Manitowoc 16000 Operator's Manual
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Manitowoc 16000 Operator's Manual

Luffing jib attachment
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Manitowoc 16000
Operator Manual
Luffing Jib Attachment

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  • Page 1 Manitowoc 16000 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 16000 LUFFING JIB OPERATOR MANUAL Boom Disassembly Safety ............2-25 General.
  • Page 7 16000 LUFFING JIB OPERATOR MANUAL TABLE OF CONTENTS Check Strut Stop Pressure ........... . . 4-16 Prepare Strut Stops for Erection .
  • Page 8 TABLE OF CONTENTS 16000 LUFFING JIB OPERATOR MANUAL Maximum Boom Angle ............6-1 Operation .
  • Page 9 Manitowoc Dealer........
  • Page 10 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 05-08-17, Control # 012-17...

  • Page 11: Section 1

    The crane or attachment model, application, and serial number are provided on the plate. If you are the new owner of a Manitowoc crane, please For the exact location of the identification plates on your register it with Manitowoc Crane Care so we can contact you crane and attachments, see Nameplates and Decals if the need arises.

  • Page 12: Identification And Location Of Components

    INTRODUCTION 16000 LUFFING JIB OPERATOR MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS Item Description #58 Boom Main Hoist (Drum 1) Luffing Hoist (Drum 3) Model 16000 Auxiliary Hoist (Drum 2) Boom Hoist (Drum 4) Boom Hoist Wire Rope Live Mast Boom Straps...
  • Page 13 16000 LUFFING JIB OPERATOR MANUAL INTRODUCTION ® With Optional MAX-ER Attachment LJ1-2a FIGURE 1-2 continued Manitowoc Published 05-08-17, Control # 012-17...

  • Page 14: English And Metric Conversions

    INTRODUCTION 16000 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 15: Manitowoc Dealers

    MANITOWOC DEALERS Follow on-screen instructions to locate distributor. When calling a dealer with parts or service questions, To locate the Manitowoc dealer nearest you: you need to know the model and serial number of your Go to www.manitowoc.com. crane or attachment. This information is located on the Crane Identification Plate on the crane cab or on the Click on Manitowoc logo.
  • Page 16 INTRODUCTION 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-08-17, Control # 012-17...

  • Page 17: Section 2

    Disassembly Precaution ............2-25 Manitowoc...
  • Page 18 16000 LUFFING JIB OPERATOR MANUAL Personnel Handling Policy ............2-26 Pedestal/barge Mounted Cranes.

  • Page 19: 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 20 SAFETY INFORMATION 16000 LUFFING JIB OPERATOR MANUAL Crush Hazards Cut or Crush Hazards Electrocution Hazard Cut Hazard Explosion Hazard Fall Hazard FIGURE 2-1 Published 05-08-17, Control # 012-17...
  • Page 21 16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION Engine Diesel Coolant Fuel Engine Coolant Hydraulic Vent Filter Fall Hazards Engine Oil Level Hydraulic Pump Drive Oil Level Fluid Symbols Flying Object Hazards Falling Boom Hazards (Crush Hazard) Overhead Obstruction Hazard Falling Load Hazards...
  • Page 22 SAFETY INFORMATION 16000 LUFFING JIB OPERATOR MANUAL Personal Fall Protection Sound Power Level Read Manual Pressure Cleaning Tire Pressure (if applicable) Pressure Release Hazard FIGURE 2-1 continued Published 05-08-17, Control # 012-17...

  • Page 23: Safety And Information Signs

    16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION SAFETY AND INFORMATION SIGNS Ordering Signs Order replacement safety and information signs from your Maintaining Signs Manitowoc dealer. The crane owner/user shall make sure that all safety and When ordering a sign, give the crane model number, the...
  • Page 24 SAFETY INFORMATION 16000 LUFFING JIB OPERATOR MANUAL A10740-26 Counterweight Boxes Have Non-Skid Surface Operator’s Platform Ladder Behind Enclosure Stairway (2 places) Stairway (2 places) Carbody and Carbody Counterweights Have Alternate Location Grated Non-Skid Surfaces of Stairway (2 places) Platforms (Walkways)

  • Page 25: Crane Access Points

    Falling from any height could result in serious injury or death. GETTING ON OR OFF CRANE Manitowoc has provided stairways, ladders, and platforms at Personnel getting on and off crane shall do so only at steps the locations shown in Figure 2-2.

