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Manitowoc 999 User Manual
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Manitowoc
Published 05-15-17, Control # 043-09
6-1
1
999 LUFFING JIB OPERA
T
OR MANUAL
MAINTENANCE
6
FIGURE
6-5
#82 Boom Point Shown
Jib Points (Luf
fing and Fixed Similar
Weight
Lift Bl
ock
Weigh
t Ball
Load Block
Limit Switch
Assembly
Upper Boom Point
or
Luffi
ng Jib Point
Lower Boom
Point
Limit Switch
Assembly
Chain
8 ft (2,4 m)
Chain
6 ft (1,8 m)
Weight
Lift Plates
A873
A848
Cable
Cable
Brackets
Cable
Luf
fing Jib Butt
(top view)
Boom Butt
(top view)
FIGURE
6-6
Fixed Jib Butt
(Side view)
Cable Reel
Cable Reel
148
150
Table of Contents
Default Chapter
5
Table of Contents
5
Section 1
11
Crane Data
11
Crane/Attachment Identification
11
Change of Ownership Registration
11
Manitowoc Dealer
11
Crane Orientation
11
Identification of Luffing Jib Components
12
Crane and Luffing Jib Weights
13
English and Metric Conversions
18
Direct Conversion
18
Inverse Conversion
18
Section 2
21
Continuous Innovation
23
Nameplates and Decals
23
Safety Messages
23
General
23
Safety Alert Symbol
23
Signal Words
23
Symbol Identification
23
Safety and Information Signs
25
Maintaining Signs
25
Ordering Signs
25
Crane Access Points
27
General
27
Getting on or off Crane
27
Operator Manual/Capacity Chart Storage
28
General
28
Storing Manuals
28
Safe Operating Practices
28
Read Operator Manual
29
Operator Qualifications
29
Operator Conduct
29
Handling Load
31
Size of Load
31
Attaching Load
31
Lifting/Moving Load
31
Multiple Load Line Operation
33
Signals
34
Safety Devices
34
Holding Load
34
Operational Aids
35
Category 1 Operational Aids
35
Category 2 Operational Aids
35
Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines
36
Electrocution Hazard
36
Set-Up and Operation
37
Electrocution Hazard Devices
37
Electrical Contact
38
Refueling
38
Fire Extinguishers
38
Accidents
38
Safe Maintenance
39
Maintenance Instructions
39
Safe Maintenance Practices
39
Environmental Protection
40
Boom Disassembly Safety
42
General
42
Location
42
Pin Removal
42
Disassembly Precaution - #82 Boom
42
Disassembly Precaution - #22E/22EL Boom
44
Personnel Handling Policy
46
Pedestal/Barge Mounted Cranes
48
Pedestal Mounted Crane
48
Barge Mounted Crane
48
Definition
48
Examples
48
Capacity Charts
50
Shock Loading
50
Operation on Barge
50
Definition
50
General
50
Definitions
50
Crane Inspection
51
Transporting Crane on Barge
51
Section 3
53
Standard Hand Signals for Controlling Crane Operations
56
Luffing Jib Operating Controls
59
Rated Capacity Indicator/Limiter (RCL)
59
Crane Mode Selector
59
Digital Display
59
Limit Bypass Switch
60
Luffing Jib Limit Bypass Switch
60
Rear Drum Park Switch
61
Boom Hoist Control
61
Luffing Hoist Control
61
Boom Angle Indicator
61
10 - Level
61
Automatic Jib Stops (Not Shown)
62
Automatic Boom Stop (Not Shown)
62
Luffing Jib up Limits
62
Luffing Jib down Limits
62
Operating Precautions
63
Wind Conditions
64
Section 4
65
Luffing Jib Attachment
67
Accessing Parts
67
Assist Crane Requirements
67
Crane Weights
67
Operating Controls
67
Counterweight Requirement
68
Blocked Crawlers
68
Rigging Drawings
68
Luffing Jib Raising Procedure
68
Identifying Boom/Jib Components
68
Handling Components
68
Retaining Connecting Pins
68
Pin and Connecting Hole Cleanliness
68
Shipping Crane Components
68
Luffing Jib Rigging Guide - #149 Jib
71
Installing Jib
71
Lower Boom
71
Prepare Crane for Jib
71
Install Jib Stop Strut Assembly
71
Install Jib Butt Assembly
