Operator Manual

OPERATORS MANUAL
This manual has been prepared for and is considered part of -
18000
Luffing Jib Model Number
18005910
Luffing Jib Serial Number
This Manual is divided into the following sections:

SECTION 1
SECTION 2
SECTION 3
SECTION 4
SECTION 5
SECTION 6
INTRODUCTION
SAFETY INFORMATION
OPERATING CONTROLS AND PROCEDURES
SET-UP AND INSTALLATION
LUBRICATION
MAINTENANCE
NOTICE
The serial number of the crane and applicable attachments (i.e. luffing jib, MAX-ER)
is the only method your distributor or the factory has of providing you with correct parts
and service information.
The serial number is located on a crane identification decal attached to the operators
cab and each attachment. Refer to the Nameplate and Decal Assembly Drawing (in
Operators Manual) for the exact location of the crane identification decal.
Always furnish serial number of crane and its attachments when ordering parts or
discussing service problems with your distributor or the factory.
To prevent death or serious injury:
Avoid unsafe operation and maintenance.

Crane and attachments must be operated and maintained by trained and
experienced personnel. Manitowoc is not responsible for qualifying
these personnel.
Do not operate or work on crane or attachments without first reading and

understanding instructions contained in Operator Information Manual
and Service Manual supplied with crane and applicable attachments.
Store Operator Information Manual and Service Manual in operators

cab.
If Operator Information Manual or Service Manual is missing from cab,
contact your Manitowoc Crane Care distributor for a new one.
2008 Manitowoc
Published 06-20-08, Control # 033-07
To Contact Us:
Manitowoc Cranes
2401 South 30th Street
Manitowoc, WI 54220
(920) 684-6621
(920) 683-6277 (fax)
http://www.manitowoccranegroup.com/MCG_MC/Home/EN/BrandHome.asp
Grove Worldwide
1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)
http://www.manitowoccranegroup.com/MCG_GRO/Home/EN/BrandHome.asp
National Crane Corporation

P.O. Box 21
(717) 597-8121
(717) 597-4062 (fax)
http://www.manitowoccranegroup.com/MCG_NAT/Home/EN/BrandHome.asp
Grove Worldwide
P.O. Box 21
(717) 597-8121
(717) 597-4062 (fax)
http://www.manitowoccranegroup.com/mcg_pot_am/home/en/brandhome.asp
Technical
Publications
Field
Service
Parts
Factory
Service
Training
18000 LUFFING JIB OPERATORS MANUAL
TABLE OF CONTENTS
See end of this manual for Alphabetical Index

SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Crane data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Crane/attachment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Crane Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Identification And Location Of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Outline Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Crane Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
English And Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Direct Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Inverse Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Manitowoc Crane Care Distributors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information

Diesel Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Nameplates and Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Luffing Jib Attachment Access Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Getting On or Off Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Personnel Fall-Protection Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operators Manual/Capacity Chart Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Storing Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Safe Operating Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Read Operators Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Operator Conduct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Handling Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Operating Near Electric Power Lines And Transmission Lines . . . . . . . . . . . . . . . . . . . 2-13
Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Boom Disassembly Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Pin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Disassembly Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Personnel Handling Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Pedestal/barge Mounted Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Pedestal Mounted Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Barge Mounted Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Index-i
TABLE OF CONTENTS
Capacity Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation On Barge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting Crane on Barge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Information Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-23
2-23
2-24
2-24
2-24
2-25
2-25
2-25
SECTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation
Standard Hand Signals for Controlling Crane Operations . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Luffing Jib Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
1 Crane Mode Select/Confirm Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
2 Drum 4 (Boom Hoist) Park Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3 Drum 6 (Luffing Hoist) Park Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4 Boom Hoist and Whip Hoist Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
5 Luffing Hoist and Swing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
6 Normal Limit Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
7 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
8 Mechanical Boom Angle Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
9 Mechanical Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Automatic Jib Stop (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Wind Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
#44 Luffing Jib on #55-79A Boom with 100 foot (30,5 m) Mast. . . . . . . . . . . . . . . . 3-9
#79A Luffing Jib on #55 or #55A Boom without MAX-ER Attachment . . . . . . . . . 3-10
79A Luffing Jib on #55 or #55A Boom with MAX-ER Attachment . . . . . . . . . . . . . 3-11
SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup And Installation

General Setup and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Accessing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Crane Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Counterweight Requirement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Blocked Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Rigging Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Luffing Jib Raising Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Identifying Jib Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Handling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Retaining Connecting Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Shipping Crane Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Removable Lacings #44 Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Luffing Jib Rigging Guide #44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Assist Crane Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Installing #44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Pre-Raising Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Raising Boom and #44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Lowering Boom and #44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Removing #44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Removing Jib Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Luffing Jib Rigging Guide #79A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Assist Crane Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Index-ii
TABLE OF CONTENTS
Preparing Crane, Boom, and Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Installing #79A Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Raising Boom and #79A Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Lowering Boom and #79A Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Removing #79A Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Wire Rope Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Removing Wire Rope from Shipping Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Seizing and Cutting Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Anchoring Wire Rope to Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Winding Wire Rope onto Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Anchoring Wire Rope to Wedge Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Anchoring Wire Rope to Button Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Breaking in Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
Pad Eye Usage for Wire Rope Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Rigging Winch Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Load Line Reeving - #44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Load Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Guide Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Duplex Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Wire Rope Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Wire Rope Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Reeving Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Load Line Reeving - #79A Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Load Block Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Load Block Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Duplex Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Guide Sheaves and Drums. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Reeving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Block Level Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Over-Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lubrication Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Oil Can Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Approved Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
#44 Luffing Jib Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
#79A Luffing Jib Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Periodic Check of Jib Stop Positioner Hydraulic Oil Level. . . . . . . . . . . . . . . . . . . . . . . . 5-6
SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Jib Stop Adjustment (Past Production) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removing Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Boom Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Index-iii
TABLE OF CONTENTS
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Jib Stop Adjustment (Current Production) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Pre-Erection Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Actuator Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Automatic Boom Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maximum Operating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Boom and Mast Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Actuator Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Adjustment (without luffing jib). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Adjustment (with luffing jib) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Physical Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Boom and Luffing Jib Angle Indicator Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Block-Up Limit Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Block-Up Limit Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Disconnecting Block-Up Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Removing Upper Boom Point or Jib Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Storing Electric Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Index-iv
SECTION 1
INTRODUCTION
TABLE OF CONTENTS
Crane data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Crane Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Direct Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Inverse Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-i
INTRODUCTION
SECTION 1
INTRODUCTION
CRANE DATA
See the end of this section for crane data specific to your
crane:
For the exact location of the identification labels on your

crane and attachments, refer to the Nameplates and Decals
Drawing in Section 2 of this manual.
Basic Specifications.
CRANE ORIENTATION
EC Declaration (if applicable).
The terms RIGHT, LEFT, FRONT, REAR used in this manual

refer to operators right, left, front, and rear sides when
seated in the operators cab looking forward.
CRANE/ATTACHMENT IDENTIFICATION
An identification label is attached to the outside of the
operators cab (see Figure 1-1) and to the attachments (i.e.
luffing jibs, MAX-ERs, and Ringers) available for this crane.
The crane or attachment model, application, and serial
number are provided on the label.
Model
Number
Operators cab is at front of upperworks.
Crawler motors are at rear of lowerworks.
Crawler pin handles on carbody are at front of

lowerworks.
Application:
LIFT = Liftcrane
CLAM = Clamshell
DRAG = Dragline
Serial
Number
FIGURE 1-1
1-1
INTRODUCTION
IDENTIFICATION AND LOCATION OF COMPONENTS

22
23
21
20
24
17
25
16
19a
18
15
13
10
14
12a
10
9
11
7
1a
3a
Item
1a
1b
2
3a
3b
4
5
6
7
8
9
10
11
12a
12b
13
14
15
16
17
18
19a
19b
20
21
22
23
24
25
26
Description
#55-79A Boom
#55 or 55A Boom
Luffing Hoist (Drum 6)
Model 18000 without MAX-ER
Model 18000 with MAX-ER
Mast Straps
#44 Mast 100 ft (39,6 m) OR 140 ft (42,7 m)
Boom Hoist Wire Rope
Boom Hoist Equalizer
Boom Straps
Jib Backstay Straps
Wire Rope Guide
Adapter Frame
Jib Strut Stop
Main Strut Stop
Jib Stop
Main Strut
Luffing Hoist Wire Rope
Jib Strut
Adjustable Jib Strap
Load Lines
#44 Luffing Jib
#79A Luffing Jib
Jib Straps
Lower Jib Point
Wire Rope Guide
Upper Jib Point with Wheels
Hook and Weight Ball
Load Block
Counterweight Straps
1-100
FIGURE 1-2
1-2
INTRODUCTION
22
23
21
20
24
25
18
16
19b
15
14
13
10
9
8
12b
7
6
1b
26
3b
1-101
FIGURE 1-2 continued
1-3
INTRODUCTION
OUTLINE DIMENSIONS
A1=100 ft (30,48 m) Mast = 118 ft, 11 in (36,25 m)