  • Page 26: Operator Manual/Capacity Chart Storage

    If the serial numbers of your manuals and capacity charts do not match the serial numbers of the crane or attachment, Crush Hazard! contact your Manitowoc dealer for the proper manual or To prevent personnel from being crushed by swinging capacity charts.

  • Page 27: Deploying Swing Radius Barrier

    16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION A13372 View A Swing Radius Barriers WORKING View B Item Description Barrier Arm View D Spring-Loaded Pin View C (2 places) (4 places) Extension Arm Rope or Ribbon (user furnished) View C Swing Radius Barriers STORED...

  • Page 28: Safe Operating Practices

    National Standard, or in any other applicable federal, state, planners, rigging personnel, and job site personnel in safe or local laws. operation. Manitowoc cannot foresee all hazards that will Operator training and qualification is crane owner’s arise in the field; therefore, safety remains responsibility responsibility.
  • Page 29 16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION The operator shall be thoroughly familiar with operation 10. The operator shall verify that the Capacity Chart being of crane and its proper care. If adjustments or repairs are used is the correct one for the cranes configuration necessary or if there are known defects that impair safe (boom length, load line reeving, counterweight, etc.).

  • Page 30: Handling Load

    NOTE: Capacity charts for Manitowoc cranes show the and the like. total weight of freely suspended loads for various boom and jib lengths and operating radii.

  • Page 31: Lifting/Moving Load

    16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION Use suitable protection between slings and any sharp While lifting or moving the load, the operator shall take edges on the load. When synthetic slings are used, the the following precautions: synthetic sling manufacturer's instructions, limitations, Accelerate and decelerate the load smoothly to specifications, and recommendations must be followed.

  • Page 32: Multiple Load Line Operation

    (lower boom point and upper point, boom point and the luffing jib at a fixed radius. fixed jib point, etc). While traveling, the operator shall take the following Manitowoc authorizes multiple load line operation for those precautions: applications requiring it, provided the following steps are performed:...

  • Page 33: Signals

    Section unless indicator(s). communications equipment (telephone, radio, etc.) is Manitowoc recommends that each load line be equipped used. with an anti two-block device. All signals shall be easily understood by the operator at Manitowoc’s Capacity Charts are based on freely all times.

  • Page 34: Safety Devices

    • Always tag-out any faulty safety device and place a Manitowoc provides the following operational aids on its warning tag in the cab stating that the crane is out of cranes, either as standard equipment or optional equipment.

  • Page 35: Category 2 Operational Aids

    16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION d. Clearly mark the boom or luffing hoist cable (so it Refer to the pendulum boom angle indicator on the can easily be seen by a designated signal person) boom butt (viewable from operator’s cab).

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

    WARNING dangerous. Electrocution Hazard! Set-Up and Operation Manitowoc cranes are not equipped with all features required to operate within OSHA 29CFR1926.1408, Table During crane use, assume that every line is energized A clearances (found in the OSHA document) when the (“hot”...

  • Page 37: Electrocution Hazard Devices

    16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION source. This person should have no other duties while insulating characteristics of these devices can be the crane is working. compromised if not kept clean, free of contamination, and undamaged. Taglines should always be made of non-conductive materials.

  • Page 38: Refueling

    Safety information in this publication is intended only as a for any evidence of damage and all damaged parts are guide to assist qualified maintenance personnel in safe repaired or replaced as authorized by Manitowoc or your maintenance. Manitowoc cannot foresee all hazards that Manitowoc dealer.
  • Page 39 16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION Place a warning sign at the start controls alerting 12. Avoid battery explosion: do not smoke while performing other personnel that crane is being serviced and the battery maintenance or short across battery terminals to engine must not be started.