71
Install Jib Stop Pendants
71
Connect Main Strut to Boom Top
73
Raise Jib Strut to Assembly Position
73
Install Jib Inserts
73
Install Jib Top
75
Connect Jib Straps
75
Install Jib Backstay Pendants
75
Install Jib Stop Control Cable
77
Install Luffing Hoist Wire Rope
77
Raise Main Strut/Connect Backstay Pendants
79
Raise Main Strut/Connect Backstay Pendants (Continued)
81
Disconnect Jib Strut from Jib Butt
81
Install Load Lines
81
Connect Electric Cords/Adjust Electronic Devices
81
Installing Intermediate Suspension
83
Pre-Raising Checks
83
General
83
Option a
83
Option B
83
Raising Boom and Jib
85
General
85
Preliminary Raising Procedure
85
In-Line Raising Procedure
87
Jack-Knife Raising Procedure
89
Lowering Boom and Jib
91
In-Line Lowering Procedure
91
Jack-Knife Lowering Procedure
93
Final Lowering Procedure
94
Lowering Struts
94
Removing Jib
95
Assemble-In-Air Raising Procedure
96
Danger Tag
96
Signal Person
96
Counterweight Requirement
96
Outrigger
96
Boom-Luffing Jib Rigging
97
Lifting Slings
97
Assist Crane
97
Prepare Crane and Boom
99
Assemble Partial Luffing Jib
99
Raising Procedure
101
Raise Jib
101
Raise Boom
102
Attach Jib Top
104
Raise Boom and Luffing Jib
104
Raise Boom, Luffing Jib, and Fixed Jib
105
Lowering Procedure
106
Lower Boom and Luffing Jib
106
Lower Boom, Luffing Jib, and Fixed Jib
106
Remove Jib Top
106
Lower Boom
107
Fixed Jib Rigging Guide - #134 Fixed on #149 Luff
108
Preparing Boom and Luffing Jib
111
Installing Jib
111
Install Jib Butt
111
Install Jib Inserts
111
Install Jib Top
111
Install Jib Pendants
111
Install Backstay Pendants
111
Connect Jib Sections to Jib Butt
111
Installing Load Line
112
Connect Jib Stop Control Cable
112
Installing Electronic Devices
113
Pre-Raising Checks
113
Raising Boom and Jib
115
Raising Boom and Jib (Continued)
117
Lowering Boom and Jib
119
Removing Fixed Jib
120
Load Block Reeving
122
Load Blocks and Weight Ball
122
Guide Sheaves
122
Wire Rope Specifications
122
Wire Rope Installation
122
Reeving
122
Rigging Winch Operation
125
Operation
125
Selecting Rigging Mode
125
Operating Rigging Winch
126
Wire Rope Installation
127
Wire Rope Storage
127
Removing Wire Rope from Shipping Reel
127
Seizing and Cutting Wire Rope
127
Anchoring Wire Rope to Drum
128
Winding Wire Rope Onto Drum
128
Anchoring Wire Rope to Wedge Socket
129
Anchoring Wire Rope to Button Socket
131
Breaking in Wire Rope
131
Pad Eye Usage for Wire Rope Reeving
131
Safety
131
Section 5
133
Lubrication
133
Lube and Coolant Product Guide
135
Section 6
137
Maintenance and Adjustment
139
Jib Stop Adjustment
141
General
141
Maintenance
141
Adjustment
141
Preliminary Adjustment
141
Max up 1 Limit Adjustment
141
Max up 2 Limit Adjustment
141
Max down Limit Adjustment
141
Operational Checks
142
Final Adjustment Steps
142
Boom and Luffing Jib Angle Indicator Calibration
143
Automatic Boom Stop Adjustment
144
Maximum Boom Angle
144
Operation
144
Maintenance
144
Bypass Limit Test
144
Adjustment
147
Actuator Rod Replacement
147
Block-Up Limit Installation and Adjustment
148
Operation
148
Installation
148
Storing Electric Cable
148
Block-Up Limit Control Deactivated
148
Block-Up Limit Control Activated
148
Disconnecting Block-Up Limit Controls
150
Removing Jib or Boom Point
150
Maintenance
151
Adjustment
152
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Manitowoc 999 Specifications
General
Brand
Manitowoc
Model
999
Category
Construction Equipment
Language
English
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