. Lower Boom If specified by raising procedure chart, remove following Travel front crawler rollers onto blocking.
  • Page 70 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Fixed A1168 Vertical View B A1077 Typical Jib Sections Removable Lacing (2 each insert) See Figure 4-1 #79 Boom 30 ft (9,1 m) Upper Point 40 ft (12,2 m)

  • Page 71: Install Jib Butt

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Jib Butt Assemble jib inserts in proper sequence — shortest inserts nearest butt (see Luffing Jib Assembly Rigging See Figure 4-4, View A for following procedure. drawing): Raise boom and block approximately 18 in (0,5 m) off Lift first insert into position and engage top ground.
  • Page 72 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1168 Strap Storage Pin Link Link (shipping position (stored) (to working position) Strap Strap Strap Storage Pin (storage position) Connecting View B View A Jib Strut Hinge Pin Lifting Lug...

  • Page 73: Complete Upper Jib Point Roller Installation

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Complete Upper Jib Point Roller Installation Install Jib Strut Assembly See Figure 4-5, View A for following procedure. See Figure 4-5 for following procedure. Attach chain slings from assist crane to lugs at end of jib The main strut and the jib strut are shipped from the factory top.
  • Page 74 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL P1386 Retaining Main Pin with Strut Keeper Plate P1387 Main Boom Strut Latch Hook View C Strut View D View B P1385 Chain Sling from Assist Crane Basic Strut...

  • Page 75: Install Main Strut

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Main Strut Attach wire rope to sucker line, if installed. If sucker line is not installed, reeve luffing hoist wire rope See Figure 4-6 for following procedure. through strut sheaves and guide sheaves as shown in reeving diagram on rigging drawing.
  • Page 76 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Assist Crane A1168 Erection Pendant Erection (disconnected) Pendant Main View B Erection Pendant Strut (to assist crane) Erection Pendant (to Drum 9) ° P1388 Load Line From Drum 9...

  • Page 77: Raise Main Strut

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Raise Main Strut Lower assist crane load block until erection pendant hangs free from top of main strut. See Figure 4-7 for following procedure. Disconnect erection pendant from assist crane.
  • Page 78 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1152 Counterbalance Valve A1168 A1247 2,400 psi (165 bar) P1633a Pressure Control Pilot Valve 2,600 psi (179 bar) Valve Knob System Pressure Gauge 2,900 psi (200 bar) Strut Stop...

  • Page 79: Connect Hydraulic Hoses

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Connect Hydraulic Hoses Connect hoses between ends of boom inserts along entire length of boom (View C). See Figure 4-8 for following procedure. Connect hydraulic hoses from jib strut to couplers on transition insert (View D).
  • Page 80 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Shown Pinned for 100 ft (30,5 m) Jib Length A1168 Outer Connecting 9 10 Link View A Slide Load Pin Shown Locked Hole Hole in Operating Position Jib Length...

  • Page 81: Set Up Adjustable Straps

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Set Up Adjustable Straps Determine correct pinning location for adjustable strap based on desired jib length. (See View A and table in See Figure 4-9 for following procedure. Figure 4-9).
  • Page 82 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1168 View H Main Strut P1630a Strut Stop Cylinder Backstay Basic Cylinder Straps Mounting Backstay Strut Stop Lugs Straps Frame both Sides of Boom Top View K Strut Stop...

  • Page 83: Raise Jib Strut

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Raise Jib Strut Then reposition stop blocks (5, View J) so distance between stop blocks and supports (4) is 5 in See Figure 4-10 for following procedure, unless otherwise (127 mm) as shown in View J-J.

  • Page 84: Install Jib Load Line

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1168 Strut Stop Cylinder Main Strut Strut ° 5 in (127 mm) Cylinder Rod Roller Bottomed Out in Strut Stop Pocket View B View A FIGURE 4-11 Install Jib Load Line...

  • Page 85: Pre-Raising Checks

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION • Adjust automatic boom stop maximum limit switch to 85° Wire rope guard pins, bars, or rollers installed to retain or 87°, depending on boom length, after boom and jib wire rope in sheaves.
  • Page 86 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1174 Numbered items correspond to step numbers for in-line raising procedure View A View B View C View D View E If steps 4 and 5 are not performed,...