  • Page 40: Environmental Protection

    ENVIRONMENTAL PROTECTION 28. Unless authorized in writing by Manitowoc, do not alter the crane in any way that affects the crane’s Dispose of waste properly! Improperly disposing of waste performance (to include welding, cutting, or burning of can threaten the environment.
  • Page 41 16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 2-23 Published 05-08-17, Control # 012-17...
  • Page 42 SAFETY INFORMATION 16000 LUFFING JIB OPERATOR MANUAL A10415 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 43: Boom Disassembly Safety

    16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION 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 44: 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 45 • 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 46: Pedestal/Barge Mounted Cranes

    If bolting carbody to foundation, contact your on barge. Manitowoc dealer for recommended bolt pattern and for type and quantity of bolts to be Manitowoc does not permit use of a truck crane on a used. barge, ship or floating platform. FIGURE 2-8...
  • Page 47 When Parked Carbody Tie-Downs Carbody Curbing Foundation Foundation NOTE: Manitowoc does not permit traveling with load. FIGURE 2-9 Crawler-mounted crane working on a timbered area of FIGURE 2-10 the barge, ship, or floating platform with the crawlers ® RINGER (crawler...

  • Page 48: Capacity Charts

    SAFETY INFORMATION 16000 LUFFING JIB OPERATOR MANUAL Capacity Charts Manitowoc provides two types of Capacity Charts for a crane mounted on a barge or other supporting structure under WARNING static conditions. Tipping Crane Hazard! A Capacity Chart based on tipping when the crane is...

  • Page 49: Crane Inspection

    16000 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION • Backhitch • Rotating Bed • Wire Rope • Pendants and Straps Through Boom • Hook and House Rollers Hinge Pins When equipped with hook rollers, it is recommended that Horizontal each hook roller assembly be inspected daily for any sign of...
  • Page 50 SAFETY INFORMATION 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-32 Published 05-08-17, Control # 012-17...

  • Page 51: Section 3

    Wind Conditions ..............3-15 Manitowoc...
  • Page 52 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-ii Published 05-08-17, Control # 012-17...
  • Page 53 16000 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 05-08-17, Control # 012-17...

  • Page 54: Standard Hand Signals For Controlling Crane Operations

    OPERATING CONTROLS AND PROCEDURES 16000 LUFFING JIB OPERATOR MANUAL STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5-2014. Table 3-1 Standard Hand Signals For Controlling Crane Operations M100118 M100119 M100120 M100121 M100122 M100123...
  • Page 55 16000 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 56 OPERATING CONTROLS AND PROCEDURES 16000 LUFFING JIB OPERATOR MANUAL A05717 P2101 Left Side of Boom Typical at Boom and Jib Points P2102 Boom Butt Mast Only with ® MAX-ER Crane Item Identification RCI/RCL Display Main Display Drum No Description Limit Bypass Switch...

  • Page 57: General Operation

    16000 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES GENERAL OPERATION 1 – Rated Capacity Indicator/Limiter (RCI/ RCL) Display The instructions in this section supplement the operating control instructions in the Crane Operator Manual. This Read and become thoroughly familiar with Rated Capacity section has two purposes: Indicator/Limiter Operation Guide —...

  • Page 58: Main Display

    OPERATING CONTROLS AND PROCEDURES 16000 LUFFING JIB OPERATOR MANUAL 2 – Main Display LIMIT BYPASS TEST: To determine if the boom up limit can be bypassed on your crane, perform the following test: Read and become thoroughly familiar with Main Display instructions in Section 3 of Operator Manual located in Operator Information Manual in operator’s cab.

  • Page 59: Luffing Jib Down Limits

    16000 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES NOTE: Cranes with 2010 European Requirements have When the limit is contacted, operation an RCL override switch mounted on the rear of the will stop and the jib down prompt operator’s cab (see Rated Capacity Indicator/ (shown to right) will appear on the main Limiter Manual).
  • Page 60 OPERATING CONTROLS AND PROCEDURES 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-08-17, Control # 012-17...

  • Page 61: Limit Bypass Switch

    16000 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 3 – Limit Bypass Switch 10 – Mechanical Boom Angle Indicator This switch bypasses the limits identified in Table 3-2 Shows the angle of the boom in degrees above horizontal Table 3-3 on current production cranes without luffing jib limit (visible through right cab window).
  • Page 62 OPERATING CONTROLS AND PROCEDURES 16000 LUFFING JIB OPERATOR MANUAL Table 3-2 Bypassable Limit Identification This Table Applies Only to Cranes with Limit Bypass Switch (3) and Luffing Jib Limit Bypass Switch (4) Luffing Jib Limit Bypass Switch Limit Bypass Switch (D3)
  • Page 63 16000 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-3 Bypassable Limit Identification This Table Applies Only to Cranes without Limit Bypass Switch (D4) Limit Bypass Switch (D3) External Override Limit Bypass Switch (D3) (momentary key switch) (momentary key switch)
  • Page 64 OPERATING CONTROLS AND PROCEDURES 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-12 Published 05-08-17, Control # 012-17...