B1=100 ft (30,48 m) Mast = 123 ft, 1 in (37,51 m)
A 2=140 ft (42,67 m) Mast = 157 ft, 3 in (47,93 m)
B 2=140 ft (42,67 m) Mast = 163 ft, 1 in (49,70 m)
B1
or
B2
A1
or
A2
49 ft-5 1/4 in
(15,07m)
5 ft-10 in
(1,78 m)
5 ft
(1,52 m)
23 ft-3 3/4 in
(7,11 m)
21 ft-6 3/4 in
(6,57 m)
8 ft-6 1/4 in
(2,60 m) 6 ft-3 1/4 in
(1,91 m)
1-102
Outline Dimensions Continued on Next Page
1-4
17 ft-10 1/4 in
11 ft-4 1/2 in
(5,44 m)
(3,46 m)
6 ft-9 1/2 in 16 ft-5 in
(5,00 m)
(2,07 m)
INTRODUCTION
33 ft -4 in
(10,16 m)
29 ft-6 3/4 in
(9,01 m)
R 33 ft-4 3/4 in
(10,18 m)
Tailswing
38 ft-9 in
(11,81 m)
52 ft-7 3/4 in
(16,05 m)
9 ft-10 in
(3,00 m)
51 ft-2 3/4 in
15,62 m
19 ft-3 1/2 in
(5,88 m)
1-103
5 ft
(1,52 m)
11 ft-4 1/4 in
(3,46 m)
5 ft
(1,52 m)
1-5
INTRODUCTION
CRANE WEIGHTS
Weight
Pounds Kilograms
Description
LIFTCRANE:
Upperworks and lowerworks complete, 4 swing drives, counterweight, 30 ft (9,1 m) live mast,
backhitch, 100 ft (30,5 m) No. 56 Mast, mast stops, 30 USt (27 t) hook and weight ball, boom stops
and load lines (includes self-erect and MAX-ER prep)
When equipped with fully rigged 120 ft (36,6 m) Boom No. 55-79A, standard upper boom point,
and 500 USt (454 t) block - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - When equipped with fully rigged 120 ft (36,6 m) Boom No. 55 or No. 55A, heavy duty upper boom
point, and 661 USt (600 t) block - - - - - - - - - - - - - - - - - - - - - - - - - - - - UPPERWORKS REAR MACHINERY MODULE:
Rotating bed rear section with pin pullers, upperworks jacking system, 30 ft (9,1 m) live mast, mast
hoist with mast hoist line, Cummins QXF15 power plant, hydraulic reservoir (full), fuel tank
(1/2 full) and operators cab (drum 3 and catwalks removed) - - - - - - - - - - - - - - - - Upperworks jacking system removed - - - - - - - - - - - - - - - - - - - - - - - - - - - ADAPTER FRAME WITH CARBODY:
Rotating bed adapter frame with bearing turntable, 4 swing drives and carbody (includes MAX-ER
prep)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MAST NO. 56 BUTT/TOP SHIPPING PACKAGE:
20 ft (6,1 m) mast butt, boom hoist drum with rope, boom hoist drum guide rollers, wire rope guide
sheave, mast stops, mast butt supports, boom equalizer, 20 ft (6,1 m) mast top with sheaves and
straps (includes MAX-ER prep) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BOOM NO. 55 BUTT SHIPPING PACKAGE:
20 ft (6,1 m) boom butt, load hoist drum with rope, luffing drum with rope, rigging winch with rope,
cable reel, boom stops and boom hinge pin-pullers
- - - - - - - - - - - - - - - - - - - - BOOM NO. 55 - 10 ft (3,0m) INSERT SHIPPING PACKAGE:
10 ft (3,0 m) insert, load hoist drum with rope and wire rope guide - - - - - - - - - - - - - CRAWLERS:
38 ft 9 in (11 811 mm) crawler assembly (each) with drive and 60 in (1 524 mm) treads - - - COUNTERWEIGHT - UPPER:
Tray (each)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Counterweight (28 total) (each) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Rear catwalk with railings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Total upperworks counterweight
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - COUNTERWEIGHT - LOWER:
Counterweight tray (each)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Counterweight (each) (6 total - 3 front, 3 rear) - - - - - - - - - - - - - - - - - - - - - - - - Stairway (each)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Total lowerworks counterweight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 ft (9,1 m) LIVE MAST:
30 ft (9,1 m) mast with straps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MACHINE OPTIONS:
Drum 3 assembly (whip line without rope) - - - - - - - - - - - - - - - - - - - - - - - - - Upperworks jacking system
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Swing drive assemblies (each) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Rotating bed alignment pendants (each)
- - - - - - - - - - - - - - - - - - - - - - - - - LOWERWORKS OPTIONS:
Carbody pedestals with pads (each)
- - - - - - - - - - - - - - - - - - - - - - - - - - - MAST NO. 56:
20 ft (6,1 m) mast butt with boom hoist drum with rope and guide sheave
- - - - - - - - - 20 ft (6,1 m) mast top with sheaves, wire rope guide and straps
- - - - - - - - - - - - - - 40 ft (12,2 m) insert with straps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20 ft (6,1 m) insert with straps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1-6
1,478,930
670 831
1,513,720
686 611
104,435
88,335
47 370
40 068
95,900
43 499
57,800
26 217
57,875
26 251
35,960
16 311
88,255
40 031
12,050
18,000
1,290
528,000
5 465
8 164
585
239 496
28,000
44,000
250
320,000
12 700
19 958
113
145 149
9,660
4 381
5,250
14,700
1,765
65
2 381
6 667
800
29
410
185
33,905
20,485
13,940
8,490
15 379
9 291
6 323
3 850
INTRODUCTION
Weight
Pounds Kilograms
Description
7 ft 1 in (2,2 m) upper backhitch strap (each)
- - - - - - - - - - - 13 ft 4-1/4 in (4,1 m) lower backhitch strap (each) - - - - - - - - - 40 ft (6,1 m) backhitch strap (with connector links) (each) - - - - - 14 ft 8 in (4,5 m) backhitch strap (each) - - - - - - - - - - - - - - Mast stop tube (each) with strut and pins - - - - - - - - - - - - - Mast support (each) - - - - - - - - - - - - - - - - - - - - - - - Wire rope guide (on mast butt for whip line) - - - - - - - - - - - - Wire rope guide (on 20 ft [6,1 m] insert for whip line)
- - - - - - - Boom hoist drum without rope
- - - - - - - - - - - - - - - - - - BOOM NO. 55-79A:
20 ft (6,1 m) butt No. 55
- - - - - - - - - - - - - - - - - - - - - 30 ft (9,1 m) top with straps, upper and lower point and wire rope guide
20 ft (6,1 m) insert No. 79 with straps - - - - - - - - - - - - - - - 40 ft (12,2 m) insert No. 79 with straps
- - - - - - - - - - - - - - 40 ft (12,2 m) transition insert No. 55-79 with links - - - - - - - - - 10 ft (3,0 m) insert No. 55
- - - - - - - - - - - - - - - - - - - - 20 ft (6,1 m) insert No. 55
- - - - - - - - - - - - - - - - - - - - 40 ft (12,2 m) insert No. 55 with sheaves - - - - - - - - - - - - - 28 ft 2-15/16 in (8,6 m) basic strap (each) - - - - - - - - - - - - - 20 ft (6,1 m) strap (with connector links) (each) - - - - - - - - - - 40 ft (12,2 m) strap (with connector links) (each)
- - - - - - - - - Links (attached to equalizer) (each set) with pins
- - - - - - - - - Equalizer with pins - - - - - - - - - - - - - - - - - - - - - - - - Boom stop (each tube) - - - - - - - - - - - - - - - - - - - - - - Drum 1 or 2 assembly (load hoist without rope) - - - - - - - - - - BOOM NO. 55 OR NO. 55A:
20 ft (6,1 m) butt - - - - - - - - - - - - - - - - - - - - - - - - - 30 ft (9,1 m) top with straps, upper and lower point and wire rope guide
10 ft (3,0 m) insert - - - - - - - - - - - - - - - - - - - - - - - - 20 ft (6,1 m) insert - - - - - - - - - - - - - - - - - - - - - - - - 40 ft (12,2 m) insert
- - - - - - - - - - - - - - - - - - - - - - - 40 ft (12,2 m) insert with equalizer rails - - - - - - - - - - - - - - 40 ft (12,2 m) insert (medium)
- - - - - - - - - - - - - - - - - - 40 ft (12,2 m) insert with sheaves - - - - - - - - - - - - - - - - - 28 ft 2-11/16 in (8,6 m) basic strap (each) - - - - - - - - - - - - - 20 ft (6,1 m) strap (with connector links) (each) - - - - - - - - - - 40 ft (12,2 m) strap (with connector links) (each)
- - - - - - - - - Links (attached to equalizer) (each set) with pins
- - - - - - - - - Equalizer with pins - - - - - - - - - - - - - - - - - - - - - - - - Boom stop (each tube) - - - - - - - - - - - - - - - - - - - - - - Drum 1 or 2 assembly (load hoist without rope) - - - - - - - - - - LUFFING JIB NO. 44:
40 ft (12,2 m) butt
- - - - - - - - - - - - - - - - - - - - - - - - 12 ft (3,7 m) lower butt - - - - - - - - - - - - - - - - - - - - - - 28 ft (8,5 m) upper butt - - - - - - - - - - - - - - - - - - - - - - 30 ft (9,1 m) top with straps, upper and lower point
- - - - - - - - 10 ft (3,0 m) insert No. 44
- - - - - - - - - - - - - - - - - - - - 20 ft (6,1 m) insert No. 44
- - - - - - - - - - - - - - - - - - - - 40 ft (12,2 m) insert No. 44 - - - - - - - - - - - - - - - - - - - - Luffing jib adapter
- - - - - - - - - - - - - - - - - - - - - - - - 31 ft 1-3/16 in (9,5 m) basic strap (each)
- - - - - - - - - - - - - 20 ft (6,1 m) strap (with connector links) (each) - - - - - - - - - - 40 ft (12,2 m) strap (with connector links) (each)
- - - - - - - - - Adjustable strap (each) with pins
- - - - - - - - - - - - - - - - -
485
615
1,805
665
1,030
335
490
600
8,110
219
278
818
301
467
151
222
272
3 678
- - - - - - - - - - - - - - -
18,440
26,620
7,260
12,130
12,110
7,680
10,715
19,640
355
290
525
95
3,675
1,795
9,970
8 364
12 074
3 293
5 502
5 493
3 483
4 860
8 908
161
131
238
43
1 666
814
4 522
- - - - - - - - - - - - - - -
18,440
40,700
7,680
10,715
18,485
19,185
13,685
19,640
755
610
1,120
110
3,675
1,795
9,970
8 364
18 461
3 483
4 860
8 384
8 702
6 207
8 908
342
276
508
49
1 666
814
4 522
8,605
4,430
5,305
14,090
1,890
3,215
5,420
4,600
400
290
525
1,565
3 903
2 009
2 406
6 391
857
1 458
2 458
2 086
181
131
238
709
1-7
INTRODUCTION
Weight
Pounds Kilograms
Description
50 ft (15,2 m) jib strut with guide sheave, luffing sheaves and links - - - - - - - - - - - 47 ft (14,3 m) main strut with luffing sheaves and links - - - - - - - - - - - - - - - - - Luffing wire rope guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38 ft 2 in (11,6 m) backstay basic strap (with connector links) (each) - - - - - - - - - - 10 ft (3,0 m) backstay strap (with connector links) (each)
- - - - - - - - - - - - - - - 20 ft (6,1 m) backstay strap (with connector links) (each)
- - - - - - - - - - - - - - - 40 ft (12,2 m) backstay strap (with connector links) (each) - - - - - - - - - - - - - - - 40 ft (12,2 m) transition backstay strap (with connector links) (each) - - - - - - - - - - 10 ft (3,0 m) No. 55 backstay strap (with connector links) (each) - - - - - - - - - - - - 20 ft (6,1 m) No. 55 backstay strap (with connector links) (each) - - - - - - - - - - - - 40 ft (12,2 m) No. 55 backstay strap (with connector links) (each)
- - - - - - - - - - - Backstay link (attached to boom butt) (each)
- - - - - - - - - - - - - - - - - - - - - Luffing jib stop assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Upper point (single sheave) with rollers - - - - - - - - - - - - - - - - - - - - - - - - FIXED JIB NO. 79A:
20 ft (6,1 m) butt No. 79A - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 ft (9,1 m) top with double straps, upper (heavy duty) and lower point and wire rope guide
20 ft (6,1 m) insert No. 79 with double straps
- - - - - - - - - - - - - - - - - - - - - 40 ft (12,2 m) insert No. 79 with double straps - - - - - - - - - - - - - - - - - - - - - 28 ft 2-15/16 in (8,6 m) basic strap (each) - - - - - - - - - - - - - - - - - - - - - - - 20 ft (6,1 m) jib strap with links (each) - - - - - - - - - - - - - - - - - - - - - - - - - 40 ft (12,2 m) jib strap with links (each)
- - - - - - - - - - - - - - - - - - - - - - - - Equalizing link (each)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10 ft (3,0 m) strap (with connector links) (each) (20 degree offset) - - - - - - - - - - - 7 ft (2,1 m) strap (with connector links) (each) - - - - - - - - - - - - - - - - - - - - - 4 ft 9 in (1,4 m) strap with pin (each)
- - - - - - - - - - - - - - - - - - - - - - - - - 4 ft 9 in (1,4 m) link with pin (set each)
- - - - - - - - - - - - - - - - - - - - - - - - 6 ft 2 in (1,9 m) strap with pin (each)
- - - - - - - - - - - - - - - - - - - - - - - - - Jib stop assembly (each) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Jib hinge pins/link assembly (each) - - - - - - - - - - - - - - - - - - - - - - - - - - 29 ft (8,8 m) strut butt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21 ft (6,4 m) strut top - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 ft 5 in (0,4 m) spreader link with pins
- - - - - - - - - - - - - - - - - - - - - - - - 1 ft 10 in (0,6 m) link with pins (each) - - - - - - - - - - - - - - - - - - - - - - - - - 1 ft 10 in (0,6 m) link (each) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 ft 7 in (0,5 m) spreader link with pins (each) - - - - - - - - - - - - - - - - - - - - - Adjustable link with pins (each) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 ft 4 in (2,2 m) backstay strap (each) - - - - - - - - - - - - - - - - - - - - - - - - - 30 ft (9,1 m) backstay strap with links (each)
- - - - - - - - - - - - - - - - - - - - - 20 ft (6,1 m) backstay strap with links (each)
- - - - - - - - - - - - - - - - - - - - - 40 ft (12,2 m) backstay strap with links (each) - - - - - - - - - - - - - - - - - - - - - 10 ft (3,0 m) backstay strap with links (each)
- - - - - - - - - - - - - - - - - - - - - 1 ft 11-1/2 in (0,6 m) backstay link, pins (each set) - - - - - - - - - - - - - - - - - - - LUFFING JIB NO. 79A:
20 ft (6,1 m) butt No. 79A - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 ft (9,1 m) top with double straps, upper (heavy duty) and lower point and wire rope guide
20 ft (6,1 m) insert No. 79 with double straps
- - - - - - - - - - - - - - - - - - - - - 20 ft (6,1 m) insert No. 79 without straps
- - - - - - - - - - - - - - - - - - - - - - - 40 ft (12,2 m) insert No. 79 with double straps - - - - - - - - - - - - - - - - - - - - - 28 ft 2-15/16 in (8,6 m) basic strap (each) - - - - - - - - - - - - - - - - - - - - - - - 20 ft (6,1 m) jib strap with links (each) - - - - - - - - - - - - - - - - - - - - - - - - - 40 ft (12,2 m) jib strap with links (each)
- - - - - - - - - - - - - - - - - - - - - - - - Equalizing link (each)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8.63 in (0,2 m) link, pins (each set)
- - - - - - - - - - - - - - - - - - - - - - - - - - -
1-8
13,285
9,425
1,070
510
175
290
525
525
405
675
1,220
115
1,850
1,220
6 025
4 275
485
231
79
131
238
238
183
306
553
52
839
553
- - - - - - - - - - - - - - - - - - - - - - - - - - - -
10,295
27,780
7,835
13,180
355
290
525
375
355
345
195
185
265
1,890
340
5,325
4,625
690
225
135
535
585
275
865
610
1,120
355
115
4 669
12 600
3 553
5 978
161
131
238
170
161
156
88
83
120
857
154
2 415
2 097
312
102
61
242
265
124
392
276
508
161
52
- - - - - - - - - -
10,315
27,835
7,835
6,700
13,180
355
290
525
375
85
4 678
12 625
3 553
3 039
5 978
161
131
238
170
38
INTRODUCTION
Weight
Pounds Kilograms
Description
17 ft 10-1/2 in (5,4 m) strap (each)
- - - - - - - - - - - - - - - - - - - 1 ft 6 in (0,5 m) link (each)
- - - - - - - - - - - - - - - - - - - - - - - Spreader with pins - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 ft 10-1/4 in (4,2 m) strap - - - - - - - - - - - - - - - - - - - - - - - Spreader link, pins - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 ft 6 in (0,5 m) link (each)
- - - - - - - - - - - - - - - - - - - - - - - 4 ft 2 in (1,3 m) strap, pin (each)
- - - - - - - - - - - - - - - - - - - - Jib hinge pins/link assembly (each) - - - - - - - - - - - - - - - - - - - Jib stop assembly (each) - - - - - - - - - - - - - - - - - - - - - - - - Automatic jib stop assembly
- - - - - - - - - - - - - - - - - - - - - - 30 ft (9,1 m) jib strut top with point sheaves - - - - - - - - - - - - - - - 29 ft (8,8 m) jib strut butt with wire rope guide - - - - - - - - - - - - - - 21 ft (6,4 m) main strut top with point sheaves and raising pendant
- - - 29 ft (8,8 m) main strut butt - - - - - - - - - - - - - - - - - - - - - - - Main strut stop assembly (each)
- - - - - - - - - - - - - - - - - - - - 8 ft 9-1/4 in (2,7 m) strap (each)
- - - - - - - - - - - - - - - - - - - - 4 ft (1,2 m) link with pins (each set) - - - - - - - - - - - - - - - - - - - 3 ft 10-1/2 in (14,2 m) adjustable strap (each) - - - - - - - - - - - - - - 20 ft (6,1 m) backstay strap with link (each) - - - - - - - - - - - - - - - 40 ft (12,2 m) backstay strap with link (each)
- - - - - - - - - - - - - - 10 ft (3.0 m) backstay strap with link (each) - - - - - - - - - - - - - - - 1 ft 11-1/2 in (0,6 m) backstay link with pin (each set)
- - - - - - - - - - Boom dolly with adapter frame, pins
- - - - - - - - - - - - - - - - - - BOOM OPTIONS:
Drum 6 assembly (luffing hoist with rope) - - - - - - - - - - - - - - - - Standard upper boom point (single sheave) - - - - - - - - - - - - - - - Heavy duty upper boom point (single sheave) - - - - - - - - - - - - - - 661 USt (600 t) load block
- - - - - - - - - - - - - - - - - - - - - - - 500 USt (454 t) load block
- - - - - - - - - - - - - - - - - - - - - - - 450 USt (408 t) load block
- - - - - - - - - - - - - - - - - - - - - - - 350 USt (318 t) load block
- - - - - - - - - - - - - - - - - - - - - - - 100 USt (91 t) load block (self-erect)
- - - - - - - - - - - - - - - - - - 30 USt (27 t) hook and weight ball
- - - - - - - - - - - - - - - - - - - 15 USt (14 t) hook and weight ball
- - - - - - - - - - - - - - - - - - - WIRE ROPE:
Mast hoist
1,230 ft (375 m) of 22 mm wire rope - 1.80 lb per ft (2,68 kg/m)
- - - - - Boom hoist
4,370 ft (1 332 m) of 1-1/8 in (28,6 mm) wire rope - 2.60 lb per ft (3,87 kg/m)
Luffing Jib Hoist
1 in (25,4 mm) wire rope - 2.00 lb per ft (2,98 kg/m)
1,700 ft (518 m) No. 44 Luffing Jib
- - - - - - - - - - - - - - - - - - - 3,100 ft (945 m) No. 79A Luffing Jib
- - - - - - - - - - - - - - - - - - Load lines
32 mm wire rope - 3.74 lb per ft (5,57 kg/m)
3,700 ft (1 128 m) Drum 1
- - - - - - - - - - - - - - - - - - - - - - - 3,400 ft (1 036 m) Drum 2
- - - - - - - - - - - - - - - - - - - - - - - 28 mm wire rope - 2.76 lb per ft (4,11 kg/m)
4,800 ft (1 463 m) Drum 1
- - - - - - - - - - - - - - - - - - - - - - - 4,000 ft (1 158 m) Drum 2
- - - - - - - - - - - - - - - - - - - - - - - Whip lines
28 mm wire rope - 2.76 lb per ft (4,11 kg/m)
1,900 ft (579 m) Drum 3
- - - - - - - - - - - - - - - - - - - - - - - - -
495
115
180
850
100
120
380
340
2,715
40
8,790
5,900
8,550
5,365
1,980
260
180
160
610
1,120
360
115
7,800
224
52
81
385
45
54
172
154
1 231
18
3 987
2 676
3 878
2 433
898
117
81
72
276
508
163
52
3 538
11,615
1,115
1,630
25,100
24,500
21,300
17,400
3,900
2,800
1,800
5 268
505
739
11 385
11 113
9 661
7 892
1 769
1 270
816
- - - - - - - - -
2,215
1 004
- - - - - - - -
11,360
5 152
- - - - - - - - - - - - - - - - -
3,400
6,200
1 542
2 812
- - - - - - - - - - - - - - - - -
13,840
12,715
6 277
5 767
- - - - - - - - - - - - - - - - -
13,250
11,040
6 010
5 007
- - - - - - - - -
5,245
2 379
1-9
ENGLISH AND METRIC CONVERSIONS
Inverse Conversion
Direct Conversion
DIVIDE ( / ) known value by conversion factor to obtain