  • Page 87: Raising Boom And Jib

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Raising Boom and Jib Install load blocks and/or weight balls (if not already done). As defined in the raising procedure chart, one of two Slowly luff up to raise jib strut until jib straps clear strap methods can be used to raise the boom and jib depending on storage brackets on jib and stop.
  • Page 88 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1174 N u mb e r e d ite ms c o rre s p o n d to s te p numbers for jack-knife raising procedure FIGURE 4-13...

  • Page 89: Jack-Knife Method

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Jack-Knife Method Jib straps and backstay straps will tighten as boom and jib rise. Use following procedure to raise boom and jib with jack- OPERATOR AND SIGNAL PERSON — watch backstay knife method (Figure 4-13).
  • Page 90 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1174 See View E View B View A Numbered items correspond to step numbers for in-line lowering procedure View C If step 6 is not performed, jib View D stop will not swing past boom top into storage position.

  • Page 91: Lowering Boom And Jib

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Lowering Boom and Jib NOTE: It is normal for BLOCK UP, MAX UP 1, and MAX UP 2 limits t o come on during the lowering As defined in the raising procedure chart, one of two procedure.
  • Page 92 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1174 N u m e r e d i t e m s c o r r e s p o n d t o s t e p...

  • Page 93: Jack-Knife Method

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Jack-Knife Method CAUTION Use this procedure to lower the boom and jib with the jack- knife method (Figure 4-15). Structural Damage! • Avoid side loading as boom and jib are lowered.

  • Page 94: Removing Jib

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Removing Jib Lower Main Strut Disconnect erection pendants from storage lugs on main Lower Jib Strut strut (Figure 4-10, View A). Connect one erection pendant to crane load line (Drum 9) (Figure 4-7, View B).

  • Page 95: Remove Jib

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Pin main strut top to jib strut top with latch pin (Figure 4-6, View D). Use assist crane to align holes if necessary. WARNING Rehook chain sling to connect sling to four lifting lugs on Collapsing Boom/Jib Hazard! main strut (Figure 4-5, View D).

  • Page 96: Wire Rope Installation

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL WIRE ROPE INSTALLATION NOTE Wire rope manufacturer’s recommendations take precedence over information in this section. Reel Wire Rope Storage Drum Store wire rope in coils or on reels off the ground or floor in a Brake clean and dry indoor location.

  • Page 97: Anchoring Wire Rope To Drum

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Seizings Wire Rope Type WARNING! Required Preformed Falling Load Hazard! Non-preformed Wire rope can be pulled out of drum if following steps are 7/8 (22 mm) Diameter or Smaller not taken.

  • Page 98: Anchoring Wire Rope To Wedge Socket

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Apply tension to wire rope as it is wound slowly onto Anchoring Wire Rope to Wedge Socket drum. First wrap must be tight against drum flange for approximately three-fourths of drum diameter (see WARNING Figure 4-20).

  • Page 99: Breaking In Wire Rope

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION practice allows the wire rope to form its natural lay and the strands to seat properly. WARNING NOTE Wire rope will stretch during the break-in period, reducing the wire rope’s diameter as the strands Falling Load Hazard! compact around the core.

  • Page 100: Anchoring Wire Rope To Button Socket

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Anchoring Wire Rope to Button Socket and periodically throughout the wire rope’s life from release of the load. See Figure 4-22 for following procedure. When slackness is noted, tightly wind the dead wraps of wire Remove pin from socket.