  • Page 65: Turning On Luffing Jib Setup Mode

    16000 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES TURNING ON LUFFING JIB SETUP MODE The screen shown in Figure 3-7 will appear. For cranes with software version FCN 2.654 and newer, the Luffing Jib Setup Mode must be turned on before the limits...

  • Page 66: Operating Precautions

    3-8) is at proper setting. For detailed instructions, see Section 4. If pressure is not 11. Do not operate crane, to include raising boom from within specified range, contact your Manitowoc dealer ground level, if wind exceeds limits given in Capacity for assistance.

  • Page 67: Wind Conditions

    16000 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES WIND CONDITIONS Wind speed (to include wind gusts) must be monitored by job planners and supervisors. Wind adversely affects lifting capacity and stability as shown Wind speed at the boom or jib point can be greater than wind Figure 3-9.
  • Page 68 OPERATING CONTROLS AND PROCEDURES 16000 LUFFING JIB OPERATOR MANUAL Forward stability is affected by wind on A910 the rear of the boom. Wind applies a force to the boom and load that adds to the crane’s overturning moment. This action has the same effect as adding load to the hook.
  • Page 69 Wire Rope Installation ............4-39 Manitowoc...
  • Page 70 16000 LUFFING JIB OPERATOR MANUAL Wire Rope Storage ............4-39 Removing Wire Rope from Shipping Reel .

  • Page 71: General Setup And Installation

    Adhere to local, state, and federal This section contains installation and removal instructions for regulations for handling personnel. the #59 luffing jib attachment on a Model 16000 with or ® without MAX-ER attachment.
  • Page 72 SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-08-17, Control # 012-17...

  • Page 73: Counterweight Requirement

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION COUNTERWEIGHT REQUIREMENT See applicable Luffing Jib Capacity Charts and Raising Procedure Charts for counterweight requirements when DANGER operating with jib. Tipping Hazard! Prevent crane from tipping or structural damage to attachment. Do not attempt to raise or lower boom and jib from or to ground until crawlers are blocked.

  • Page 74: Identifying Boom And Jib Components

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL IDENTIFYING BOOM AND JIB Boom and jib pendants are marked for proper identification as shown in View C, Figure 4-1. COMPONENTS Boom straps and links are marked for proper identification as Boom and jib sections are marked for proper identification as...

  • Page 75: Handling Components

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION HANDLING COMPONENTS Handle boom and jib components with care to avoid CAUTION damaging lacings and chords. Lift against chords only, never Personal Injury or Property Damage! against lacings. Ensure the boom straps remain properly secured in the...
  • Page 76 SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-08-17, Control # 012-17...
  • Page 77 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION #58 Boom Section #58 Boom Section 19.7 ft (6 m) or 39.4 ft (12 m) 19.7 ft (6 m) or 39.4 ft (12 m) LJ4-2 Roller with Stop (2 Places) Roller (2 or 4 Places)

  • Page 78: Retaining Connecting Pins

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL RETAINING CONNECTING PINS SHIPPING CRANE COMPONENTS Connecting pins are retained in various ways: To ensure the crane’s self-erecting system can load and unload the carbody and upperworks assembly, the trailer • Snap pins...
  • Page 79 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION LJ4-3b View B Working Position View A LJ4-3a At Boom Butt View C LJ4-3c Shipping Position LJ4-3d View D Lift Here Store Wire Rope in Boom Butt if ® Equipped with MAX-ER...

  • Page 80: Preparing Crane And Boom

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL PREPARING CRANE AND BOOM to Luffing Jib Assembly Drawing. This step is required only if straps are not stored on boom sections. As stated earlier, the instructions in this section assume the If straps are already installed, connect straps at top end boom is already installed.
  • Page 81 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION LJ4-5 Lift Here In Lower Holes Item Description View A Boom Top Strut Install/Shipping Position Jib Stop Shims View B Lifting Lug Outer Tube Retracted Pin with Cotter Pins NO SPRING FORCE...