equivalent value in desired units. For example, 3,6576 m is
converted to feet, as follows:
MULTIPLY ( x ) known value by conversion factor to obtain

equivalent value in desired units. For example, 12 ft is
converted to meters (m), as follows:
3,6576 m / 0.3048 = 12
12 ft x 0.3048 = 3,6576 m
To Convert
Symbol
Application
To
Symbol
Multiply By
Filter Area
Clutch Contact
Square Centimeter
cm2
6.4516
Ground Contact
Square Meter
m2
0.0929
AREA
2
Square Inch
in
Square Foot
ft2
FORCE
Pound Force
lb
Pedal Effort
KiloNewton
Newton
kN
N
0.00445
4.4482
Pound Force
lb
Line Pull
KiloNewton
kN
0.00445
Pound Force Per Inch
lb/in.
Newton per millimeter
Nmm
Pound Force Per Foot
lb/ft
Newton per meter
Nm
14.5939
25.4000
Spring Force
0.1751
LENGTH
Inch
in.
Adjustments
Millimeter
mm
Foot
ft
Outline Dimensions
Meter
0.3048
Mile
miles
Travel Distance
Kilometer
km
1.6093
Horsepower
hp
Engine
Kilowatt
kW
0.7457
POWER
PRESSURE
Pound/Sq. In.
psi
Hydraulic & Air
Bar
0.0689
TEMPERATURE
Degrees Fahrenheit
Degrees Centigrade
Oil, Air, Etc.
Degrees Centigrade
F - 32 / 1.8
Degrees Fahrenheit
C x 1.8 + 32
Newton Meter
Nm
0.1129
Newton Meter
Nm
1.3558
TORQUE
Inch Pound
in lb
Foot Pound
ft lb
Miles Per Hour
mph
Vehicle Speed
Kilometers Per Hour
km/h
1.6093
Miles Per Hour
mph
Wind Speed
Meters Per Second
m/s
0.4470
Feet Per Minute
fpm
Line Speed
Meters Per Minute
m/min
0.3048
Cubic Meter
m3
0.7646
Cubic Meter
m3
0.0283
Cubic Centimeter
cm3
16.3871
Bolt Torque
VELOCITY
VOLUME
Cubic Yard
yd3
Cubic Foot
ft3
Cubic Inch
in3
Bucket Capacity
Pump Displacement
To Convert
Symbol
INTRODUCTION
Application
To
Symbol
Multiply By
Milliliter
mL
Liter
0.4732
Liter
0.9464
Liter
3.7854
Liters Per Minute
L/min
3.7854
Kilogram
kg
0.4536
Metric Ton
0.9072
Kilogram
kg
VOLUME (LIQUID)
Ounce
oz
Pint
pt
Quart
qt
Gallon
gal
Gallon Per Minute
gpm
Fluid Capacities
Pump Flow
29.5735
WEIGHT
Pound
lb
US Ton (2,000 lb)
USt
US Ton (2,000 lb)
USt
Unit/Component
Load Ratings
MANITOWOC CRANE CARE DISTRIBUTORS

To locate the Manitowoc Crane Care distributor nearest you:
1.
Go to www.manitowoc.com.
2.
Click on Manitowoc logo.
3.
Click on Dealers.
4.
907.1847
Follow on-screen instructions to locate your Manitowoc

Crane Care distributor.
When calling a distributor with parts or service questions,

you need to know the model and serial number of your crane
or attachment. This information is located on the Crane
Identification Label on the crane cab or on the attachment.
1-11
OPERATORS MANUAL SECTION 1 INSERTS

18000 Luffing Jib Serial Number 18005910
Basic Specs.
08132008
Basic Specs.
Manitowoc Cranes, Inc.

Serial #: 18005910
BASIC SPECIFICATION
TYPE: LUFFING JIB ATTACHMENT
MODEL: 18000 LUFFING JIB
S.O. NUMBER: 1850
SERIAL NO: 18005910
MONTH SHIPPED: AUGUST 2008
BOOM DATA
BOOM LENGTH:
#55/79A BOOM RIGGING

SECTION
PART#
LENGTH
|
|
|
|
|
|
|
|
STRAP
|
|
|
|
|
|
|
|
21949932
2A051982
2A051962
2A051972
2A071112
21798382
61798392
LENGTH
|
|
|
|
|
|
|
|
38 2"
10
20
40
40
20
40
BASIC
JIB
JIB
JIB
JIB
JIB
JIB
BACKSTAY
BACKSTAY
BACKSTAY
BACKSTAY
BACKSTAY
BACKSTAY
BACKSTAY
LUFFING JIB DATA

RIGGING ASSEMBLY: #A07766
JIB TYPE: #44
SECTION
PART #
LENGTH
BUTT:
BUTT:
TOP:
INSERT:
INSERT:
INSERT:
1712837
1712846
1799159
1799129
1799132
1799142
|
|
|
|
|
|
12
28
30
10
20
40
MAIN STRUT: 1941612

JIB STRUT: 1941599
|
|
47 FT |
50 FT |
FT
FT
FT
FT
FT
FT
JIB LENGTH: 140 FT
STRAP
|
|
|
|
|
|
LENGTH
|
|
|
|
|
|
21798402
21798412
21798372
21798382
21798392
31
1"
BASIC
10
20
40
0"
0"
0"
INSERT
INSERT
INSERT
|
|
MACHINE DATA
DRUMS
LUFFING HOIST:
A052742
LAGGING
WEDGE
NONE
196162
ROPE SIZE
1"
LUFFING JIB WIRE ROPE

JIB HOIST:
1700 FT
1" DYFORM 8PI
CAPACITY CHARTS
COUNTERWEIGHT ARRANGEMENTS: 8577A
DRUM AND LAGGING CHART: 8512A
LIFTCRANE BOOM CAPACITIES WITH LUFFING JIB ATTACHED:
LIFTCRANE BOOM CAPACITIES WITH LUFFING JIB ATTACHED:
LIFTCRANE FIXED JIB CAPACITIES ON LUFFING JIB:
LIFTCRANE LUFFING JIB CAPACITIES: 8515AM
MAXIMUM ALLOWABLE TRAVEL SPECIFICATIONS: 8543A
OPERATING RANGE DIAGRAM:
RAISING/LOWERING PROCEDURE: 8542A
RANGE DIAGRAM: A07738
TRAVEL SPECIFICATIONS:
#A141273

Serial #: 18005910
WIND CONDITIONS: FOLIO 2067
WIRE ROPE SPECIFICATIONS: 8516A
SECTION 2
SAFETY INFORMATION
TABLE OF CONTENTS
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Getting On or Off Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Personnel Fall-Protection Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Storing Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Safe Operating Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Read Operators Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Operator Conduct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Handling Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Size of Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Attaching Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Lifting/Moving Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Multiple Load Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Holding Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Electrocution Hazard Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Pin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Disassembly Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Pedestal Mounted Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Barge Mounted Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-i
Capacity Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation On Barge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting Crane on Barge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Information Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-ii
2-23
2-23
2-23
2-24
2-24
2-24
2-24
2-24
2-25
2-25
2-25
SAFETY INFORMATION
SECTION 2
SAFETY INFORMATION
Signal Words
DIESEL ENGINE EXHAUST
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
DANGER
Identifies imminent hazards that will result in death or
serious injury if the message is ignored.
2
WARNING
NAMEPLATES AND DECALS
Identifies potential hazards that could result in death or

serious injury if the message is ignored.
See drawing at the end of this section.
SAFETY MESSAGES
CAUTION
General
The importance of safe operation and maintenance cannot
be over emphasized. Carelessness or neglect on the part of
operators, job supervisors and planners, rigging personnel,
and job site workers can result in their death or injury and
costly damage to the crane and property.
To alert personnel to hazardous operating practices and
maintenance procedures, safety messages are used
throughout the manual. Each safety message contains a
safety alert symbol and a signal word to identify the hazards
degree of seriousness.
Safety Alert Symbol
Identifies potential hazards that could result in minor or

moderate injury if the message is ignored.
CAUTION
Without the safety alert symbol, identifies potential
hazards that could result in property damage if the
message is ignored.
NOTE:
Highlights operation or maintenance procedures.
Safety Symbols
Safety symbols used in the decals on this crane are
identified in Figure 2-1.
This safety alert symbol means ATTENTION!

Become alert your safety is involved! Obey all safety
messages that follow this symbol to avoid possible death
or injury.
2-1
SAFETY INFORMATION
Crush Hazards
Cut or Crush Hazards
Electrocution Hazard
Cut Hazard
Explosion Hazard
Fall Hazard
FIGURE 2-1
2-2
SAFETY INFORMATION
Engine
Coolant
Diesel
Fuel
Engine
Coolant
Vent
Hydraulic
Filter
Fall Hazards
Engine
Oil Level
Pump Drive
Oil Level
Hydraulic
Oil
Fluid Symbols
Flying Object Hazards

Falling Boom Hazards
(Crush Hazard)
Overhead Obstruction Hazard
Falling Load Hazards

(Crush Hazard)
Power Line Hazard

(Electrocution)
Fire Extinguisher
2-3
SAFETY INFORMATION
Personal Fall Protection
Sound Power Level
Read Manual
Pressure Cleaning
Tire Pressure
Pressure Release Hazard

2-4
SAFETY INFORMATION
LUFFING JIB ATTACHMENT ACCESS

POINTS
To reduce the risk of slipping, non-skid material (sand in

paint) has been applied to painted walkways and
platforms. However, walkways and platforms can be
slippery when wet and when oil or grease is spilled on
them. Keep walkways and platforms clean and dry to
prevent slipping on them. When non-skid material
wears out, reapply it.
Wear shoes with a highly slip-resistant sole material.

