Manitowoc 999 Operator's Manual
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Manitowoc 999 Operator's Manual

Luffing jib attachment
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Manitowoc 999
Operator Manual
Luffing Jib Attachment

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  • Page 1 Manitowoc 999 Operator Manual Luffing Jib Attachment...
  • Page 3 The serial number of the crane and applicable attachments (i.e. luffing jib, MAX-ER ) is the only method your Manitowoc dealer or the Manitowoc Crane Care Lattice Team has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator’s cab and each attachment.
  • Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH...

  • Page 5: Table Of Contents

    Manitowoc Dealer........
  • Page 6 TABLE OF CONTENTS 999 LUFFING JIB OPERATOR MANUAL Pin Removal ..............2-20 Disassembly Precaution —...
  • Page 7 999 LUFFING JIB OPERATOR MANUAL TABLE OF CONTENTS Outrigger ..............4-30 Boom-Luffing Jib Rigging.
  • Page 8 TABLE OF CONTENTS 999 LUFFING JIB OPERATOR MANUAL Actuator Rod Replacement ........... . . 6-9 Block-up Limit Installation and Adjustment .
  • Page 9 Manitowoc Dealer........
  • Page 10 999 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 05-15-17, Control # 043-09...

  • Page 11: Section 1

    • Basic Specifications MANITOWOC DEALER CRANE/ATTACHMENT IDENTIFICATION For questions about this manual or the 999 crane, contact An identification label is attached to the outside of the your Manitowoc dealer. If you do not know the contact operator’s cab (see...

  • Page 12: Identification Of Luffing Jib Components

    INTRODUCTION 999 LUFFING JIB OPERATOR MANUAL IDENTIFICATION OF LUFFING JIB COMPONENTS Figure 1-2 for identification of the luffing jib components. See Section 1 of the Crane Operator Manual for identification of crane components. Item Description Front Load Drum Luffing Hoist Drum (rear drum)

  • Page 13: Crane And Luffing Jib Weights

    48 in (1 219 mm) treads (each) 43,260 19 622 COUNTERWEIGHT - UPPER: Box - Side (6 on 999 Series 1; 8 on Series 2; 10 on Series 3) with pins (each) 17,500 7 937 Box - Center - - - - - -...
  • Page 14 INTRODUCTION 999 LUFFING JIB OPERATOR MANUAL Weight Pounds Kilograms 2 ft, 2 in (0,7 m) link (each) with pin - - - 8-1/2 in (216 mm) link (each) with pin - - 9 ft, 1-1/4 in (2,8 m) strap (each) - - - - BOOM NO.
  • Page 15 999 LUFFING JIB OPERATOR MANUAL INTRODUCTION Weight Pounds Kilograms Intermediate fall assembly including wire rope guide 21 ft, 9-1/2 in (6,6 m) basic strap (each) 10 ft (3,0 m) strap with link (each) 20 ft (6,1 m) strap with link (each)
  • Page 16 INTRODUCTION 999 LUFFING JIB OPERATOR MANUAL Weight Pounds Kilograms 1060 ft (323 m) of 7/8 in (22 mm) wire rope - 1.50 lb per ft (2,23 kg/m) 1,590 Luffing Jib Hoist - No. 149 Luffing Jib 900 ft (274 m) of 1 in (25,4 mm) wire rope - 2.00 lb per ft (2,98 kg/m)
  • Page 17 999 LUFFING JIB OPERATOR MANUAL INTRODUCTION Weight Pounds Kilograms WIRE ROPE: 26 mm - 2.28 lb per ft (3,39 kg/m) 1010 ft (308 m) No. 82 or 22EL Boom - - - - - - - - - - - - - -...

  • Page 18: English And Metric Conversions

    INTRODUCTION 999 LUFFING JIB OPERATOR 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 19 999 LUFFING JIB OPERATOR 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 WEIGHT...
  • Page 20 INTRODUCTION 999 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-10 Published 05-15-17, Control # 043-09...

  • Page 21: Section 2

    Personnel Handling Policy ............2-24 Manitowoc...
  • Page 22 999 LUFFING JIB OPERATOR MANUAL Pedestal/Barge Mounted Cranes ........... 2-26 Pedestal Mounted Crane .

  • Page 23: Continuous Innovation

    Used with the safety alert symbol, indicates a hazardous manual is subject to change without notice. If you are in situation which, if not avoided, could result in minor or doubt about any procedure, contact your Manitowoc dealer moderate injury. or the Manitowoc Crane Care Lattice Team.
  • Page 24 SAFETY INFORMATION 999 LUFFING JIB OPERATOR MANUAL Table 2-1 Common Safety Symbols Cut or Crush Hazards Cut Hazard M100090 M100091 M100066 M100065 M100069 M100067 Fire Crush Hazards Extinguisher M100070 M100071 M100072 M100073 M100074 M100082 Explosion Fall Hazards Falling Boom (Crush) Hazards...