  • Page 82: Installing Luffing Jib

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL 10. Perform the following steps if lower boom point (9) is Support jib stop (2) with slings from assist crane. installed (Figure 4-7, View E): Remove spring retainer (7, View B) from strut (5).
  • Page 83 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION LJ4-6a View A 7a or 7b Pin Jib Stored Strut Here Pin Jib LJ4-6ab Butt Here Item Description LJ4-6b Boom Top Main Strut Jib Strut View B End Plate with Hex Screws...

  • Page 84: Install Struts

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Install Struts Lift main strut (2) into position at end of boom top (1, View D) and align connecting holes. Figure 4-8 for the following procedure. 10. Install pins (14, View E) to connect main strut (2) to...
  • Page 85 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION LJ4-7a View B View A LJ4-6d View D View C LJ4-7c LJ4-7d Item Description Luffing Hoist in Boom Butt 1a – Installed Guide Pin with Cotter Pin Here Guide Pin with Cotter Pin...

  • Page 86: Install Luffing Hoist Wire Rope

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Install Luffing Hoist Wire Rope See Luffing Jib Rigging Drawing for wire rope specifications. Figure 4-9 for the following procedure. WARNING Make sure wire rope is properly anchored to luffing hoist Explosion Hazard! drum and tightly spooled onto drum.
  • Page 87 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Strut Stop Lower Tube Pin with Cotter Pins Strut Stop Upper Tube Pin with Cotter Pin Pendant Storage Pin with Cotter Pins Cylinder Rod Retaining Pin with Cotter Pins LJ4-8a...

  • Page 88: Prepare Strut Stops For Erection

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Prepare Strut Stops for Erection Figure 4-10 for the following procedure. Attach a sling from assist crane hook to pin in end of WARNING strut stop lower tube (1, View B). Cylinder Movement Hazard Support lower tube with assist crane and remove pin (2).
  • Page 89 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION POSITION POSITION POSITION POSITION POSITION View A LJ4-9a LJ4-9b View B ® With MAX-ER View C LJ4-9d Attachment ® Without MAX-ER 236.2 ft (72 m) Boom, 255.9 ft (78 m) Boom, Attachment 275.6 ft (84 m) Boom,...

  • Page 90: Raise Main Strut (Continued)

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Raise Main Strut (continued) Once main strut is at approximately 45° (POSITION C), slowly haul in Drum 2 load line (3) while paying out Figure 4-11, View A for the following steps.
  • Page 91 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION LJ4-10b POSITION View B LJ4-10c LJ4-10a View A Edge of Lower Tube Close to Being In Line with Hole in Upper Tube. View C Operating Position 70° Maximum View D View E...

  • Page 92: Raise Jib Strut

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Raise Main Strut (continued) g. Check that both cylinder rod retaining pins (9, View D) are loose in holes B. If they are, remove them. Figure 4-12 for the following procedure. h. If they are not loose: 16.
  • Page 93 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION LJ4-11c 12 Storage View B Working Position LJ4-11b LJ4-11d View A View C Shipping Position View D LJ4-11e 5 Storage 6 Storage View E LJ4-11f View F Item Description Item Description Jib Butt...

  • Page 94: Install Jib

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Install Jib Lower jib butt and insert onto blocking so insert is horizontal. Figure 4-13 for the following procedure. Connect Basic Jib Straps Install Jib Butt and First Insert Figure 4-13 for the following procedure.
  • Page 95 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION LJ4-3b View A LJ4-3c Working Position View B Shipping Position View C Lift Here 4 Storage Item Description 5 Storage Insert Fixed Pin LJ4-12b Hooked Connector View E Pin with Safety Pin...

  • Page 96: Install Jib Stop Control Cable

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Complete Jib Assembly Disconnect assist crane. Figure 4-14, View D for the following procedure. Install Jib Stop Control Cable Assemble remaining jib sections in proper sequence as See Jib Stop Assembly Drawing at the end of this section for shown on Luffing Jib Assembly Drawing at the end of detailed instructions.