Clean any mud or debris from shoes before entering the
crane cab or climbing onto the crane. A shoe that is not
clean might slip off a control pedal during operation.
Do not make modifications or additions to the cranes

access system that have not been evaluated and
approved by Manitowoc.
Do not use top of mast, boom, or jib as walkways (unless

they have optional catwalks).
DANGER
Crushing Injury Hazard!
Upperworks can swing into and crush personnel climbing
on or off crane.
Moving crawlers can crush personnel climbing on or off
crane.
To prevent death or serious injury:
Barricade all accessible areas to crane so personnel
cannot be struck or crushed when upperworks is swung.
Do not climb on or off crane while upperworks is

being swung or crane is being traveled.
Signal operator that you need to climb on or off crane.
Operator: do not swing or travel while personnel are

climbing on or off crane. Stop swing and travel
motions. Apply swing brake and turn on travel park.
Operator: Always sound horn to alert personnel

before you swing or travel.
NOTE:
Optional walkways (catwalks) are available for the

boom and luffing jib sections, but only for those
countries that authorize their use.
Two ladders, stored in insert next to boom butt, are
available for boom assembly and disassembly. See
Boom Ladder Assembly in Section 4 of crane
Operators Manual for instructions.
Getting On or Off Crane
General
Take necessary precautions to prevent slipping and/or falling
off the crane during assembly, disassembly, maintenance, or
other work. Falling from any height could result in
serious injury or death.
Manitowoc has provided steps, ladders, catwalks, and
platforms at the locations shown in Figure 2-2.
The owner/user must provide workers with approved ladders
or aerial work platform to access those areas of the crane
that cannot be reached from the ground or from steps,
ladders, catwalks, and platforms provided by Manitowoc.
Adhere to local, state, and federal regulations for handling

personnel and for personnel fall protection.
Access points must be kept clear to prevent personal

injury and unsafe operation of crane. Store clothing and
other personal belongings so they do not interfere with
controls in operators cab or with operation of crane.
Tools, oil cans, spare parts, and other necessary

equipment must be stored in tool boxes or other
appropriate locations. Do not allow these items to lie
around loose in operators cab or on steps, ladders,
catwalks, and platforms.
Personnel getting on and off the crane shall do so only at the

steps provided and only while crane is parked.
Never climb onto or off a moving crane. Climb onto and off
crane only when it is parked and only with operators
permission.
When personnel use ladders to get on or off the crane, their
hands shall be free of any objects. Objects which cannot be
carried in pockets or tool belts shall be lifted into place with a
hand line or hoist.
Personnel Fall-Protection Anchors

Manitowoc has provided fourteen anchors on the
upperworks (Figure 2-2) to which workers can attach their
personnel fall-protection equipment.
WARNING
Fall Hazard!
Anchors are designed to handle only one person at a
time.
Dot use anchors for lifting or pulling loads.
2-5
SAFETY INFORMATION
A1119
Anchors for personnel fall-protection equipment:

4 Places Front of Rotating Bed
3 Places on Engine Covers
3 Places on Rear of Rotating Bed (under mast)
2 Places Each Upper Counterweight Tray
Counterweight
Boxes Have NonSkip Surfaces
Ladder
Steps Both Sides

of Both Carbody
Counterweights
P1951
Ladder
Operators
Cab
Steps
Carbody Has
Non-Skip
Surface
Steps
Shaded Areas
Indicate Steps
and Walkways
Ladder
Both Sides
Counterweight Boxes
and Trays Have
Non-Skip Surfaces
2-100
FIGURE 2-2
2-6
SAFETY INFORMATION
OPERATORS MANUAL/CAPACITY CHART

STORAGE
General
Manitowoc provides the following manuals and other
important literature with your crane and attachment (Luffing
Jib, etc.):
Operators Manual (Serial Numbered)

Contains safety information, crane specifications,
assembly/erection procedures, operating instructions,
lubrication and maintenance checks.
Parts Manual (Serial Numbered)

Contains illustrations and part numbers of replaceable
parts.
Capacity Chart Manual (Serial Numbered)

Contains lifting capacities and related information (wire
rope specifications, drum and lagging information, etc.)
Maintenance Checks and Lube Guide

Contains lists of maintenance checks and lube services
and their prescribed intervals.
Rated Capacity Indicator/Limiter Operation

Contains Load capacity operation and calibration
procedures.
Service Manual (Serial Numbered)

Contains theory of operation, maintenance procedures,
troubleshooting information, and shop procedures.
Vendor Instructions Manual (Serial Numbered)

Contains OEM instructions for servicing purchased
components, (engines, pumps, valves, etc.).
If the serial numbers of your manuals and capacity charts do

not match the serial numbers of the crane or attachment,
contact your Manitowoc Crane Care distributor for the proper
manual or capacity charts.
Do not operate crane or attachment if proper Capacity

Chart is not in cab.
Storing Manuals
Store the Operator Information Manuals for the crane and
each applicable attachment on the bookshelf in the
Operators cab (Figure 2-3).
Attach the chain from the manual in use to the link behind the
operators seat.
Keep all other manuals provided with the crane in the crane
owners/users office so they are readily available when
needed.
Operator Information
Manual
P431a
The manuals which must be retained in the operators cab

(Operators Manual, Capacity Charts, Maintenance Checks
and Lube Guide, and RCL Operation) are supplied in a
OPERATOR INFORMATION binder. A separate binder is
provided for the crane and each applicable attachment.
The Operators Manuals and Capacity Charts are stamped
with the serial number of the crane or attachment. The serial
number on the manuals and capacity charts must match the
serial number of the crane and attachment in use. Using any
other manual or capacity chart is prohibited.
The crane model and serial number is located on the

Crane Identification Label on the crane cab.
The model and serial number of the attachment (other

than standard boom) is located on the Crane
Identification Label on the attachment.
Bookshelf Behind
Operators Seat
Link
Chain Ring
P431b
FIGURE 2-3
2-7
SAFETY INFORMATION
their duties require them to do so, and then only

with knowledge of the operator or other qualified
person.
SAFE OPERATING PRACTICES

General
The importance of safe operation cannot be over
emphasized. Carelessness and neglect on the part of
operators, supervisors and planners, rigging personnel and
job site personnel can result in their death or injury and costly
damage to the crane or property.
The safety information in this publication is intended only as
a guide to assist qualified operators in safe operation.
Manitowoc cannot foresee all hazards that will arise in the
field; therefore, safety remains responsibility of crane
operators and owner.
Qualified person is defined as one who by reason of

training and experience is thoroughly familiar with crane
operations and the hazards involved. Such a person shall
meet the operator qualifications specified in OSHA
Regulations (United States Federal Law), in ASME B30.5
American Nation Standard, or in any other applicable
federal, state, or local laws.
Operator training and qualification is crane owners
responsibility.
NOTE:
Local, state, and other governmental agencies may require

stricter operating practices. When a conflict in practices
exists, follow the strictest practice.
US DOL/ OS HA R ules and R eg ulat ions are

available by mail from the Superintendent of
Documents, PO Box 371954, Pittsburgh, PA,
15250-7954 or by:
Read Operators Manual

Safe and efficient operation of this crane requires that it be
maintained in proper working order and that its operators and
maintenance personnel be familiar with the crane's functions
and capabilities.
The Operators Manual supplied with and considered part of
your crane must be read and completely understood by each
person responsible for operation and maintenance of the
crane.
Operator Qualifications
The crane shall be operated only by the following qualified
personnel:
1.
Designated operators.
2.
Trainees under direct supervision of a designated

operator.
3.
Supervisors, inspectors and maintenance or test

personnel when necessary in performance of their
duties. Operation of the crane by these personnel shall
be limited to the crane functions needed to perform the
inspection or to verify the cranes performance after
maintenance procedures.
No personnel shall be allowed to climb onto the

crane or enter the crane cab unless performance of
2-8
Phone 202-512-1899
Fax 202-512-2250
Electronically via GPO Access at docs or from

www.osha.gov.
ASME (formerly ANSI) B30 Series American

National Standards are available by mail from the
ASME, 22 Law Drive, Fairfield, New Jersey, 07002900 or by:
The Operators Manual must be read to personnel who can

not read or understand English or other language the manual
is translated into.
Because of a program of continuing improvement in product
design, Manitowoc reserves the right to change the
information and specifications contained in the Operators
Manual at any time without notice. If you have any questions
regarding the crane or its Operators Manual, please contact
your Manitowoc Crane Care distributor.
The regulations and standards mentioned above

and latter in this section can be obtained from:
Phone US & Canada 800-843-2763
Phone Mexico 95-800-843-2763
Phone Universal 973-882-1167
Fax 973-882-1717 or 973-882-5155
E-mail [email protected].
Operator Conduct
1.
Operator shall not engage in any practice which diverts

his/her attention while operating crane.
2.
Operator shall not operate crane when physically or

mentally unfit.
3.
Operator shall be responsible for all operations under

his/her direct control. When safety of an operation is in
doubt, operator shall consult with person supervising lift
before lifting load.
4.
Operator shall be thoroughly familiar with operation of

crane and its proper care. If adjustments or repairs are
necessary or if there are known defects that impair safe
operation, crane shall not be operated until unsafe
conditions have been corrected.
SAFETY INFORMATION
5.
If there is a warning sign at start controls, operator shall

not start engine until warning sign has been removed by
person who installed it.
6.
Before starting engine, operator shall make sure that:
7.
a.
All daily inspection and maintenance services have

been performed.
b.
All controls are in off position and all brakes and

locking devices are applied or engaged.
c.
All personnel are clear of crane. Deploy a swing

radius barrier.
Operator shall test all controls, limits, and

communication systems at start of each shift. Any
defects found shall be corrected before operation is
begun.
WARNING
Operational aids (accessories) such as rated capacity
indicator or limiter, boom and jib angle indicator or limiter,
anti-two-block device, level indicator, swing limiter,
proximity device, etc., may be installed on your crane.
Such devices are to be used only as AIDS TO ASSIST
OP ERATOR ; t he i r pre s en c e o n cra n e i n n o w ay
substitutes for or lessens requirement that operator
knowledge, experience, and judgment are required to
ensure safe operation of crane.
Crane shall not be loaded beyond applicable static or

dynamic ratings given on capacity chart for crane.
See Size of Load later in this section.
See Section 3 of this manual and Operation Aids

topic in this section for purpose of each operational
aid.
8.
9.
Operator shall not start crane movement if the load or

designated signal person is not within his/her range of
vision or communication.
Operator shall understand and respond to signals from
the person directing the lift or from the designated signal
person. When a signal person or crane follower is not
required, operator is responsible for lift. Operator shall
obey a stop signal at all times, no matter who gives
it.
10. Operator shall verify that the capacity chart being used
is the correct one for how the crane is equipped (boom
length, load line reeving, counterweight, etc.).
11. Operator shall verify that:
a.
All attachments are properly assembled and

attached to the crane according to the rigging
drawings called for on the capacity chart.
b.
The counterweight to include applicable auxiliary

counterweight is in place and of proper weight.
Maximum required counterweight shall not be
exceeded.
12. Operator shall perform the following operations before

leaving operators cab for any reason:
a.
Park crane (if mobile) and position upperworks so

the crane does not interfere with operation of other
equipment.
b.
Apply travel and swing brakes or locking devices.
c.
Land any attached load.
d.
Lower boom onto blocking at ground level or onto a

boom rest if possible; otherwise, securely fasten
boom from movement by wind or other outside
forces.
e.
Move all controls to off.
f.
Apply all drum brakes and pawls.
g.
Disengage master clutch, if equipped.
h.
Stop engine.
13. Operator shall perform following operations if power or a

control function fails during operation:
a.
Land all suspended loads, if possible, under brake

or power control.
b.
Apply all brakes and locking devices.
c.
Move all controls to off.
14. If crane will be operated at night, operator shall make

sure that there is sufficient lighting for safe operation.
Load and landing area shall be illuminated.
15. Operator shall not operate crane during periods of bad
weather if his or her ability to see load or signal person is
impaired by darkness, fog, rain, snow, etc.
Never operate crane during an electrical thunderstorm.
When a local weather storm warning exists, Manitowoc
recommends that operation be stopped and the crane
secured. See step 12 under Operator Conduct topic.
NOTE:
DO NOT depend on grounding. Grounding of a

crane affords little or no protection from electrical
hazards. The effectiveness of grounding is limited
by size of conductor (wire) used, condition of
ground, magnitude of voltage and current present,
and numerous other factors.
16. Wind can cause crane to tip or boom and other

attachments to collapse. Operator or qualified person
directing lift shall compensate for effect of wind on load
2-9
SAFETY INFORMATION
and boom by reducing ratings, reducing operating

speeds, or a combination of both.
Attaching Load
1.
Unless otherwise specified on Capacity Chart, or in

Operators Manual, stop operation under following wind
conditions:
a.
b.
If wind causes load to swing forward past allowable

operating radius or sideways past either boom
hinge pin, land load and apply drum brakes.
If wind exceeds 35 mph, land all loads and apply
drum brakes, lower boom onto blocking at ground
level or otherwise restrain it, and apply swing and
travel brakes and/or locks.
Attach hook to load with slings, or other suitable rigging.