  • Page 25: Safety And Information Signs

    999 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION Table 2-2 Miscellaneous Symbols Engine Coolant Diesel Fuel Engine Coolant Engine Oil Level Hydraulic Filter Hydraulic Oil Vent M100271 M100267 M100268 M100269 M100272 M100273 Pump Drive Oil Tire Pressure Level (if equipped) M100270...
  • Page 26 SAFETY INFORMATION 999 LUFFING JIB OPERATOR MANUAL Item Description Steps A1185 Platforms (front and rear) Platforms (side) Catwalk (operator’s cab) Ladder (behind door) Enclosure Doors Platform (between drums) Tool Storage Compartment (front corner of right enclosure) Non-Skid Surfaces Platforms and Steps...

  • Page 27: Crane Access Points

    NOTE: Catwalks are available from Manitowoc for boom and jib sections. General Two optional ladders, stored in 40 ft (12 m) insert Take necessary precaution to prevent slipping and/or falling...

  • Page 28: Operator Manual/Capacity Chart Storage

    Manitowoc cannot foresee all hazards that will arise in the contact your Manitowoc Dealer for the proper manual or field. Therefore, safety remains responsibility of crane capacity charts.

  • Page 29: Read Operator Manual

    Phone Mexico 95-800-843-2763 Because of a program of continuing improvement in product • Phone Universal 973-882-1167 design, Manitowoc reserves the right to change the • Fax 973-882-1717 or 973-882-5155 information and specifications contained in the Operator Manual at any time without notice. If you have any questions •...
  • Page 30 SAFETY INFORMATION 999 LUFFING JIB OPERATOR MANUAL 12. Operator shall perform the following operations before leaving operator’s cab for any reason: Park crane and position upperworks so crane does WARNING not interfere with operation of other equipment. Safety devices and operational aids such as rated b.

  • Page 31: Handling Load

    NOTE: Capacity charts for Manitowoc cranes show the Crane has a firm, uniformly supporting foundation total weight of freely suspended loads for various under all crawlers. Unless otherwise specified in the boom and jib lengths and operating radii.
  • Page 32 SAFETY INFORMATION 999 LUFFING JIB OPERATOR MANUAL b. The load is secured and properly balanced in the h. Do not hoist, lower, or swing the load while slings or the lifting device before lifting the load personnel are on the load or the hook. See more than 3 to 6 in (76 to 152 mm).

  • Page 33: Multiple Load Line Operation

    999 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION o. Engage the luffing hoist pawl when operating with Manitowoc authorizes multiple load line operation for those the luffing jib at a fixed radius. applications requiring it, provided the following steps are performed:...

  • Page 34: Signals

    For operations not covered in the standard signals, or for special situations or emergencies, additional signals Manitowoc provides the following safety devices on its may be required. In those cases, the signals used must cranes: be agreed upon in advance by the operator and the signal person.

  • Page 35: Operational Aids

    Manitowoc provides the following operational aids on its cranes, either as standard equipment or optional equipment. NOTE:...

  • Page 36: Assembling, Disassembling, Or Operating Crane Near Electric Power And Transmission Lines

    The qualified person directing the lift shall establish Electrocution Hazard! procedures to furnish equivalent protection (for Manitowoc cranes are not equipped with all features example, assign an additional signal person to observe required to operate within OSHA 29CFR1926.1408, Table the distance between the boom or load and job site A clearances when the power lines are energized.

  • Page 37: Set-Up And Operation

    999 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION Most overhead power lines ARE NOT insulated. Treat all should be constructed to ensure sufficient clearance is overhead power lines as being energized unless you maintained between crane and power lines. have reliable information to the contrary from the utility Appoint a reliable and qualified signal person, equipped company or owner.

  • Page 38: Electrical Contact

    Some variables you shall know and understand are: repaired or replaced as authorized by Manitowoc or your Manitowoc Dealer. • Proximity devices are advertised to detect the...

  • Page 39: Safe Maintenance

    Never climb onto or off a moving crane. Climb onto and off crane only when it is parked and only with To ensure safe and proper operation of Manitowoc cranes, operator’s permission. they must be maintained according to the instructions...

  • Page 40: Environmental Protection

    28. Unless authorized in writing by Manitowoc, do not alter a battery. the crane in any way that affects the crane’s 14. Avoid battery acid contact with skin and eyes. If contact...
  • Page 41 999 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 2-19 Published 05-15-17, Control # 043-09...