  • Page 97: Pre-Raising Checks

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Pre-Raising Checks  Proper amount of crane counterweight and, if required, ® MAX-ER counterweight installed. Make the following checks and correct any defects before raising the attachment.  Wind within allowable limits for raising boom and jib.
  • Page 98 SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL NOTE: The intermediate suspension parts are LJ4-13 stored in the luffing jib butt and in the parts box supplied with the luffing jib. Hole Stored 275.6 ft (84 m) Jib With ®...
  • Page 99 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Control Cable Jib Stop Jib Stop Strut View A Spring Retainer Pin with Cotter Pins View B LJ4-14 FIGURE 4-16 Jack-Knife Raising Procedure CAUTION Structural Damage! WARNING Avoid possible structural damage to boom and jib from...
  • Page 100 SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-30 Published 05-08-17, Control # 012-17...
  • Page 101 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION View A Circled Numbers Correspond to Steps in JACK-KNIFE RAISING PROCEDURE LJ4-15a LJ4-15b View B LJ4-15d LJ4-15c View D 145° View C LJ4-15e View E View F LJ4-15f Figure 4-17 Circled numbers in...
  • Page 102 SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Disengage swing lock (past production cranes) and 11. Slowly continue with Jack-Knife Raising Procedure release swing brake. steps 5 - 7 until specified boom to luffing jib angle is reached. Luff up (raise jib strut) until straps are clear of strap supports on butt and first insert (jib strut at approximately 60°).

  • Page 103: Lowering Boom And Luffing Jib

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Circled Numbers Correspond to Steps in JACK-KNIFE LOWERING PROCEDURE LJ4-15e View B LJ4-15f View A View D LJ4-15c 145° View C LJ4-15d LJ4-15a LJ4-15b View F View E Figure 4-18 Lowering Boom and Luffing Jib...
  • Page 104 SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Jack-Knife Lowering Procedure Remove block-up limit weights and chains and connect block-up limit electric cables to terminator plugs on junction boxes. CAUTION b. Securely fasten load lines to jib point so load lines cannot fall off boom and jib.

  • Page 105: Removing Luffing Jib

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION 13. Using hand winch on jib top, haul in control cable until jib b. If equipped, attach terminator plugs to unused stops are clear of jib butt. receptacles. Remove Jib Load Line...

  • Page 106: Remove Jib

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Remove Jib Lifting lugs on counterweight box must be in line with lugs on end of jib strut. Jib removal is the reverse of installation. Attach shackles and suitable lifting slings to lugs on Raise jib stops to “Jib Assembly Position”...

  • Page 107: Store Luffing Hoist Wire Rope

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Under some conditions, it may be necessary to luff up to 21. Continue to lower main strut with assist crane while remove load from tubes. luffing up until main strut is at POSITION A,...

  • Page 108: Store Backstay Straps

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Store Backstay Straps The backstay straps can be stored or shipped on the boom sections as shown in Figure 4-5, View C. WARNING Tipping Hazard! REMOVE BACKSTAY STRAPS from boom sections before operating without a luffing jib.

  • Page 109: Wire Rope Installation

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION WIRE ROPE INSTALLATION NOTE: Wire rope manufacturer’s recommendations take Reel precedence over information in this section. Wire Rope Storage Drum Brake Store wire rope in coils or on reels off the ground or floor in a clean and dry indoor location.

  • Page 110: Anchoring Wire Rope To Drum

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Tighten wedge by rapping back of wedge with a brass drift pin and hammer. Seizings Wire Rope Type Required Drum Guards Preformed Non-preformed The drums are equipped with guards which cover the dead- end sockets on the outside of the drum flanges.

  • Page 111: Winding Wire Rope Onto Drum

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Winding Wire Rope onto Drum Wraps of First Layer Tight Against Wedge See Drum and Lagging Chart in Capacity Chart Manual for Drum and Against Each Other. P448 correct size of drum laggings, if used.
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  • Page 113: Anchoring Wire Rope To Wedge Socket

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Anchoring Wire Rope to Wedge Socket Figure 4-26 for the following procedure. 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.
  • Page 114 SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL T (Rope Clip Nut Torque) Wire Rope/Clip Size TL (Tail Length) inch 1-1/8 1-1/4 Standard 6 to 8 Strand Wire Rope (mm) (22,23) (25,4) (28,58) (31,75) Minimum of 6 rope diameters, Torque but not less than 6 in (152 mm).