Each hook shall have a latch that is in proper working
order. Hook latches shall not be wired open.
a.
Inspect each hook and latch before using.
b.
Never use a hook or latch that is distorted or bent.
c.
Make sure spring will force latch against tip of hook.
d.
Make sure hook supports load. Latch must never

support load. Latches are only intended to retain
loose slings under slack conditions.
2.
Only use slings and other rigging that are in safe

operating condition and have a rating equal to or greater
than the load to be lifted.
3.
Do not wrap load line around load.
Workers shall not go under boom, jib, or mast

sections when removing connecting pins or bolts.
4.
Use suitable protection between slings and any sharp

edges on load.
18. Each outrigger shall be visible to operator or signal

person during extension and retraction.
5.
Secure unused legs of a multi-leg sling before handling

a load with one leg of sling.
17. Booms, jibs, or masts which are being assembled or

disassembled on ground (with or without support of
boom rigging) shall be securely blocked to prevent
dropping of boom, jib, or mast sections.
Lifting/Moving Load
Handling Load
Size of Load
1.
Before lifting or moving load, operator or qualified

person directing lift shall make following checks:
1.
a.
Crane shall not be loaded beyond applicable static or

dynamic ratings given on the capacity chart for the crane
configuration.
NOTE:
Capacity charts for Manitowoc cranes show the

total weight of freely suspended loads for various
boom and jib lengths and operating radii.
When such a surface is not available, it shall be

provided with timbers, cribbing, or other structural
members to distribute load such that allowable
bearing capacity of underlying member is not
exceeded.
To determine actual weight of load which can be

lifted at a given radius (working load), operator
must deduct weight of certain lifting equipment
from total weight given on chart. See specific
capacity chart for your crane for a list of lifting
equipment which must be deducted.
Operators judgment must be used to further
reduce total weight to allow for dynamic effects of
swinging, hoisting, or lowering, and adverse
weather conditions to include wind.
2.
Operator or other designated person directing the lift

shall verify that weight of load is within static or dynamic
rating for radius at which load will be lifted.
Verified weights and measured radii shall take

priority over RCI/RCL readings.
2-10
Crane has a firm uniformly supporting foundation

under both crawlers, all tires, or each outrigger jack
pad or float. Unless otherwise specified on capacity
chart, foundation shall be level to within 1% 1 ft
(0,3 m) rise or fall in 100 ft (30,5 m) distance.
Contact Manitowoc Crane Care Customer Service

at Manitowoc for ground bearing data.
b.
Load is secured and properly balanced in slings or

lifting device before lifting the load more than 3 6
in (76 152 mm).
c.
Lift and swing paths are clear of personnel and

obstructions.
d.
Load is free to be lifted.
e.
Load line is not kinked or otherwise damaged.
f.
Multiple part load lines are not twisted around each

other in such a manner that lines will not separate
when load is lifted.
g.
Hook is brought over load in a manner that will

minimize twisting or swinging.
2.
SAFETY INFORMATION
h.
Load line and boom hoist ropes are properly

spooled on drums and seated in sheaves.
Wood blocking or steel plates used under jack pads

or floats shall be:
i.
Load drum brakes are in proper working order.
Free of defects.
Operator shall test load drum brakes each time a

load approaching rated load is handled. Lift load 3
6 in (76 152 mm) and fully apply brakes load
must not lower through applied brakes.
Strong enough to prevent crushing, bending, or

shear failure.
Of sufficient thickness, width, and length to

completely support the jack pad or float,
transmit the load to the supporting surface, and
p r e v en t s h ift i n g, t o p p l in g , o r e xc e ss iv e
settlement under load.
j.
Unused load drums are parked (working and

parking brakes applied; if equipped, drum pawls
engaged).
k.
All personnel are clear of swing radius of cranes

counterweight.
j.
Fully retract and lock jacks and outrigger beams so

they cannot extend when not in use.
While lifting or moving load, operator shall take following

precautions:
k.
Operate with extreme caution when using two or

more cranes to lift same load.
a.
Accelerate and decelerate load smoothly to avoid

excessive stress on crane boom and machinery.
b.
Avoid sudden starts and stops while swinging. Keep

swing speed under control to prevent load from
swinging out beyond radius at which load can be
handled and to minimize the pendulum action of
load.
c.
Use taglines or other restraints to control load when

necessary.
d.
Do not exceed any swing limitations (areas of

operation) given on capacity chart.
e.
Do not allow load, boom, or any other part of crane

to contact obstructions.
f.
Do not use crane to drag a load.
g.
Do not hoist, lower, or swing load while personnel

are on load or hook. See Personnel Handling in this
section.
h.
i.
One designated person shall be responsible for

operation when two or more cranes are used to lift
same load. Designated person shall analyze lift and
instruct all personnel involved in proper rigging and
positioning of load and all movements to be made.
Decisions such as necessity to reduce crane
ratings, load position, boom position, ground
support, and speed of movements shall be in
accordance with designated persons decision.
l.
m. Engage boom hoist pawl when operating with boom

at a fixed radius.
3.
Avoid carrying load over personnel. Loads which

are suspended shall be blocked or cribbed before
personnel are allowed to work under or between
them.
Before lifting a load which requires use of outriggers
(or anytime outriggers are used), fully extend
outrigger beams and jacks so the truck tires do not
bear any load.
Securely fasten outrigger jack pads or floats to jacks
and set them on a flat, firm surface that will support
load placed on pads or floats. Do not set jack pads
or floats in holes, on rocky ground, or on extremely
soft ground.
When dictated by ground conditions, install wood
blocking or steel plates under jack pads or floats to
properly distribute loading on the supporting
surface.
Do not lower load or boom to a point where less

than two full wraps of wire rope remain on the
respective drum (or as otherwise indicated in local,
state, or federal regulations).
4.
While traveling,
precautions:
operator
shall
take
following
a.
Sound signal horn before traveling and

intermittently while traveling, especially when
approaching personnel.
b.
Carry boom in-line with lowerworks and facing

direction of travel.
c.
Do not position boom so high that it could bounce

over backwards whether traveling with or without
load.
d.
Lock upperworks against rotation except when it is

necessary to negotiate a turn, and then only when
operator is seated at controls or the boom is
supported on a dolly.
e.
Lash or otherwise restrain unused hooks so they

cannot swing freely.
Before traveling with a load, operator shall take following

additional precautions:
2-11
SAFETY INFORMATION
a.
A designated person shall be responsible for

operation. Decisions such as necessity to reduce
crane ratings, load position, boom position, ground
support, and speed of movements shall be in
accordance with designated persons decision.
b.
Maintain specified tire pressures (truck cranes).
c.
Avoid sudden starts and stops. Use taglines or other

restraints to control position of load.
A qualified lift planner and crane operator shall read and

become thoroughly familiar with appropriate Capacity
Charts and Wire Rope Specification Charts.
2.
Lift planner and crane operator shall make sure total

load does not exceed rated capacity given in Capacity
Chart and Wire Rope Specification Chart for given boom
point or jib point.
EXAMPLE: If one of load line is lifting from jib point,
proper jib chart applies.
3.
Crane shall be thoroughly inspected by a qualified

person prior to setup.
4.
Crane shall be thoroughly inspected for load line

interference caused by routing and reeving of multiple
load lines. If interference is found, it shall be eliminated.
5.
For cranes produced before 2003, Rated Capacity

Indicators/Limiters were not required by ASME B30.5 for
non-personnel lifting.
Load lines should be located over loads center of

gravity as it is supported on a trailer, barge, or
ground.
Crane operator must be familiar with operational

characteristic of crane as it relates to multiple drum
operation (simultaneous operation, same or opposite
direction, or individual operation).
9.
When using tandem drums, maximum operating layers

may be limited depending on whether crane was initially
designed for tandem drum operation or not.
Manitowoc authorizes multiple load line operation for those

applications requiring it, provided following steps are
performed:
1.
Load must remain centered on boom and jib point

shafts unless special lift approval is granted by
Manitowoc.
8.
Multiple Load Line Operation

Multiple load line operation is becoming common practice for
applications like panel tilt-up, pile tilt-up, pile driving, rolling
fabricated sections, etc. The multiple lines may be on a
common shaft (each with different parts of line) or on multiple
shafts (boom and upper point, boom and fixed jib point, etc).
WARNING
Avoid Over Load and Side Load Damage to Crane
Manitowoc highly recommends that you contact your
Manitowoc Crane Care distributor for lift planning
assistance and approval.
Holding Load
When a load is suspended, operator shall take following
precautions:
1.
Not leave his/her position at controls.
2.
Not allow personnel to stand or pass under load.
3.
Move all controls to off, apply all drum brakes, engage

boom hoist pawl, and apply swing and travel brakes or
locks.
Signals
1.
Continuous communication shall be maintained

between operator and signal person during all crane
movements. If communication is disrupted, operator
shall stop all crane movements.
2.
Signals to operator shall be in accordance with standard

signals shown in Section 3, unless communications
equipment (telephone, radio, etc.) is used.
Operator is still responsible knowing load and

radius whether or not crane is equipped with load
indicator(s).
3.
All signals shall be easily understood by operator at all

times. Operator shall not respond to any signal which is
not clearly understood.
6.
Manitowoc also recommends that each load line be

equipped with an anti two-block device.
4.
7.
Manitowocs Capacity Charts are based on freely

suspended loads. To prevent side load damage to
boom, jib, and sheaves:
For operations not covered in standard signals, or for

special situations or emergencies, additional signals
may be required. In those cases, signals used shall be
agreed upon in advance by operator and signal person.
Signals used shall not conflict with or have potential to
be confused with standard signals.
To aid operator in staying within crane's capacity chart

with total applied load, Manitowoc recommends that its
cranes be equipped with Rated Capacity Indicators/
Limiters to monitor load on each load line.
2-12
Load lines must hang as near vertical as possible to

minimize side and forward loads.
SAFETY INFORMATION
5.
When it is necessary to give instructions to operator

(other than those established by signal system), all
crane motions shall be stopped.
6.
Signal person shall:

a.
b.
7.
Be tested by a designated person and show that he

o r sh e h a s a b a s i c u n d e r s ta n d i n g o f c r a n e
operations and limitations and is thoroughly familiar
with the standard hand signals and voice signals if
used.
4.
When boom or jib angle limiter (automatic boom or

jib stop) is inoperative or malfunctioning, qualified
person directing lift shall make sure maximum boom
angle/radius specified on capacity chart for load being
handled is not exceeded. Radius and boom angle shall
be determined by measurement (i.e., measure radius
with tape measure; measure angle with a protractorlevel on centerline of boom).
5.
When anti-two-block device is inoperative or

malfunctioning, qualified person directing lift shall
establish procedures to furnish equivalent protection
(i.e., assign an additional signal person to observe
distance between load and boom or jib point).
Be positioned in clear view of operator. Signal

persons position should give him or her a clear view
of load, crane, and operating area.
c.
Direct load so it does not pass over personnel.
d.
Keep unnecessary personnel out of cranes

operating area.
When moving crane, following audible signals shall be

used:
a.
STOP - one short audible signal.
b.
GO AHEAD - two short audible signals.
c.
BACK UP - three short audible signals.
This practice does not apply when lifting personnel in

load line supported baskets. Personnel shall not be
lifted in load line supported baskets when anti-twoblock devices are not functioning properly.
6.
When level indicator is inoperative or malfunctioning,

other means shall be used to level crane within limits
specified on capacity chart (i.e., level crane using a
carpenter level on rotating bed).
7.
When boom length indicator is inoperative or

malfunctioning, qualified person directing lift shall
establish boom length at which lift will be made by actual
measurement and marking of boom.
8.
When swing limiter or other proximity device is

inoperative or malfunctioning, qualified person directing
lift shall establish procedures to furnish equivalent
protection (i.e., assign an additional signal person to
observe distance between boom or load and job site
obstructions to include power lines).
9.
When drum spooling limiter (maximum or minimum

bail limit) is inoperative or malfunctioning, qualified
person directing lift, operator, or designated signal
person shall watch drum and make sure it is not over
spooled (rope does not jump off drum) and that there are
never less than 2 full wraps of wire rope on load drum or
boom hoist (or as otherwise indicated in local, state, or
federal regulations).
Operational Aids
Verified weights, measured radii, and Manitowocs Capacity
Charts and instructions shall take precedence over
operational aids when handling a load. If it is necessary to
temporarily override an operational aid, crane user shall stay
within limits of Manitowocs Capacity Charts and instructions.
A designated, qualified person responsible for directing the
lift shall make sure load does not exceed capacity chart.
When operational aids are inoperative or malfunctioning, the
following steps shall be taken to ensure safe continued
operation of the crane.
1.
2.
3.
Steps shall be taken to schedule repairs and calibration

immediately. Operational aids shall be put back into
service as soon as replacement parts, if required, are
available and repairs and calibration can be carried out.
Every reasonable effort must be made to expedite
repairs and calibration.
When rated capacity indicator/limiter is inoperative or
malfunctioning, designated, qualified person directing lift
shall establish procedures for determining load weights
and shall make sure that weight of load does not exceed
crane rating at radius where load is handled.
When boom angle or radius indicator is inoperative or
malfunctioning, radius or boom angle shall be
determined by measurement (i.e., measure radius with
tape measure; measure boom angle with a protractorlevel on centerline of boom).
OPERATING NEAR ELECTRIC POWER

LINES AND TRANSMISSION LINES
Electrocution Hazard
Thoroughly read, understand, and abide by all applicable
federal, state, and local regulations regarding operation of
cranes near electric power lines or equipment.
United States federal law prohibits the use of

cranes closer than 10 ft (3 m) to power sources up
to 50,000 volts, and greater distances for higher
voltages [29CFR1910.180 and 29CFR1926.550].
2-13
SAFETY INFORMATION
To avoid death or serious injury, Manitowoc

recommends that all parts of crane, boom, and
load be kept at least 20 ft (6 m) away from all
electrical power lines and equipment.
NOTE:
For detailed guidelines on operating near power

lines, refer to current edition of ASME B30.5
American National Standard.
Keep all personnel and their personal belongings (clothing,

water coolers, lunch buckets, etc.) away from crane if it is
being operated near electrical power lines or equipment.
Before operating crane in the vicinity of electrical power lines
or equipment, notify the power utility company. Obtain
positive and absolute assurance that the power has been
turned off.
The crane is NOT INSULATED. Always consider all parts of
the load and the crane, including the wire rope, pendants or
straps, and tag lines as conductors.
Set-Up and Operation

During crane use, assume that every line is energized (hot
or live) and take necessary precautions.
Position the crane such that the load, boom, or any part of
the crane and its attachments cannot be moved to within 20
ft (6 m) of electrical power lines or equipment. This includes
the crane boom and all attachments. Overhead lines tend to
blow in the wind so allow for lines movement when
determining safe operating distance.
A suitable barricade should be erected to physically restrain
the crane, all attachments, and the load from entering into an
unsafe distance from electrical power lines or equipment.
Plan ahead and always plan a safe route before traveling
under power lines. Rider poles should be erected on each
side of a crossin g to assure sufficient clea rance is
maintained.
Most overhead power lines ARE NOT insulated. Treat all

overhead power lines as being energized unless you have
reliable information to the contrary from the utility company
or owner.
Appoint a reliable and qualified signal person, equipped with

a loud signal whistle or horn and voice communication
equipment, to warn the operator when any part of the crane
or load moves near a power source. This person should
have no other duties while the crane is working.
The rules in this section must be followed at all times, even if

the electrical power lines or equipment have been deenergized.
Tag lines should always be made of non-conductive

materials. Any tag line that is wet or dirty can conduct
electricity.
Crane operation is dangerous when close to an energized

electrical power source. Exercise extreme caution and
prudent judgement. Operate slowly and cautiously when in
the vicinity of power lines.
DO NOT store materials under power lines or close to

electrical power sources.
If the load, wire rope, boom, or any portion of the crane

contacts or comes too close to an electrical power source,
everyone in, on, and around the crane can be seriously
injured or killed.
The safest way to avoid electrocution is to stay away from
electrical power lines and electrical power sources.
The operator is responsible for alerting all personnel of
dangers associated with electrical power lines and
equipment. The crane is not insulated. Do not allow
unnecessary personnel in the vicinity of the crane while
operating. Permit no one to lean against or touch the crane.
Permit no one, including riggers and load handlers, to hold
the load, load lines, tag lines, or rigging gear.
Even if the crane operator is not affected by an electrical
contact, others in the area may become seriously injured or
killed.
It is not always necessary to contact a power line or power
source to become electrocuted. Electricity, depending on
magnitude, can arc or jump to any part of the load, load line,
or crane boom if it comes too close to an electrical power
source. Low voltages can also be dangerous.
2-14
Prior to operating near transmitter towers where an electrical

charge can be induced into the crane or load:
The transmitter shall be deenergized OR,
Tests shall be made to determine if an electrical charge

will be induced into the crane or load.
Every precaution shall be taken to dissipate induced

voltages. Consult local, state, and federal codes and
regulations.
Electrocution Hazard Devices