  • Page 42: Boom Disassembly Safety

    SAFETY INFORMATION 999 LUFFING JIB OPERATOR MANUAL BOOM DISASSEMBLY SAFETY blocking, individual pin connections may still be under load. Pins can be ejected forcefully if the boom has any pressure NOTE: The term boom used in the following instructions on it or if the boom is not supported properly.
  • Page 43 999 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION A10415 View A WRONG – DANGEROUS! Typical Crane Shown 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 44: Disassembly Precaution - #22E/22El Boom

    SAFETY INFORMATION 999 LUFFING JIB OPERATOR MANUAL Disassembly Precaution — #22E/22EL Boom Lower boom onto blocking on the ground. Block boom sections on both sides of each connection. Figure 2-5 in the following procedure. If boom to be disassembled is not cantilevered, pay out Always block boom sections so they are securely supported boom hoist line so that line is slack.
  • Page 45 999 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 2-23 Published 05-15-17, Control # 043-09...

  • Page 46: 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 47 • Hoisting personnel within 20 ft (6 m) of a power line that signs must be in place and legible. We also urge Manitowoc is up to 350 kV or within 50 ft (15 m) of a power line that...

  • Page 48: Pedestal/Barge Mounted Cranes

    NOTE: If bolting carbody to foundation, contact your Manitowoc does not permit use of a truck crane on a Manitowoc dealer for recommended bolt barge, ship or floating platform. pattern and for type and quantity of bolts to be used.
  • Page 49 Rear When Parked Carbody Foundation Curbing Foundation FIGURE 2-8 NOTE: Manitowoc does not permit traveling with load. FIGURE 2-9 Crawler-mounted crane working on a timbered area of the barge, ship, or floating platform with the crawlers ® RINGER (crawler mounted,...

  • Page 50: Capacity Charts

    SAFETY INFORMATION 999 LUFFING JIB OPERATOR MANUAL 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 51: Crane Inspection

    999 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION Crane Inspection • Deformation of roller path • Proper hook roller adjustment To aid in preventing harmful and damaging failure as previously indicated, regular inspection for signs of • Deformation or cracks in hook roller hanger overloading in the following load bearing components is •...
  • Page 52 SAFETY INFORMATION 999 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-30 Published 05-15-17, Control # 043-09...

  • Page 53: Section 3

    Wind Conditions ..............3-10 Manitowoc...
  • Page 54 999 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-ii Published 05-15-17, Control # 043-09...
  • Page 55 999 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 05-15-17, Control # 043-09...

  • Page 56: Standard Hand Signals For Controlling Crane Operations

    OPERATING CONTROLS AND PROCEDURES 999 LUFFING JIB OPERATOR MANUAL STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5-2014. Table 3-1Standard Hand Signals for Controlling Crane Operations M100118 M100119 M100120 M100121 M100122 M100123 M100124...
  • Page 57 999 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Item Description HOIST—With forearm vertical, forefinger pointing up, move hand in small horizontal circles. LOWER—With arm extended downward, forefinger pointing down, move hand in small horizontal circles. USE MAIN HOIST—Tap fist on head. Then use regular signals.
  • Page 58 OPERATING CONTROLS AND PROCEDURES 999 LUFFING JIB OPERATOR MANUAL Numbers Correspond to the Luffing Jib Operating Controls A1182 P2101 Left Leg of Boom Butt P2102 Cab Support Outside Right Window FIGURE 3-1 Published 05-15-17, Control # 043-09...

  • Page 59: Luffing Jib Operating Controls

    999 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES LUFFING JIB OPERATING CONTROLS Use the LUFFING JIB SETUP mode during luffing jib assembly and disassembly to bypass the limits identified in See for Location of Controls. Table 3-3. The instructions in this section supplement the operating See the Crane Operator Manual for detailed instructions on control instructions in the Crane Operator Manual.

  • Page 60: Limit Bypass Switch

    OPERATING CONTROLS AND PROCEDURES 999 LUFFING JIB OPERATOR MANUAL 4 – Limit Bypass Switch will remain bypassed for as long as the handle is moved in either direction. This switch bypasses the limits identified in and . • The limits will remain bypassed for 10 seconds Insert key.

  • Page 61: Rear Drum Park Switch

    999 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-3 Bypassable Limit Identification (S/N 9991326 and newer) This Table Applies to Cranes Without Luffing Jib Limit Bypass Switch (5) Limit Bypass Switch (4) External Limit Bypass Switch (4) (momentary key switch)

  • Page 62: Automatic Jib Stops (Not Shown)

    OPERATING CONTROLS AND PROCEDURES 999 LUFFING JIB OPERATOR MANUAL Automatic Jib Stops (not shown) Luffing Jib Down Limits— Luffing Jib Up Limits— Two luffing jib up limits are provided: WARNING • LUFFING JIB MAX UP 1 limit which automatically stops...

  • Page 63: Operating Precautions

    999 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES The boom can be lowered after the limit is contacted. Read and comply with instructions in this manual and in Crane Operator Manual. Read and comply with Maximum Allowable Travel Specifications in Luffing Jib Capacity Chart Manual.

  • Page 64: Wind Conditions

    OPERATING CONTROLS AND PROCEDURES 999 LUFFING JIB OPERATOR MANUAL WIND CONDITIONS Wind speed (to include wind gusts) must be monitored by job planners and supervisors. Wind adversely affects lifting capacity and stability. The Be aware that wind speed at boom or jib point can be greater result could be loss of control over the load and crane, even than wind speed at ground level.