  • Page 115: Anchoring Wire Rope To Button Socket

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Anchoring Wire Rope to Button Socket long boom lengths with small fleet angles where the wire rope might stack up along either drum flange. Figure 4-26 for the following procedure. Observe the wire rope during initial break-in and periodically Remove pin from socket.

  • Page 116: General

    Inspect pad eye prior to each use. Replace it if: • Any original dimensions have changed Some rotation-resistant wire rope supplied by Manitowoc is • Cracks or breaks exist in metal or weld equipped with a No. 1.5 pad eye welded to the leading end of the wire rope or to the button on the end of the wire rope.

  • Page 117: Rigging Winch Operation

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION A1189 A09310 Rope Pull Rigging Line Clips with Winch or Fork-Lift Truck Rigging Line Wire Rope from Drum Wire Rope P1519 Boom Point Sheaves Wire Rope Load Block Sheaves EXAMPLE without Button No.

  • Page 118: Operating Rigging Winch

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL In level 3, enter data box and use the select buttons to Pull out locking pin (1) and hold. turn ON rigging winch. Pull out knob (2). The yellow box with “I” icon appears when winch is ON.

  • Page 119: Power Operation

    16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Current Production Rigging Winch Gear Mode Free-Spool Engaged Gear Mode Disengaged Item Description Gear Shifting Lever FIGURE 4-31 Power Operation NOTE: The stall line pull of the rigging winch is regulated with a proportional relief valve controlled by the Turn free spool off and engage gear mode.

  • Page 120: Reeving - Load Block

    SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL Wire Rope Specifications b. Pay out rigging line to slacken load line by pushing Drum 0 handle forward. See Wire Rope Specifications chart in Capacity Chart Disconnect rigging line from load line.
  • Page 121 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Main Hoist (in boom butt) Drum 2 – Whip Hoist (in crane) Drum 3 – Luffing Hoist (in boom butt) Wire Rope Guide (on boom butt) Wire Rope Guide Sheaves (in first insert)
  • Page 122 SET-UP AND INSTALLATION 16000 LUFFING JIB OPERATOR MANUAL LJ4-17 Item Description Wire Rope Guide Sheaves Lower Jib Point Dead-End Link with Pin with Cotter Pin Load Cell – 35,000 lb (13 063 kg) Links with Collars, Retaining Pins, and Cotter Pins Swivel Button Socket –...
  • Page 123 16000 LUFFING JIB OPERATOR MANUAL SET-UP AND INSTALLATION LJ4-31 6 Part 4 Part 2 Part 12 Part 10 Part 8 Part Item Description Wire Rope Guide Sheave Lower Jib Point Load Block Dead-End Socket Two-Block Weight FIGURE 4-34 Manitowoc 4-53...
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  • Page 125: Section 5

    Lubrication ..............5-1 Manitowoc...
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  • Page 127: Section 6

    16000 LUFFING JIB OPERATOR MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION See F2109 at the end of this section. Manitowoc Published 05-08-17, Control # 012-17...
  • Page 128 LUBRICATION 16000 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-08-17, Control # 012-17...
  • Page 129 Adjustment..............6-14 Manitowoc...
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  • Page 131: General Maintenance

    16000 LUFFING JIB OPERATOR MANUAL MAINTENANCE SECTION 6 MAINTENANCE GENERAL MAINTENANCE When the boom is raised to the maximum angle, boom butt (1) pushes adjusting rod (2a or 2b) in and actuator rod (11, This section contains maintenance and adjustment View A) opens limit switch (5).

  • Page 132: Bypass Limit Test

    MAINTENANCE 16000 LUFFING JIB OPERATOR MANUAL Table 6-1 — Automatic Boom Stop Angles Angle A (see Figure 6-1) 83° — #58 Boom without Luffing Jib For Cranes with a Boom Up Limit that Can be Bypassed 87° — #58 Boom with #59 Luffing Jib 84°...
  • Page 133 16000 LUFFING JIB OPERATOR MANUAL MAINTENANCE Centerline of Boom 2a or 2b See Table 6-2 See Table 6-1 Horizontal Right Side of Crane Item Description Boom Butt Switch Assembly FIGURE 6-1 Table 6-2 — Adjusting Rods Adjusting Rod and Length...
  • Page 134 MAINTENANCE 16000 LUFFING JIB OPERATOR MANUAL Roller Over-Travel VIEW A SWITCH OPENED 2a or 2b 2a or 2b VIEW B STORED SWITCH CLOSED Item Description Boom Butt Limit Switch Wiring Adjusting Rod – Boom only Switch Receptacle Function Adjusting Rod – Boom with Luffing Jib...