The use of insulated links, insulated boom cages/guards,
proximity warning devices, or mechanical limit stops does
not assure that electrical contact will not occur. Even if codes
or regulations require the use of such devices, failure to
follow the rules in this section may result in serious injury or
death.
Be aware that such devices have limitations and you should
follow the rules and precautions outlined in this section at all
times even if the crane is equipped with these devices.
Insulating links installed into the load line afford limited
protection from electrocution hazards. Links are limited in
their lifting abilities, insulating properties, and other
properties that affect their performance. Moisture, dust, dirt,
SAFETY INFORMATION
oils, and other contaminants can cause a link to conduct

electricity. Due to their capacity ratings, some links are not
effective for large cranes and/or high voltages/currents.
The only protection that may be afforded by an insulated link
is below the link (electrically downstream), provided the link
has been kept clean, free of contamination, has not been
scratched or damaged, and is periodically tested (just before
use) for its dielectric integrity.
Boom cages and boom guards afford limited protection from
electrocution hazards. They are designed to cover only the
boom nose and a small portion of the boom. Performance of
boom cages and boom guards is limited by their physical
size, insulating characteristics, and operating environment
(e.g. dust, dirt, moisture, etc.). The insulating characteristics
of these devices can be compromised if not kept clean, free
of contamination, and undamaged.
Proximity sensing and warning devices are available in
different types. Some use boom nose (localized) sensors
and others use full boom length sensors. No warning may be
given for components, cables, loads, and other attachments
located outside of the sensing area. Reliance is placed upon
the operator in selecting and properly setting the sensitivity
of these devices.
Never rely solely on a device to protect you and your fellow
workers from danger.
Some variables you must know and understand are:
Proximity devices are supposed to detect the existence

of electricity and not its distance, quantity, or magnitude.
Some proximity devices will detect only alternating

current (AC) and not direct current (DC).
Some proximity devices detect radio frequency (RF)

energy and others do not.
1.
Stay in the crane cab. DONT PANIC.
2.
Immediately warn PERSONNEL in the vicinity to STAY

AWAY.
3.
Attempt to move the crane away from the contacted

power source using the cranes controls which are likely
to remain functional.
4.
Stay in the crane until the power company has been

contacted and the power source has been de-energized.
NO ONE must attempt to come close to the crane or
load until the power has been turned off.
Only as a last resort should an operator attempt to leave the

crane upon contacting a power source. If it is absolutely
necessary to leave the cab, JUMP COMPLETELY CLEAR
OF CRANE. DO NOT STEP OFF. Hop away with both feet
together. DO NOT walk or run.
Following any contact with an energized electrical source,
your Manitowoc Crane Care distributor must be immediately
advised of the incident and consulted on necessary
inspections and repairs. Thoroughly inspect the wire rope
and all points of contact on the crane. Should the distributor
not be immediately available, contact Crane Care Customer
Service at the factory. The crane must not be returned to
service until it is thoroughly inspected for any evidence of
damage and all damaged parts are repaired or replaced as
authorized by your Manitowoc Crane Care distributor or the
factory.
REFUELING
1.
When using a portable container to refuel crane,

container shall be a safety-type can equipped with an
automatic closing cap and a flame arrester.
2.
Engine shall be stopped before refueling crane.

Smoking and open flames shall be prohibited in
refueling area.
Most proximity devices simply provide a signal (audible,

visual, or both) for the operator and this signal must not
be ignored.
3.
Sometimes the sensing portion of the proximity devices

becomes confused by complex or differing arrays of
power lines and power sources.
FIRE EXTINGUISHERS
DO NOT depend on grounding. Grounding of a crane affords

lit tl e o r n o p r ot e cti on fro m e lec tric al h az ar d s. T h e
effectiveness of grounding is limited by the size of the (wire)
conductor used, the condition of the ground, the magnitude
of the voltage and current present, and numerous other
factors.
Electrical Contact
If the crane comes in contact with an energized power
source, the operator must:
1.
A portable fire extinguisher with a minimum rating of 10

BC shall be installed in operators or machinery cab of
crane.
2.
Operator and all maintenance personnel shall be

thoroughly familiar with location, use, and care of fire
extinguisher(s) provided.
ACCIDENTS
If this crane becomes involved in a property damage and/or
personal injury accident, immediately contact Crane Care
Customer Service or the Product Safety and Reliability
Manager at the following address:
2-15
SAFETY INFORMATION
Manitowoc Cranes
2401 So. 30th St.
Manitowoc, WI 54220
d.
Move all controls to off and secure all functions

against movement by applying or engaging all
brakes, pawls, or other locking devices.
Phone:
Fax:
e.
Stop engine and render starting means inoperative.
f.
Place a warning sign at start controls alerting other

personnel that crane is being serviced and engine
must not be started. Do not remove sign until it is
safe to return crane to service.
1-888-499-7278 or
920-683-6390
Provide a complete description of the accident, including the

crane model and serial number.
SAFE MAINTENANCE PRACTICES
2.
If engine must be run, keep your clothing and all parts of

your body away from moving parts. Maintain constant
verbal communication between person at controls
and person performing maintenance or repair
procedure.
WARNING
Imp or ta nce of saf e main ten an ce ca nno t be ove r
emphasized. Carelessness and neglect on part of
maintenance personnel can result in their death or injury
and costly damage to the crane or property.
Safety information in this publication is intended only as a
guide to assist qualified maintenance personnel in safe
maintenance. Manitowoc cannot foresee all hazards that
will arise in field; therefore, safety remains
responsibility of maintenance personnel and crane
owner.
3.
Wear clothing that is relatively tight and belted.
4.
Wear appropriate eye protection and approved hard hat.
5.
Never climb onto or off a moving crane. Climb onto and

off crane only when it is parked and only with
operators permission.
Use both hands and handrails, steps and ladders
provided to climb onto and off crane.
Maintenance Instructions
To ensure safe and proper operation of Manitowoc cranes,
they must be maintained according to the instructions
contained in this manual and the Service Manual provided
with the crane.
Crane maintenance and repair must be performed by
personnel who by reason of training and experience are
thoroughly familiar with the cranes operation and required
maintenance. These personnel must read Operators
Manual and Service Manual before attempting any
maintenance procedure. If there is any question regarding
maintenance procedures or specifications, contact your
Manitowoc Crane Care distributor for assistance.
Training/qualification of maintenance personnel is

responsibility of crane owner.
Safe Maintenance Practices

1.
Perform following steps (as applicable) before starting a

maintenance procedure:
a.
b.
c.
2-16
Park crane where it will not interfere with other

equipment or operations.
Lower all loads to ground or otherwise secure them
against movement.
Lower boom onto blocking at ground level, if
possible, or otherwise secure boom against
dropping.
Do not attempt to maintain or repair any part of crane

while engine is running, unless absolutely necessary.
Lift tools and other equipment which cannot be carried in

pockets or tool belts onto and off crane with hand lines or
hoists.
6.
Boom and gantry are not intended as ladders. Do not

attempt to climb lattice work of boom or gantry to get to
maintenance points. If boom or gantry is not equipped
with an approved ladder, lower them before performing
maintenance or repair procedures.
7.
Do not remove cylinders until working unit has been

securely restrained against movement.
8.
Pinch points are impossible to eliminate; watch for them

closely.
9.
Pressurized air, coolant, and hydraulic oil can cause

serious injury. Make sure all air, coolant, and hydraulic
lines, fittings, and components are tight and serviceable.
Do not use your hands to check for air and hydraulic

oil leaks:
Use a soap and water solution to check for air leaks

(apply to fittings and lines and watch for bubbles).
Use a piece of cardboard or wood to check for

hydraulic oil leaks.
10. Relieve pressure before disconnecting air, coolant, and

hydraulic lines and fittings.
SAFETY INFORMATION
11. Do not remove radiator cap while coolant is hot or under

pressure. Stop engine, wait until pressure drops and
coolant cools, then slowly remove cap.
12. Avoid battery explosion: do not smoke while performing
battery maintenance, do not short across battery
terminals to check its charge.
13. Read safety information in battery manufacturers
instructions before attempting to charge a battery.
14. Avoid battery acid contact with skin and eyes. If contact
occurs, flush area with water and immediately consult a
doctor.
15. Stop engine before refueling crane.
16. Do not smoke or allow open flames in refueling area.
17. Use a safety-type can with an automatic closing cap and
flame arrestor for refueling.
18. Hydraulic oil can also be flammable. Do not smoke or
allow open flames in area when filling hydraulic tanks.
19. Never handle wire rope with bare hands. Always wear
heavy-duty gloves to prevent being cut by broken wires.
20. Use extreme care when handling coiled pendants.
Stored energy can cause coiled pendants to uncoil
quickly with considerable force.
21. When inflating tires, use a tire cage, a clip-on inflator,
and an extension hose which permits standing well away
from tire.
22. Only use cleaning solvents which are non-volatile and
non-flammable.
23. Do not attempt to lift heavy components by hand. Use a
hoist, jacks, or blocking to lift components.
24. Use care while welding or burning on crane. Cover all
hoses and components with non-flammable shields or
blankets to prevent a fire or other damage.
25. To prevent damage to crane parts (bearings, cylinders,
swivels, slewing ring, computers, etc.), perform following
steps before welding on crane:
Disconnect all cables from batteries.
Disconnect output cables at engine junction box.
Attach ground cable from welder directly to part

being welded and as close to weld as possible.
Do not weld on engine or engine mounted parts (per

engine manufacturer).
26. Disconnect and lock power supply switch before
attempting to service high voltage electrical components
and before entering tight areas (such as carbody
openings) containing high voltage components.
27. When assembling and disassembling booms, jibs, or
masts on ground (with or without support of boom
rigging pendants or straps), securely block each section
to provide adequate support and alignment.
Do not go under boom, jib, or mast sections while

connecting bolts or pins are being removed.
28. Unless authorized in writing by Manitowoc, do not alter
crane in any way that affects cranes performance (to
include welding, cutting, or burning of structural
members or changing pressures and flows of air/
hydraulic components). Doing so will invalidate all
warranties and capacity charts and make crane owner/
user liable for any resultant accidents.
29. Keep crane clean. Accumulations of dirt, grease, oil,
rags, paper, and other waste will not only interfere with
safe operation and maintenance but also create a fire
hazard.
30. Store tools, oil cans, spare parts, and other necessary
equipment in tool boxes. Do not allow these items to lie
around loose in operators cab or on walkways and
stairs.
31. Do not store flammable materials on crane.
32. Do not return crane to service at completion of
maintenance or repair procedures until all guards and
covers have been reinstalled, trapped air has been bled
from hydraulic systems, safety devices have been
reactivated, and all maintenance equipment has been
removed.
33. Perform a function check to ensure proper operation at
completion of maintenance or repair.
2-17
SAFETY INFORMATION
BOOM DISASSEMBLY SAFETY

NOTE:
The term boom used in the following instructions

applies to all lattice attachments (fixed jib, luffing
jib, mast, etc.)
blocking, individual pin connections may still be under load.