  • Page 65: Section 4

    Assemble-in-air Raising Procedure ..........4-30 Manitowoc...
  • Page 66 999 LUFFING JIB OPERATOR MANUAL Danger Tag..............4-30 Signal Person .

  • Page 67: Luffing Jib Attachment

    Either the Model 999 or an assist crane can be used to install • Maintain communication between operator and and remove the jib. If the Model 999 is used, it must be in the assemblers to avoid accidents. setup configuration (same as when installing counterweights •...

  • Page 68: Counterweight Requirement

    SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL COUNTERWEIGHT REQUIREMENT IDENTIFYING BOOM/JIB COMPONENTS See applicable Luffing Jib Capacity Charts and Raising Boom and jib sections are marked for proper identification as Procedure Charts for counterweight requirements when shown in Views A and B, Figure 4-1.
  • Page 69 999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Use nylon tie-downs to secure components as shown in When securing boom sections, wrap tie-downs over Figure 4-2, View A. chords — never over lacings. Keep tie-downs as close to blocking as possible (View A) to prevent bending the If chain tie-downs are used, install protective covering chords.
  • Page 70 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Upper Wire Rope A1204 Guide Must Be Item Description Removed Guide Roller Shaft with Cotter Pins Storage Pin with Snap Pins Pin with Cotter Pins Lifting Slings Lifting Lug (4 places) Keeper Plate with Screws and Lock...

  • Page 71: Luffing Jib Rigging Guide - #149 Jib

    Figure 4-3 for the following procedure. Contact the Manitowoc Crane Care Lattice Team for Attach lifting slings (5) from assist crane to four lifting details. lugs (6, View D) on jib strut (pass slings through opening Check that all boom inserts and boom straps are in main strut).
  • Page 72 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL 14 Stored Main 14 Rigging Strut Position VIEW A-A Boom Strut VIEW A Butt Item Description Lifting Slings Lifting Lugs (4 places) Pin with Cotter Pins Strut Support VIEW B Pin with Snap Pins...

  • Page 73: Connect Main Strut To Boom Top

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Connect Main Strut to Boom Top Rotate strut support (16) to assembly position and install pins (15, View C). Figure 4-4, View A for the following procedure. Remove pins (17, View B) from strut supports.
  • Page 74 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL 1 – Top VIEW A 1 – Bottom Slings from VIEW B Assist Crane Upper Point Roller Assembly Insert Upper Point Roller Assembly VIEW C Item Description Item Description Connecting Pin with Snap Pins Link with Pin —...

  • Page 75: Install Jib Top

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Install Jib Top Rotate links (24) forward and pin to adjacent straps with pins (26, View E) — pin heads toward outside of jib. Figure 4-5 for the following procedure. Install Jib Backstay Pendants The following procedure assumes that the upper point roller assembly was removed from the jib top for shipping.
  • Page 76 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1204 Route Luffing Hoist Route Luffing Hoist Route Luffing Hoist Wire Rope Around Main Wire Rope Between Main Wire Rope Over Main Right Side of Boom Top Dead-End Wedge Socket Strut Strut Stop Tubes Guide...

  • Page 77: Install Jib Stop Control Cable

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Install Jib Stop Control Cable Pay out luffing hoist wire rope and route under top sheave in boom butt wire rope guide (View C). Figure 4-6, View B for the following procedure.
  • Page 78 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Storage Shipping Shipping VIEW B VIEW A Front Drum Store Pin Storage Load Line (2) Here VIEW C FAR SIDE VIEW D Stored VIEW E 12 Rigging Position VIEW F Main Strut...

  • Page 79: Raise Main Strut/Connect Backstay Pendants

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Raise Main Strut/Connect Backstay Pendants Connect wedge socket (10, View A) to load line from front drum (this is same wedge socket used to anchor Figure 4-7 for the following procedure. load line to jib point).
  • Page 80 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1204 Erection VIEW B VIEW A Item Description Main Strut Pendant — 9 ft, 8 in (2,9 m) VIEW C Basic Backstay Pendant — 20 ft, 1-1/2 in (6,1 m) Pin with Cotter Pin...

  • Page 81: Raise Main Strut/Connect Backstay Pendants (Continued)

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Raise Main Strut/Connect Backstay Pendants • Fixed Jib Point (continued) See Capacity Charts for lifting limitations and required deducts when handling loads from selected locations. Unless otherwise specified, see Figure 4-8 for the remaining steps.
  • Page 82 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1204 Item Description Links Pin with Snap Pins Pin with Snap Pins Jib Links Pendant – 13 ft, 8 in (4,2 m) * Pin with Cotter Pin Pendant – 2 ft, 6 in (0,8 m) *...