  • Page 101: Load Block Reeving

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Rope A1189 Clips Sucker Line Sucker Pull Sucker Line with Line Winch or Fork-Lift Truck Wire Rope from Drum P1519 Boom Point Wire Sheaves Rope Load Block Sheaves (EXAMPLE)

  • Page 102: Duplex Hook

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A802 Duplex Hook WARNING Falling Load Hazard! Use only a load block with a capacity equal to or greater 0-30° 0-30° than load to be handled. Avoid overloading bearings of load block sheaves. Attach load to duplex hook so load hangs straight.
  • Page 103 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION NOTE 1: Sheave used only A1193 Drum 9 luffing hoist wire rope. (Boom NOTE 2 Butt) NOTE 2: See Figure 4-27 for guide 9 - O NOTE 3 3 - O sheave positioning.
  • Page 104 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A616 Bolt Clamp Lockwasher Nuts Tighten each side equally to provide an GUIDE SHEAVES equal gap. See NOTE 1 for torque value. LOWER POINT SHEAVES Location of Guide Sheaves with Lead Line...
  • Page 105 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL SET-UP AND INSTALLATION Wire Rope Guide A712 Lower Boom Point Load Block 6 PART 7 PART 8 PART 9 PART See Figure 4-27 for =Suggested Location of Guide Sheave Location Weight for Block-Up Limit...
  • Page 106 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL 14 PART 15 PART 16 PART 17 PART Load Sensing Sheaves Wire Rope Upper Guide Jib Point Dead End Here 18 PART For 2 Parts Dead End Here for...

  • Page 107: Load Block Tieback

    See Figure 4-29 for identification of tieback hole diameter General and shackle size. Manitowoc provides a lug on the front of the rotating bed (Figure 4-29, View A) and on the luffing hoist frame (Figure 4-29, View B) for tieing back the load block when not CAUTION in use.
  • Page 108 SET-UP AND INSTALLATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A769 VIEW A Without Luffing Hoist Item Description Tieback Lug (1-3/4 inch Diameter) Tieback Lug (1-5/16 inch Diameter) Shackle (1-1/2 inch) Shackle (1-1/8 inch) Tieback Sling VIEW B Load Block...

  • Page 109: Section 5

    Every 1,000 Hours or Semiannually (whichever comes first) ....5-4 Each Time Boom and Luffing are Lowered to Ground ..... . . 5-4 Manitowoc Published 4-19-2011, Control # 072-04...

  • Page 111: General Lubrication

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL LUBRICATION SECTION 5 LUBRICATION GENERAL LUBRICATION OVER-LUBRICATION Depending on options the crane or attachment is equipped Over-lubrication is not only wasteful but also harmful: with, some lubrication points given in this section may not •...

  • Page 112: Wire Rope Lubrication

    LUBRICATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL WIRE ROPE LUBRICATION Casing Filled with New wire rope is lubricated during manufacturing, but this Swab and Lubricant. 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.

  • Page 113: Lubrication Points

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL LUBRICATION LUBRICATION POINTS A1152 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 Premium Plus hydraulic oil (MCC #549318). Be sure that jib strut cylinders and supply lines are completely drained before refilling.

  • Page 114: Lubrication Intervals

    LUBRICATION 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL LUBRICATION INTERVALS Item Description Required Service (see Note 1) Every 40 Hours or Weekly (whichever comes first) Weight Ball Swivel Grease. Load Block Sheaves Grease if equipped with fittings. Load Block Trunnion/Swivel Grease if equipped with fittings.

  • Page 115: Section 6

    Adjustment ............6-15 Manitowoc...

  • Page 117: Limit Devices

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL MAINTENANCE SECTION 6 MAINTENANCE LIMIT DEVICES The sending unit for the boom and for the luffing jib are identical in appearance. The two units are different, This section contains maintenance and adjustment however, and must not be interchanged.

  • Page 118: Adjusting Angle Indicators

    MAINTENANCE 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL A1168 Item Description Angle Sending Unit Shorting Plug for Luffing Jib Angle • Left Outboard Side of Luffing Jib Butt Electric Cord Electric Cord to Luffing Angle Sending Unit • Right Inboard Side of Boom Butt...
  • Page 119 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL MAINTENANCE View A #44 Boom or Luffing Jib Butt (left outboard side) Protractor-Level To locate center of boom or jib butt, punch mark two points equally spaced between edges of plate work about 1 ft (0,3 m) apart.