Pins can be ejected forcefully if the boom has any pressure
on it or if the boom is not supported properly.
DANGER!
Collapsing Boom Hazard!
Prevent death or serious injury when disassembling boom
sections read and adhere to following instructions.
Safe handling of lattice booms during disassembly is a
primary concern for preventing serious or fatal injuries. A
boom can collapse during disassembly if workers fail to
observe safe working practices.
Accidents during boom disassembly usually result from one
of three primary causes:
Workers are not familiar with equipment or are not

properly trained.
Disassembly area is not suitable.
Safe procedures are overlooked because not enough

time is allocated for the task.
General
FIGURE 2-4
Disassembly Precaution
Always block boom sections so they are securely supported
and cannot shift or move suddenly when pins are removed. If
there is any doubt about a boom disassembly procedure,
block tightly under boom sections before removing any
pin.
DANGER
Collapsing Boom Hazard!
Boom can collapse or shift violently when pins are
removed. To avoid death or serious injury:
Safety decals (Figure 2-4) are placed near the connectors on

the boom sections as shown on the Boom Disassembly
Decal Drawing at the end of this section.
Do not remove bottom connecting pins from any

boom section when boom is supported by straps as
shown in Figure 2-5, View A.
Workers involved with boom disassembly must be trained

and experienced in the operation and disassembly of
construction cranes. Everyone must read and understand
these instructions, the information in the Boom Assembly
Drawing, and the instructions in Section 4 of this manual
before beginning disassembly. Anyone who has a question
should ask for an explanation. One worker who does not
fully understand or fails to follow correct procedures
can endanger other workers.
Do not remove strap connecting pins until straps are

fully lowered into supports as shown in Figure 2-5,
View C.
Do not remove bottom connecting pins from any

boom section when boom point is resting on ground
and handling pendants are slack as shown in
Figure 2-5, View B.
Never work or stand inside boom unless it is lowered

and securely blocked as shown in Figure 2-5, View C.
Location
Do not stand or walk on top of boom unless it has

walkways.
Select a suitable location for boom disassembly. It must be

firm, level, and be free of obstructions. It should have enough
open space to accommodate the crane, the length of boom,
and if required movement of an assist crane or other
equipment. If possible, secure the area to keep unauthorized
personnel and vehicles away.
Pin Removal
When removing pins from boom sections, stand clear of pins
being removed. Even though the boom is resting on
2-18
DANGER
Falling Boom Hazard!
Crane can tip or boom can collapse if excess boom is
cantilevered. Never cantilever more boom than allowed in
rigging drawings or capacity charts.
SAFETY INFORMATION
A10415
View A
WRONG DANGEROUS!
2-101
and there is No Blocking

Under Boom Sections...
If Boom is Off Ground

and Supported by Straps...
3
Boom will COLLAPSE when
Lower Pins are Removed!
View B
WRONG DANGEROUS!
2
Handling Pendants are Slack...
2-102
and there is No Blocking

Under Boom Sections...
If Boom Point
is on Ground...
4
Boom will COLLAPSE when
Lower Pins are Removed!
View C
1
Handling Pendants Taut
and Supporting Boom...
RIGHT SAFE
Straps Fully Lowered onto

Supports Before Removing Pins
2-103
before Removing
Bottom Pins!
Boom Sections Lowered

and Securely Blocked!
FIGURE 2-5
2-19
SAFETY INFORMATION
PERSONNEL HANDLING POLICY
In 1998, the American Society of Mechanical Engineers

issued a new American National Standard entitled,
Personnel Lifting Systems, ASME B30.23-1998. This
standard provides, lifting and lowering of personnel
using ASME B30 Standard hoisting equipment shall be
undertaken only in circumstances when it is not
possible to accomplish the task by less hazardous
means. Unless all of the applicable requirements of this
volume are met, the lifting or lowering of personnel
using ASME B30 Standard equipment is prohibited.
The crane is equipped with a positive acting device

which prevents contact between the load block or
overhaul ball and the boom tip (anti-two block device).
For friction cranes, this implies the addition of spring
applied brakes activated by the anti-two block device.
The load line hoist drum shall have a system or device
on the power train, other than the load hoist brake, which
regulates the lowering rate of speed of the hoist
mechanism (controlled load lowering).
The cranes Operators Manual is in the cranes cab,

readily accessible to the Operator.
The cranes load capacity chart is affixed inside the

cranes cab, readily accessible to the operator. The total
weight of the loaded personnel platform and related
rigging shall not exceed 50 percent of the rated capacity
for the radius and configuration of the crane.
The crane is uniformly level within one percent of level

grade and located on a firm footing. Some capacity
charts require more stringent levelness criteria. Cranes
with outriggers shall have them all fully deployed
following manufacturers specifications.
Manitowoc prohibits personnel handling from its luffing

jibs.
The platform meets the requirements as prescribed by

applicable standards and regulations.
Applicable personnel protection equipment is provided

(i.e., personnel fall-protection system, etc.)
Use of a Manitowoc crane to handle personnel is acceptable

provided:
For wire rope suspended platforms, the crane is

equipped with a hook latch that can be closed and
locked, eliminating the throat opening.
The platform is properly attached and secure.
The crane user shall comply with the manufacturers

specifications and limitations for lifting accessories
(hooks, slings, personnel platforms, etc.)
Direct attachment of a work platform to a luffing jib is

prohibited.
The requirements of the applicable national, state and

local regulations and safety codes are met.
Personnel platforms must not be used if wind exceeds

20 mph (9 m/s).
A determination has been made that use of a crane to

handle personnel is the least hazardous means to
perform the work.
Hoisting personnel within 20 ft (6 m) of a power line that

is up to 350 kV or within 50 ft (15 m) of a power line that
is over 350 kV is PROHIBITTED, except for work
covered in OSHA 29CFR1926 subpart V.
The crane operator shall be qualified to operate the

specif ic t yp e of hoisting eq uipment used in t he
personnel lift.
The crane operator and occupants have been instructed

in the recognized hazards of personnel platform lifts.
The ASME Standards recognize that mobile and locomotive

cranes are primarily designed and intended for handling
materials and not personnel. The ASME Standards have a
retrofit statement that applies to existing cranes after the
standards go into effect. It is not the intent of the standards to
require retrofitting of existing equipment. If an item is being
modified, the performance requirement shall be reviewed
relative to the current standard. The standards contain more
criteria than the current OSHA 1926.550.
This new standard is consistent with the U.S. Department of
Labor, Occupational Safety and Health Administration
( OS H A) r e g u la t io n s fo r C o n st r u ct io n th a t stat e , in
29CFR1926.550(g)(2) General Requirements: The use of
a crane or derrick to hoist employees on a personnel
platform is prohibited, except when the erection, use,
and dismantling of conventional means of reaching the
work site, such as a personnel hoist, ladder, stairway,
aerial lift, elevating work platform or scaffold, would be
more hazardous or is not possible because of structural
design or work site conditions.
The crane is in proper working order.
Load and boom hoist drum brakes, swing brakes, and

locking devices such as pawls and dogs shall be
engaged when the occupied personnel platform is in a
stationary position.
2-20
For operation outside the United States, the requirements of

the applicable national, state and local regulations and
safety codes must be met. This may include, in addition to
the above:
Automatic brakes such that when the equipment

operating controls are released, the motions are brought
to rest.
A holding device (such as a load hold check valve) shall

be provided in the hydraulic or pneumatic systems to
SAFETY INFORMATION
preve nt u ncon tr o lled mo veme nt o f t he h oistin g

equipment in the case of a system failure.
Manitowoc offers upgrade packages for friction controlled
models to install anti-two block, dead man control, and
automatic hoist system control requirements to satisfy other
codes and standards.
Manitowoc continues to recommend that cranes be properly
maintained, regularly inspected and repaired as necessary.
Manitowoc reminds crane owners that all safety decals must
be in place and legible. Manitowoc continues to urge
Manitowoc crane owners to upgrade their cranes with rated
capacity indicator/limiter systems for all lifting operations.
Should you have any questions about this subject or other
product safety matters relating to the operation and use of a
Manitowoc crane, please contact Crane Care Customer
Service or the Product Safety and Reliability Manager at the
following address:
Manitowoc Cranes
2401 So. 30th St.
Manitowoc, WI 54220
Phone:
Fax:
1-888-499-7278
920-683-6390
WARNING
Overload Hazard!
A pedestal mounted crane will not tip to indicate to
operator that cranes capacity has been exceeded. When
capacity of a pedestal mounted crane is exceeded,
turntable bearing, hook rollers (if equipped), or other
structural components may break, before load lines fail,
causing crane to separate from pedestal.
For this reason, great care must be taken to operate a
pedestal mounted crane within its rated capacity.
Careful planning is required before a crane can be
operated on a barge. Crane user shall verify that barge is
capable of limiting crane list and/or dynamics to maximum
allowable specified on capacity charts. If specified crane
list and/or dynamic conditions are exceeded, cranes
capacity may be exceeded; therefore, turntable bearing,
hook rollers (if equipped), or other structural components
may break, causing crane to separate from pedestal.
Definition
PEDESTAL/BARGE MOUNTED CRANES
A pedestal mounted crane is a crane which is securely

fastened to a foundation, barge, ship or floating platform so
the crane is restrained from tipping.
Examples
1.
WARNING
Crane owner/user must verify that method used to fasten
or restrain crane to foundation, barge, ship or floating
platform is strong enough, under all operating conditions,
to prevent crane from breaking off foundation or moving
on barge.
Crane upperworks mounted on a turret (or tub) which is

securely fastened to foundation (Figure 2-6).
Manitowoc does not permit use of a truck crane on a

barge, ship or floating platform.
Pedestal Mounted Crane

Also see ASME publication B30.8-2004, Floating Cranes
and Derricks.
Turret
Foundation
2-104
FIGURE 2-6
2-21
SAFETY INFORMATION
2.
Crane upperworks mounted on a carbody (crawlers

removed) which is securely fastened to foundation
(Figure 2-7).
Tie-Downs
Carbody
Foundation
2-106
Carbody
FIGURE 2-8
Foundation
2.
2-105
NOTE:
If bolting carbody to foundation, contact your

Manitowoc Crane Care distributor for
recommended bolt pattern and for type and
quantity of bolts to be used.
Crawler-mounted crane working on timbered area of

barge, ship or floating platform with crawlers restrained
by curbing and end stops (Figure 2-9). When not
working, crane carbody is anchored with tie-downs to
foundation. Traveling with load is not permitted.
FIGURE 2-7
Barge Mounted Crane

Definition
A barge mounted crane is a crane that is anchored or
restrained in a work area of the barge, ship or floating
platform and is subjected to tipping forces.
1.
2-22
End Stop
Front and
Rear
Carbody
Curbing
Examples
NOTE:
Tie-Downs
Required
When Parked
Foundation
The foundation is the deck of the barge, ship or

floating platform.
2-107
NOTE:
Crawler-mounted crane with carbody anchored with tiedowns to foundation (Figure 2-8).
Manitowoc does not permit traveling with load.
FIGURE 2-9
3.
RINGER (crawler mounted, carbody mounted)

supported on blocking, screw jacks or steel pedestals
which are braced and fastened to foundation in such a
manner as to prevent movement (Figure 2-10).
4.
RINGER (platform mounted) which has ring braced and

fastened directly to foundation in such a manner as to
prevent movement.
SAFETY INFORMATION
NOTE:
Ringers
must
be
equipped with hook
rollers on boom and
counterweight carriers.
Bracing
2-108
Ring Support
Ring Assembly
Foundation
FIGURE 2-10
Y
AXIS
TRANSITIONAL
SYMBOL
NAME
STATIC
ROTATIONAL
DYNAMIC
STATIC
DYNAMIC
Longitudinal
Surge
Heel List
Roll
Vertical
Heave
Lateral
Sway
Trim
Pitch
Yaw
Z
X
2-109
FIGURE 2-11
Capacity Charts
Manitowoc provides two types of capacity charts for a crane
mounted on a barge or other supporting structure under
static conditions.
1.
A capacity chart based on tipping when crane is

anchored only to prevent shifting.
2.
A capacity chart based on structural competence when

crane is securely fastened for use as a pedestal
mounted crane.
NOTE:
Unless otherwise specified on a machine list

capacity chart, a "0" degree machine list capacity
chart rating applies to machine list not to exceed
1/2 degree. All other machine list ratings 1, 2,
and 3 must NOT be exceeded.
Shock Loading
Definition
Shock loads to the crane can be experienced when the
barge is subjected to up and down movement of wave action
(referred to as DYNAMICS). Figure 2-11 illustrates the

dynamic conditions of the barge which influence crane
capacity.
CAUTION
Structural Damage Hazard!
If crane boom or structure is shock loaded during
operation, or there is any indication of shock loading, all
structural components of crane shall be inspected to
detect cracks and other damage. Nondestructive test
equipment, such as magnetic particle or ultrasonic
procedures, is recommended for this inspection.
NOTE:
Manitowoc does not recommend crane operation

under dynamic conditions. However, if operation
under dynamic conditions is required, Manitowoc
will consider issuing a capacity chart for dynamic
conditions only after the crane user has provided
the information listed on Technical Data Sheet,
T.S.100. This technical data sheet is available to
the crane user upon request.
2-23
SAFETY INFORMATION
Operation On Barge
General
Machine list and/or dynamics will be experienced when a
crane is operated on a barge, ship or floating platform. Both
of these conditions reduce the cranes capacity, and each
must be taken into account for safe operation on a barge,
ship or floating platform.
CL
Through Boom
Hinge Pins
Horizontal
Barge Deck
WARNING
Tipping Crane Hazard!
Tie-downs which only prevent crane from shifting as in
barge, ship or floating platform mounting, may not provide
adequate support when using a capacity chart for
pedestal mounting. Before operating a crane on a barge,
ship or floating platform, crane user shall verify that
correct capacity chart is being used pedestal mounted,
barge mounted, 0, 1, 2 or 3 list or dynamic capacity
chart.
Failing to use correct capacity chart can result in an
accident.
Definitions
1.
2.
3.
2-24
Machine List, as defined by Manitowoc, is cranes outof-level condition from side-to-side as measured
by angle between horizontal and a line drawn through
centerline of cranes boom hinge pins (Figure 2-12).
This out-of-level condition creates side load and effects
cranes lifting capacity.
2-110
L = Degrees of Machine List

(Maximum allowable is
specified on Capacity Chart)
FIGURE 2-12
Crane Inspection
To aid in preventing harmful and damaging failure as
previously indicated, regular inspection for signs of
overloading in the following load bearing components is
required. Correct each defect found before placing the crane
into service.
Boom
Gantry
Backhitch
Rotating Frame
Barge List (also referred to as heel or trim) causes swing

out of the load and may produce side load. When
Manitowoc provides a capacity chart showing capacities
for a 2 degree machine list for example, we are referring
to maximum allowable lifting capacity for crane when
experiencing an out-of-level condition (side-to-side) of 2
degrees as measured by angle between horizontal and
a line drawn through centerline of cranes boom hinge
pins.
Wire Rope
Pendants and Straps
Turntable Bearing
Deformation of roller path.
Unless otherwise specified on capacity chart, barge list

(heel or trim) must not exceed machine list degrees
given on the capacity chart.
Proper hook roller adjustment.
Deformation or cracks in hook roller hanger.
Bent hook roller shaft.
Damaged bearings.
Barge List and Machine List are not same. As machine

rotates on barge, barge list (as defined above) will
change. Worst machine list condition generally occurs
when machine swings over corner of barge, producing
maximum side load.
When equipped with hook rollers, it is recommended that

each hook roller assembly be inspected daily for any sign of
overloading, to include:
Transporting Crane on Barge