  • Page 83: Installing Intermediate Suspension

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Installing Intermediate Suspension  Boom and jib insert straps installed in the proper sequence according to Rigging Drawing. General  Backstay pendants installed in the proper sequence according to Rigging Drawing. Intermediate suspension is required for the following jib lengths: ...
  • Page 84 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1204 View A View C Outer View B Strut Pin Storage Strut Pins Hole Quick-Release Engaged Pin Stored Quick-Release Inner Pin Installed Strut Inner Strut Jib Stop Pendant Fully Extended 9 ft, 6-1/2 in (2,9 m)

  • Page 85: Raising Boom And Jib

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Raising Boom and Jib Preliminary Raising Procedure Figure 4-10 for the following procedure. General Using hand winch on left side of jib top, slacken jib stop control cable until it rests on bottom lacings in jib.
  • Page 86 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1204 CIRCLED NUMBERS CORRESPOND TO IN-LINE RAISING PROCEDURE STEPS FIGURE 4-11 4-20 Published 05-15-17, Control # 043-09...

  • Page 87: In-Line Raising Procedure

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION In-Line Raising Procedure Slowly luff up until backstay pendants and jib straps start to go into tension and stop. It will be necessary to use Figure 4-11 for the following procedure. Circled limit bypass switch if MAX UP 1 limit is on.
  • Page 88 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1204 CIRCLED NUMBERS CORRESPOND TO JACK-KNIFE RAISING PROCEDURE STEPS 6 – 12 in (152 – 305 mm) FIGURE 4-12 4-22 Published 05-15-17, Control # 043-09...

  • Page 89: Jack-Knife Raising Procedure

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Jack-Knife Raising Procedure hoist wire rope (luff down) at a rate of speed that allows backstay pendant connectors nearest you to Figure 4-12 for the following procedure. Circled float up and down 6 – 12 in (152 – 305 mm) above...
  • Page 90 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL 10. Slowly raise boom and jib (boom up) to 85° boom angle. 11. Pay out load line as boom and jib are raised. WARNING 12. Luff up to position jib at required operating radius for load to be handled.

  • Page 91: Lowering Boom And Jib

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Lowering Boom and Jib 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. WARNING...
  • Page 92 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL CIRCLED NUMBERS CORRESPOND TO JACK-KNIFE LOWERING PROCEDURE STEPS 6 – 12 in (152 – 305 mm) FIGURE 4-14 4-26 Published 05-15-17, Control # 043-09...

  • Page 93: Jack-Knife Lowering Procedure

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Jack-Knife Lowering Procedure CAUTION Figure 4-14 for the following procedure. Circled numbers in Figure 4-14 correspond to numbered steps in the Side Loading Hazard! following procedure. Avoid possible structural damage to boom and jib from...

  • Page 94: Final Lowering Procedure

    SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Lowering Struts CAUTION Jib Stop Damage! WARNING Once jib stop pendants start to go into tension, do not lower boom any farther until jack-knife lowering step Moving Part Hazard! performed. Damage to jib stop struts or pendants will Do not stand on boom top or jib butt while main strut is result if struts are over tensioned.

  • Page 95: Removing Jib

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION 12. Pin wedge socket (10, Figure 4-7, View A) to strut b. Slowly lift main strut until it is supported by assist handling pendant and link (7). crane. 13. Haul in front drum load line so load line and strut...

  • Page 96: Assemble-In-Air Raising Procedure

    Assemble-In-Air Raising Procedure — one to attachment raised and lowered must be firm, level to within 1 operate the 999 crane and one to operate the assist crane. A ft in 100 ft (0,3 m in 30 m), and free of ground and overhead qualified signal person shall be provided to coordinate the obstructions.

  • Page 97: Boom-Luffing Jib Rigging

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Boom-Luffing Jib Rigging Lifting Slings The boom, luffing jib, and fixed jib components must be Lifting slings are required to raise the jib with the assist assembled according to the instructions in this section and in crane.
  • Page 98 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Item Description Outrigger Assembly Outrigger Side Beam Crawler Side Frame Pin with Collar and Retaining Pin Collar Storage Lug Jack Pad Screw Jack P1644 View A P1646 View B P1645 View C...

  • Page 99: Prepare Crane And Boom

    (View B). To prevent excessive side load on boom, luffing jib, and Place collar over outrigger pin and secure with collar swing drive, release 999 swing brake and disengage pin (View B). swing lock while rollers are touching ground.
  • Page 100 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL at 30° Lifting Point (typical) A1228 Lifting point varies depending on boom and View C jib length. See View D for lifting points for various boom-jib combinations. CONNECTING LOCATION FOR LIFTING SLINGS FROM ASSIST CRANE...

  • Page 101: Raising Procedure

    FIGURE 4-18 Apply 999 swing brake and engage swing lock. Using assist crane, lift partial jib 1 - 2 ft (0,3 - 0,6 m) off Swinging 999 is not permitted while jib rollers are off ground (Figure 4-19). Assist crane must not exert side ground.