  • Page 135: Adjustment

    16000 LUFFING JIB OPERATOR MANUAL MAINTENANCE Loosen jam nut (3, View B). Digital Level b. Turn adjusting rod (2a or 2b) all the way into Angle A Angle coupling (4). 83° 75.3° Boom up slowly until the boom reaches the 84°...
  • Page 136 MAINTENANCE 16000 LUFFING JIB OPERATOR MANUAL Deactivated Activated Item Description Edge of Actuator Rod to 0.71 in (18,0 mm) 0.48 in (12,2 mm) Edge of Jib Stop Tube Edge of Actuator Rod to 2.22 in (56,3 mm) 1.99 in (50,5 mm)

  • Page 137: Jib Stop Adjustment

    16000 LUFFING JIB OPERATOR MANUAL MAINTENANCE JIB STOP ADJUSTMENT Jib Maximum Up 1 and 2 Limit Checks Figure 6-4 for the following procedure. Perform the following steps with the boom and luffing jib on the ground: WARNING Check Dimension D1, View A. If necessary, adjust...

  • Page 138: Actuator Rod Replacement

    MAINTENANCE 16000 LUFFING JIB OPERATOR MANUAL Actuator Rod Replacement Fault alarm should come on indicating JIB MAXIMUM UP 1 limit has been reached. Figure 6-5 (Past Production) or Figure 6-6 (Current Turn normal limit bypass key clockwise to bypass Production) for the following procedure.
  • Page 139 16000 LUFFING JIB OPERATOR MANUAL MAINTENANCE View B Switch Activated Current Production Circuit Opened Roller Over-Travel JIB MAXIMUM DOWN Limit Switch Shown View A JIB MAXIMUM UP 2 Limit Switch Opposite Switch Deactivated Circuit Closed Limit Switch Wiring Receptacle Switch Terminals...
  • Page 140 MAINTENANCE 16000 LUFFING JIB OPERATOR MANUAL View A LJ4-16 View B 2-Part Line Dead-End Load Line or Slowest Live Line See Load Block Reeving Diagrams for Suggested Location of Weight 1-Part with Multiple Part Reeving Line View C Item Description...

  • Page 141: Block-Up Limit Installation And Adjustment

    16000 LUFFING JIB OPERATOR MANUAL MAINTENANCE General A1131 Electric Cable To The block-up limit control (also called anti two-block device) Jib Top Node is a two-blocking prevention device which automatically Controller stops the load drum from hoisting and the luffing jib (and...
  • Page 142 MAINTENANCE 16000 LUFFING JIB OPERATOR MANUAL A1237 View A Item Description Dust Cap (3 each) Terminating Plug Dust Cap Terminating Plug Boom Top Node Controller Electric Cable Out to Jib Luffing Jib Min Angle Limit Luffing Jib Max Angle Limit...

  • Page 143: Disconnecting Block-Up Limits

    16000 LUFFING JIB OPERATOR MANUAL MAINTENANCE Disconnecting Block-Up Limits At least once weekly, inspect and test block-up limit switches, as follows: Figure 6-9 for the following procedures. Lower boom onto blocking at ground level and carefully Failing to perform the following steps will prevent load...

  • Page 144: Adjustment

    MAINTENANCE 16000 LUFFING JIB OPERATOR MANUAL Adjustment Manually lift weight to allow actuating lever (6) to rotate Figure 6-10 for the following procedure. Hold lever (6) at Dimension A. NOTE: Past production shown, current production similar. Hold roller (5) on limit switch lever (4) against actuating Adjustment procedure applies to past and current lever (6) while performing step 6.
  • Page 145 Manitowoc Dealer........
  • Page 146 16000 LUFFING JIB OPERATOR MANUAL Reeving – Load Block ............4-50 Refueling .

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