  • Page 120: Replacing Sending Unit Assembly

    MAINTENANCE 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Replacing Sending Unit Assembly Solid State Sensor When replacing an existing pendulum-type potentiometer Replacement sending units can be either the pendulum-type with a current production solid state sensor, take the potentiometer (past production) or the solid state sensor following precautions (see Figures 6-4 and 6-5, View B): (current production).
  • Page 121 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL MAINTENANCE A1049 178° Pendulum-Type Potentiometer 5° M.E.C. #575886 Vendor #CP17-0694-1 0 - Black 3-Pole Receptacle with Protective Cap Luffing Jib Angle Sending Unit 87BA - Green VIEW A 87FA - White A1294 3.2°...

  • Page 122: Automatic Boom Stop Adjustment

    MAINTENANCE 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL AUTOMATIC BOOM STOP ADJUSTMENT Rotate MAX actuator CLOCKWISE in its slots so it does not contact limit switch roller when step 5 is performed. Unless otherwise specified, see Figure 6-7 for following Raise boom: procedure.
  • Page 123 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL MAINTENANCE A487 A1162 Actuator Centerline Boom Angle Position Boom Butt All #79 Boom Lengths with 83° Luffing Jib Removed Less than 200 ft (61 m) of #79 Boom with 85° #44 Luffing Jib Installed 200 ft (61 m) or More or #79 Boom with 87°...
  • Page 124 MAINTENANCE 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Alignment Butt Hole A Alignment Hole B Load Sensor 2 View A Inside Boom Top #79 Boom LIMIT SWITCH WIRING Cord Terminal Wire System Operation J1-1 WHT S1-22 12 Volts DC, System Bus...

  • Page 125: Jib Stop Adjustment - #44 Luffing Jib On #79 Boom

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL MAINTENANCE JIB STOP ADJUSTMENT — #44 LUFFING JIB NOTE: Cord C does not have a shorting plug. ON #79 BOOM Adjustment General See Figure 6-8 for following procedures. The luffing jib attachment is equipped with three limit...

  • Page 126: Operational Checks

    MAINTENANCE 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL MAX UP 2 Limit Adjustment Operational Checks Turn limit bypass key clockwise to bypass MAX UP 1 Make the following operational checks after the boom and jib limit. are raised. Rotate actuator (2) clockwise so MAX UP 2 limit switch Make sure boom and luffing jib angle indicators are roller (3) contacts cam (6) and limit switch clicks open.
  • Page 127 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL MAINTENANCE THIS PAGE BLANK Manitowoc 6-11 Published 4-19-2011, Control # 072-04...

  • Page 128: Block-Up Limit Control

    MAINTENANCE 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL BLOCK-UP LIMIT CONTROL Block-Up Limit Control Deactivated During normal operation, the weight overcomes the spring General force and rotates the actuating lever away from the limit switch lever. This action allows the limit switch to close the The block-up limit control (also called anti two-block device) load drum UP and boom/luffing jib DOWN electric circuits.
  • Page 129 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL MAINTENANCE A1050 Lower Jib Point Limit Switch Assembly Junction Box Upper Jib Point Chain Chain Weight Weight Lift Block Lift Plates Electric Cord #44 Luffing Jib to Reel on Weight Ball Boom Butt...

  • Page 130: Disconnecting Block-Up Limit Control

    MAINTENANCE 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL Two Chains Prevent A1050 Weight from Turning Dead-End Load Line or Slowest Live Line Chain Chain Connecting Shackle Shackle Weight Weight Connecting Lower Luffing Upper Luffing Jib Point (multiple part) Jib Point (1 part)

  • Page 131: Adjustment

    2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL MAINTENANCE BOOM LOWERED: Manually lift each weight — one Lower boom onto blocking at ground level and adjust each at a time — while the engine is running. The load limit switch as follows:...
  • Page 132 THIS PAGE BLANK...
  • Page 133 Manitowoc Distributors ........
  • Page 134 2250 MAX-ER 2000 #44 LUFFING JIB OPERATOR’S MANUAL 2550 Pedestal/Barge Mounted Cranes ......... 2-29 Personnel Handling Policy .

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