  • Page 102: Raise Boom

    SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Lift with Assist A1228 Crane (typical) Maintain View A 1 - 2 ft (0,3 - 0,6 m) Clearance View B View C Pin Storage Strut Pins Item Description Hole Engaged Outer Stop Strut...
  • Page 103 999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION P1649 P1650 Left Inboard Side View B View C View B A1228 View A Shipping Rotated to rear Stored View D P1652 P1651 View E Item Description View F Jib Insert P1653...

  • Page 104: Attach Jib Top

    21. Disengage swing lock and release swing brake. Using four-point hook-up, lift jib top into place with assist 22. The 999 can now raise the boom and luffing jib to the crane. working position.

  • Page 105: Raise Boom, Luffing Jib, And Fixed Jib

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Also perform Raising Boom and Jib steps in this section to assemble and attach fixed jib to luffing jib. CAUTION Perform the remaining raising steps to include pinning Tipping Hazard! fixed jib stop in operating position, installing load block Make sure luffing jib is within radius specified in or weight ball, and connecting electronic devices.

  • Page 106: Lowering Procedure

    SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Lowering Procedure Lower Boom and Luffing Jib Read and fully understand Jack-Knife Lowering Procedure in Two lowering procedures are provided: this section before proceeding. • Procedure A – Lower Boom and Luffing Jib Perform Jack-Knife Lowering Procedure steps to lower •...

  • Page 107: Lower Boom

    (View E). Figure 4-19 for the following procedure. To prevent excessive side load on boom and jib, release 999 swing brake and disengage swing lock CAUTION while rollers are touching ground. Structural Damage Hazard! Lower jib until rollers are on ground and lifting slings are slack.

  • Page 108: Fixed Jib Rigging Guide - #134 Fixed On #149 Luff

    #149 luffing jib are identical 10. Perform Lowering Struts and Removing Jib steps in as to the #134 jib components used on the 777, 888, and 999 described in this section. liftcrane booms. Be sure to check part numbers of each FIXED JIB RIGGING GUIDE —...
  • Page 109 999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION A1208 30 ft 40 ft (9,1 m) (12,2 m) 50 ft (15,2 m) 50 ft (15,2 m) 60 ft (18,3 m) 60 ft (18,3 m) 70 ft (21,3 m) 70 ft (21,3 m)
  • Page 110 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1208 Spreader Strut Strut Jib Stop Stored Stored Link VIEW B Pendant P1, P2, or P3 Pendant Fixed Luffing Jib Butt Jib Top VIEW A VIEW D VIEW C Point 40 ft (12,2 m) Insert...

  • Page 111: Preparing Boom And Luffing Jib

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Preparing Boom and Luffing Jib Install Jib Pendants Figure 4-23 for the following procedure. The luffing jib must be prepared as follows for fixed jib installation and use: The jib pendants are furnished in matched sets of two and must be installed in matched sets —...

  • Page 112: Installing Load Line

    SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL P546 A1208 Safety Pin Jib Stop Pin (Installed) (Disengaged) P550 Winch P551 VIEW B Control Cable from Jib Stop Pins Shackle VIEW C P552 Pawl Haul In Cable VIEW A Control Cable...

  • Page 113: Installing Electronic Devices

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Pre-Raising Checks perform steps before raising the boom and luffing jib and securely fasten the load line to the jib  Boom and luffing jib properly assembled according to point. instructions in this manual and in Crane Operator See Load Block Reeving in this section for proper Manual.
  • Page 114 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Backstay Fixed Jib A1208 Pendant Strut (P4) VIEW B Link Pendant CIRCLED NUMBERS CORRESPOND TO STEPS IN RAISING BOOM AND JIB PROCEDURE VIEW A VIEW C Safety Pin (STORED) VIEW D P550b...

  • Page 115: Raising Boom And Jib

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Raising Boom and Jib b. Support outer tube (2) with slings from assist crane and remove pins (3, View C) connecting outer tube NOTE: Circled numbers in Figure 4-25 Figure 4-26 to jib strut.
  • Page 116 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1208 CIRCLED NUMBERS CORRESPOND TO STEPS IN RAISING BOOM AND JIB PROCEDURE VIEW G Wedge Socket at Anchor Joint 1-Sheave Load Block Weight Ball 2-PART 1-PART View H View J FIGURE 4-26...

  • Page 117: Raising Boom And Jib (Continued)

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Raising Boom and Jib (continued) b. If not already done, install pins (4, Figure 4-25, View F) to anchor links (5) to luffing jib top. Slowly raise boom — do not raise luffing jib — until...
  • Page 118 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1208 CIRCLED NUMBERS CORRESPOND TO STEPS IN RAISING BOOM AND JIB PROCEDURE VIEW A Figure 4-25 (see VIEW B FIGURE 4-27 4-52 Published 05-15-17, Control # 043-09...

  • Page 119: Lowering Boom And Jib

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Lowering Boom and Jib Slowly lower boom until fixed jib roller just lightly contacts ground. NOTE: Circled numbers in Figure 4-27 correspond to Unpin fixed jib stop. A personnel hoist will be required for numbered steps in the following procedure.

  • Page 120: Removing Fixed Jib

    SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL 11. Disconnect fixed jib backstay pendants: Using an assist crane, support fixed jib strut so it cannot fall. WARNING b. Unpin backstay pendants (P4, Figure 4-25, View B) Collapsing Jib Hazard! from links and lay pendants on ground.
  • Page 121 999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-55 Published 05-15-17, Control # 043-09...

  • Page 122: Load Block Reeving

    SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL LOAD BLOCK REEVING Guide Sheaves Figure 4-28 for identification of the guide sheaves and Load Blocks and Weight Ball other components. The following load blocks and weight ball are available from Once wire rope is routed through guide sheaves, be sure to...
  • Page 123 999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Load Sensing Adapter Sheaves Dead-End Lug 2-Part Load Sensing Dead-End Sheaves Anchor Joint Upper Jib Point 2-Part 1 or 2-Part Weight Ball or 1-Sheave Load Block Fixed Jib Point 1 or 2-Part Reeving...
  • Page 124 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL A1204 Jib Point Wire Rope Guide Upper Luffing Jib Point Wire Rope Guide Left Sheave (typical) Jib Point Center Sheave Lower Jib Point 1-Part Line to Luffing Jib Point Must Be Routed to Upper Point...

  • Page 125: Rigging Winch Operation

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION RIGGING WINCH OPERATION Turn the crane mode selector clockwise and hold until RIG WINCH ON appears in the display as shown in This crane is equipped with an optional hydraulically Figure 1.

  • Page 126: Operating Rigging Winch

    SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Operating Rigging Winch b. Push knob (3) in. Release locking pin (2). Pin the guide sheaves on the bottom of the boom (and luffing jib if used) in the reeving position. See Rigging Remove slack from the rigging rope (pull boom hoist Winch Assembly drawing at the end of this section.

  • Page 127: Wire Rope Installation

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION WIRE ROPE INSTALLATION NOTE: Wire rope installation instructions from various OEM’s are provided at the end of this section. If a Reel conflict exists between the following instructions and the OEM instructions, the OEM instructions apply.

  • Page 128: Anchoring Wire Rope To Drum

    SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Straight Wedge Seizings Outside Drum Wire Rope Type Required Seizing Wire Preformed Rope Non-preformed Place free end of seizing wire in valley between two stands. Then wind seizing wire over free end as shown. Finally, twist Don’t Allow End of...

  • Page 129: Anchoring Wire Rope To Wedge Socket

    999 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Anchoring Wire Rope to Wedge Socket Wraps of First Layer Tight Against Wedge Drum and Against Each Other P448 WARNING Falling Load Hazard! • Inspect all parts prior to use. Do not use parts that are cracked or otherwise defective.
  • Page 130 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL After socket is pinned in place, hoist load slowly so wedge seats tight. Do not shock load socket and wedge. WARNING Falling Load Hazard! Wire rope can break if the following precaution is not observed: •...

  • Page 131: Anchoring Wire Rope To Button Socket

    Securely tighten locking screw. REEVING Figure 4-39 for the following procedure. Some rotation-resistant wire rope supplied by Manitowoc is Button equipped with a No. 1.5 pad eye welded to the leading end of the wire rope. A sucker-line can be attached to the pad eye to make it easier to reeve the load block.
  • Page 132 SETUP AND INSTALLATION 999 LUFFING JIB OPERATOR MANUAL Rope Clips Sucker Line Sucker Pull Sucker Line with Line Winch or Fork-Lift Truck Sucker Line Wire Wire Rope Rope from Drum P1519 A1189 Boom Point Sheaves Wire Rope Load Block Sheaves...

  • Page 133: Section 5

    Lube and Coolant Product Guide ........... . . 5-1 Manitowoc...
  • Page 134 999 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-ii Published 05-15-17, Control # 043-09...

  • Page 135: Lube And Coolant Product Guide

    999 LUFFING JIB OPERATOR MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION LUBE AND COOLANT PRODUCT GUIDE See F2080 at the end of this section. See the publication at the end of this section. Manitowoc Published 05-15-17, Control # 043-09...
  • Page 136 LUBRICATION 999 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-15-17, Control # 043-09...

  • Page 137: Section 6

    Adjustment..............6-14 Manitowoc...
  • Page 138 999 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6-ii Published 05-15-17, Control # 043-09...

  • Page 139: Maintenance And Adjustment

    999 LUFFING JIB OPERATOR MANUAL MAINTENANCE SECTION 6 MAINTENANCE MAINTENANCE AND ADJUSTMENT • Straps • Wire Rope This section contains maintenance and adjustment instructions for the limit devices used with the luffing jib • Load Block and Weight Ball attachment.
  • Page 140 MAINTENANCE 999 LUFFING JIB OPERATOR MANUAL A1205 Lead Wire Seal and Roll Pin (Typical) P1518 Left Side of Boom Jib Butt Boom Top In Hole A Item Description Junction Box Actuator Hole B Limit Switch — MAX UP 1 Limit Switch — MAX UP 2 Limit Switch —...

  • Page 141: Jib Stop Adjustment

    999 LUFFING JIB OPERATOR MANUAL MAINTENANCE JIB STOP ADJUSTMENT adjustments must be checked and readjusted if required each time the attachment is reassembled and when parts are NOTE: Past production design is identified with the jib stop replaced. Seals must be removed to allow readjustment.

  • Page 142: Operational Checks

    MAINTENANCE 999 LUFFING JIB OPERATOR MANUAL After boom and jib are raised, check operation of MAX Make sure boom and luffing jib angle indicators are UP 2 limit following instructions under Operational properly adjusted prior to raising boom and luffing jib.

  • Page 143: Boom And Luffing Jib Angle Indicator Calibration

    999 LUFFING JIB OPERATOR MANUAL MAINTENANCE BOOM AND LUFFING JIB ANGLE INDICATOR CALIBRATION Potentiometer Mounted Inside The angle indicator potentiometers are located inside the P1518 node controllers mounted on the boom top and on the luffing jib top (Figure 6-2).

  • Page 144: Automatic Boom Stop Adjustment

    MAINTENANCE 999 LUFFING JIB OPERATOR MANUAL AUTOMATIC BOOM STOP ADJUSTMENT • Parts are replaced. Maximum Boom Angle WARNING B o o m s t o p l i m i t s w i t c h a s s e m b l y ( 5 ,...
  • Page 145 999 LUFFING JIB OPERATOR MANUAL MAINTENANCE Table 6-1 Angle A Adjusting Rod — Length 81° — #82 Long Reach Boom 2a — 7 in (178 mm) 82° — #22E Open Throat Top 2a — 7 in (178 mm) 83° — #82 or 22EL Heavy Lift Boom 2a —...
  • Page 146 MAINTENANCE 999 LUFFING JIB OPERATOR MANUAL Roller Over-Travel Left Leg VIEW A 9 10 SWITCH OPENED VIEW B SWITCH STORED CLOSED Limit Switch Wiring Past Production Switch Receptacle Function Terminals 1 (green) Max Angle 2 (black) 3 (white) 12 VDC Supply...

  • Page 147: Adjustment

    999 LUFFING JIB OPERATOR MANUAL MAINTENANCE Adjustment Loosen jam nut (3, View B). b. Turn adjusting rod (2a, 2b, or 2c) out against boom Figure 6-4 for the following procedure. butt (1) until limit switch (5) “clicks” open and the NOTE: Reference to LED is past production only.

  • Page 148: Block-Up Limit Installation And Adjustment

    MAINTENANCE 999 LUFFING JIB OPERATOR MANUAL BLOCK-UP LIMIT INSTALLATION AND Operation ADJUSTMENT Figure 6-5 Figure 6-9 for component identification. A block-up limit control (also called anti-two-block device) is NOTE: See wiring diagrams in Boom Wiring Drawing in a two-blocking prevention device which automatically stops Section 4.
  • Page 149 999 LUFFING JIB OPERATOR MANUAL MAINTENANCE A873 Upper Boom Point Limit Switch Assembly Luffing Jib Point Lower Boom Point Limit Switch Assembly Chain 8 ft (2,4 m) Weight Lift Block Chain 6 ft (1,8 m) Weight Ball Weight Lift Plates...

  • Page 150: Disconnecting Block-Up Limit Controls

    MAINTENANCE 999 LUFFING JIB OPERATOR MANUAL Disconnecting Block-Up Limit Controls Removing Jib or Boom Point Shorting plug (SP1, View A, Figure 6-7) is provided on the The junction boxes on the boom and jib points are equipped left front corner of the rotating bed so the block-up limit...

  • Page 151: Maintenance

    999 LUFFING JIB OPERATOR MANUAL MAINTENANCE Two Chains Prevent See Load Block Reeving Drawing Weight Weight from Turning for Suggested Location of Weight Lift Block Chain Shackle Dead-End Load Line Weight or Slowest Live Line Multiple Part Reeving Connecting Dead Ended at Block...

  • Page 152: Adjustment

    MAINTENANCE 999 LUFFING JIB OPERATOR MANUAL Adjustment Hold lever at Dimension A. Hold the roller on the limit switch lever against the Figure 6-9 for the following procedure. actuating lever while performing step 6 Lower the boom onto blocking at ground level and adjust...
  • Page 153 Manitowoc Dealer........
  • Page 154 LUFFING JIB OPERATOR MANUAL Shipping Crane Components ............4-2 Signals.

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