If it is necessary to transport the crane on a barge, ship or
f l o a t i n g p l a tf o r m w h e n d y n a m i c co n d it io n s w il l b e
experienced, the boom shall be lowered onto a cradle (or
other support) and the boom, crane upperworks and
lowerworks shall be secured against movement. If the crane
SAFETY INFORMATION
is equipped with a mast, the mast shall be securely tied down

with guylines. Failing to take these steps can result in shock
load or side load damage to the boom and mast.
When ordering a sign, give the crane model number, the

serial number, and the name and part number of the sign
(Figure 2-13). If the sign has a figure number, it can be used
if the drawing number is missing.
SAFETY AND INFORMATION SIGNS

Maintaining Signs
The crane owner/user shall make sure that all signs are
legible and installed at the proper locations on the crane. If a
sign has been defaced or removed, it must be replaced
immediately. See Nameplates and Decals Drawing in this
section for the installation locations of signs.
Ordering Signs
Order replacement signs from your Manitowoc Crane Care
distributor or from the factory at the following address:
Manitowoc Crane Care
2401 So. 30th St.
Manitowoc, WI 54220
Phone:
Fax:
E-mail:
Part
Number
920-684-6621
920-683-6278
[email protected]
FIGURE 2-13
2-25

Drawing 175916
Drawing A06702
08132008
G
06/25/2008
Nameplates and Decals Boom Disassembly

Nameplate And Decals
Group F
MANITOWOC CRANES, INC.
Bottom
Chord
Butt
Insert
MALE
CONNECTOR
Bottom
Chord
Male
Connector
1
Box Section
Eng Rev
02-22-05
Angle
Tubular
MODEL
All
NAMPLATE & DECAL ASSEMBLY

Boom Disassembly (see Note 1)
PART #
QTY.
DESCRIPTION OF PART
DANGER DECAL (ENGLISH)

1
147852
2
DECAL, Danger (Boom Hazard) (see Notes 2 & 3)
DANGER DECAL (DUTCH)
1
386315
2
DANGER DECAL (CHINESE)
1
386299
2
DANGER DECAL (SPANISH)
1
386300
2
DANGER DECAL (FRENCH)
1
386301
2
DANGER DECAL (PORTUGESE)
1
386492
2
DANGER DECAL (GERMAN)
1
A10090
2
DANGER DECAL (RUSSIAN)
1
A12529
2
DANGER DECAL (ITALIAN)
1
A11581

Note 1:
Note 2:
Note 3:
Applies to all pin-connected booms, jibs, masts and towers.

Two decals required on bottom chords (1 per side) of butt and each insert (at male connector end).
Apply decal to clean smooth surface as close as possible to both bottom male connectors
as shown.
PLEASE GIVE MACHINE SERIAL NUMBER WITH ORDER
ASSEMBLY
REVISION
175916
G
1 of 1
NAMEPLATE & DECALS (BOOM DISASSEMBLY)
ITEM
Group A

20
69
72
Rotating Bed
(Front View)
27
22
Each Carbody
Counerweight Tray
Each Carbody
Counterweight
27
Tray
Each Carbody
CounerweightTray
Both Sides
Front View
21
Boom Ladder
26
36
Boom Equalizer Rail

8
Boom Top
Must Be Readable
From Engine Side
66
24
23
Horizontally
Center Decal
With Sight Gauge
17
Hydraulic Tank
Must Be Readable With

Mast Down Over Rear
39
19
Horizontally
Center Decal
With Sight Gauge
Radiator
Fuel Tank
Above Opening 33 or 34
55 29 0n
Rotating Bed
35
25
Each Side
Of Jacking
Cylinder
2 3
37
31
18
42
Front Bottom Edge

Of Adapter Frame
46
27
42
Both Sides
Of Both Steps
27
Eng Rev
06-25-08
ASSEMBLY
REVISION
A06702
NAMEPLATE & DECALS
Carbody
(Left Front View)
1 of 8
ASSEMBLY
REVISION
A06702
2 of 8
Near
Side 51
Near
Side 51
Max-er Wheeled Counterweight
53
Max-er Hanging Counterweight
53
59
Near
Outboard
Outboard
Each
Each
JackJack
59
Both
Sides
51
Near Side
And Far Side
61
61 or 62
51 Side
51Near
Side
51
Near Side
And Far Side
50
Outboard
Each Jack
61
58 Both
Sides
50
Both
60Sides
56
64
#79A Boom Butt
60
ASSEMBLY
REVISION
A06702
3 of 8
MODEL
18000
NAMEPLATE & DECALS
ITEM
1
2
5
6
8
9
10
11
12
13
14
PART #
QTY.
2
2
2
2
2
2
4
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
95494
386218
386219
A11570
81000708
95496
386239
386240
A11571
81000709
97281
386203
386204
A11572
81000710
147834
147848
386272
386273
A11579
81000712
172859
386290
386291
A11582
81000714
175916
176835
176882
A09047
A01131
A11586
81000718
176927
A09050
A01161
A11587
81000720
181503
184679
386212
386213
A11591
81000732
197025
A09061
A01143
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SIGN, Boom-Manitowoc (see Note 3)

DECAL, Danger-Stay Clear (English Language)
DECAL, Danger-Stay Clear (Chinese Language)
DECAL, Danger-Stay Clear (Spanish Language)
DECAL, Danger-Stay Clear (Italian Language)
DECAL, Danger-Stay Clear (Korean)
DECAL, Danger-Electrocution Hazard (English Language)
DECAL, Danger-Electrocution Hazard (Chinese Language)
DECAL, Danger-Electrocution Hazard (Spanish Language)
DECAL, Danger-Electrocution Hazard (Italian Language)
DECAL, Danger-Electrocution Hazard (Korean)
DECAL, Warning-Fall Hazard (English Language)
DECAL, Warning-Fall Hazard (Chinese Language)
DECAL, Warning-Fall Hazard (Spanish Language)
DECAL, Warning-Fall Hazard (Italian Language)
DECAL, Warning-Fall Hazard (Korean)
DECAL, Epic (3" X 8 7/8") (see Note1)
DECAL, Patents (English Language)
DECAL, Patents (Chinese Language)
DECAL, Patents (Spanish Language)
DECAL, Patents (Italian Language)
DECAL, Patents (Korean)
DECAL, Warning-Read Manual Remote (English Language)
DECAL, Warning-Read Manual Remote (Chinese Language)
DECAL, Warning-Read Manual Remote (Spanish Language)
DECAL, Warning-Read Manual Remote (Italian Language)
DECAL, Warning-Read Manual Remote (Korean)
DECAL, Danger-Boom Sections (English Language) (see Note 4)
DECAL, Made In USA
DECAL, Warning-Operators Manual (English Language)
DECAL, Warning-Operators Manual (Chinese Language)
DECAL, Warning-Operators Manual (Spanish Language)
DECAL, Warning-Operators Manual (Italian Language)
DECAL, Warning-Operators Manual (Korean)
DECAL, ANSI B30.B (English Language)
DECAL, ANSI B30.B (Chinese Language)
DECAL, ANSI B30.B (Spanish Language)
DECAL, ANSI B30.B (Italian Language)
DECAL, ANSI B30.B (Korean)
PLATE, Crane I.D
DECAL, Hand Signal (English Language)
DECAL, Hand Signal (Chinese Language)
DECAL, Hand Signal (Spanish Language)
DECAL, Hand Signal (Italian Language)
DECAL, Hand Signal (Korean)
DECAL, Caution-Welding (English Language)
DECAL, Caution-Welding (Chinese Language)
DECAL, Caution-Welding (Spanish Language)
A11622
DECAL, Caution-Welding (Italian Language)
ASSEMBLY
REVISION
A06702
4 of 8
DESCRIPTION OF PART
MODEL
18000
NAMEPLATE & DECALS
ITEM
15
16
17
18
19
20
21
22
23
24
PART #
QTY.
DESCRIPTION OF PART
81000738
179030
386530
A09559
A11589
81000727
A06914
A10475
A12562
A11639
81001103
A06726
A10476
A12561
A11638
81001104
81003025
81003026
81003029
81003027
81003028
A06725
A10478
A12560
A11637
81001114
A07227
A10479
A12563
A11640
81001115
A18077
A18991
A18858
A18994
81000724
98739
386224
A12555
A11573
81000711
A06703
A10481
A12557
A11634
81001113
A04412
A09043
1
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
3
3
3
1
1
1
1
1
4
4
4
4
4
1
1
1
1
1
1
1
DECAL, Caution-Welding (Korean)

DECAL, Warning-Rotating Drive Shaft (English Language)
DECAL, Warning-Rotating Drive Shaft (Chinese Language)
DECAL, Warning-Rotating Drive Shaft (Spanish Language)
DECAL, Warning-Rotating Drive Shaft (Italian Language)
DECAL, Warning-Rotating Drive Shaft (Korean)
DECAL, Drum Identification (English Language)
DECAL, Drum Identification (Chinese Language)
DECAL, Drum Identification (Spanish Language)
DECAL, Drum Identification (Italian Language)
DECAL, Drum Identification (Korean)
DECAL, Coolant Level (English Language)
DECAL, Coolant Level (Chinese Language)
DECAL, Coolant Level (Spanish Language)
DECAL, Coolant Level (Italian Language)
DECAL, Coolant Level (Korean)
DECAL, Radius (English Language)
DECAL, Radius (Chinese Language)
DECAL, Radius (Spanish Language)
DECAL, Radius (Italian Language)
DECAL, Radius (Korean)
DECAL, Diesel Fuel Level (English Language)
DECAL, Diesel Fuel Level (Chinese Language)
DECAL, Diesel Fuel Level (Spanish Language)
DECAL, Diesel Fuel Leve (Italian Language)
DECAL, Diesel Fuel Leve (Korean)
DECAL, Warning-Fall Hazard (English Language) (see Note 5)
DECAL, Warning-Fall Hazard (Chinese Language) (see Note 5)
DECAL, Warning-Fall Hazard (Spanish Language) (see Note 5)
DECAL, Warning-Fall Hazard (Italian Language) (see Note 5)
DECAL, Warning-Fall Hazard (Korean) (see Note 5)
DECAL, Cauton-Hydraulic Tank Fill (English Language)
DECAL, Cauton-Hydraulic Tank Fill (Chinese Language)
DECAL, Cauton-Hydraulic Tank Fill (Spanish Language)
DECAL, Cauton-Hydraulic Tank Fill (Italian Language)
DECAL, Cauton-Hydraulic Tank Fill (Korean)
DECAL, Warning-Crush Hazard (English Language)
DECAL, Warning-Crush Hazard (Chinese Language)
DECAL, Warning-Crush Hazard (Spanish Language)
DECAL, Warning-Crush Hazard (Italian Language)
DECAL, Warning-Crush Hazard (Korean)
DECAL, Hydraulic Oil Level (English Language) (see Note1)
DECAL, Hydraulic Oil Level (Chinese Language) (see Note1)
DECAL, Hydraulic Oil Level (Spanish Language) (see Note1)
DECAL, Hydraulic Oil Level (Italian Language) (see Note1)
DECAL, Hydraulic Oil Level (Korean) (see Note1)
Decal, Warning-Coolant Burn Hazard (English Language) (see Note1)
Decal, Warning-Coolant Burn Hazard (Chinese Language) (see Note1)
A09569
Decal, Warning-Coolant Burn Hazard (Spanish Language) (see Note1)
ASSEMBLY
REVISION
A06702
Y
5 of 8
MODEL
18000
NAMEPLATE & DECALS
ITEM
25
26
27
28
29
30
31
33
34
35
36
37
38
39
PART #
QTY.
A11630
81000741
A07321
A10482
A12564
A11641
81001116
194183
A10483
A09365
A11595
81001108
A07339
A10484
A12565
A11642
81000743
A07353
A10485
A12566
A11643
81001117
192249
A10486
A12556
A11594
81001107
A07388
A10487
A12557
A11644
81001118
386567
539090
or
539091
A07883
A10489
A12569
A11646
81001120
A08167
A10490
A12570
A11647
81001121
A10544
A06767
A06768
1
1
1
1
1
1
1
2
2
2
2
2
8
8
8
8
8
3
3
3
3
3
2
2
2
2
2
1
1
2
2
2
2
5
5
5
5
5
1
1
1
1
1
2
2
1
ASSEMBLY
REVISION
A06702
6 of 8
DESCRIPTION OF PART
Decal, Warning-Coolant Burn Hazard (Italian Language) (see Note1)

Decal, Warning-Coolant Burn Hazard (Korean) (see Note1)
DECAL, Crawler Pins Controls (English Language)
DECAL, Crawler Pins Controls (Chinese Language)
DECAL, Crawler Pins Controls (Spanish Language)
DECAL, Crawler Pins Controls (Italian Language)
DECAL, Crawler Pins Controls (Korean)
DECAL, Caution-Boom Equalizer Rails (English Language)
DECAL, Caution-Boom Equalizer Rails (Chinese Language)
DECAL, Caution-Boom Equalizer Rails (Spanish Language)
DECAL, Caution-Boom Equalizer Rails (Italian Language)
DECAL, Caution-Boom Equalizer Rails (Korean)
DECAL, Warning-moving Part Hazard (English Language)
DECAL, Warning-moving Part Hazard (Chinese Language)
DECAL, Warning-moving Part Hazard (Spanish Language)
DECAL, Warning-moving Part Hazard (Italian Language)
DECAL, Warning-moving Part Hazard (Korean)
DECAL, Warning-Pinch Point Hazard (English Language)
DECAL, Warning-Pinch Point Hazard (Chinese Language)
DECAL, Warning-Pinch Point Hazard (Spanish Language)
DECAL, Warning-Pinch Point Hazard (Italian Language)
DECAL, Warning-Pinch Point Hazard (Korean)
DECAL, Manitowoc
DECAL, Manitowoc Logo (40") Red Ball
DECAL, Manitowoc Logo (40") Red Ball
DECAL, Manitowoc Logo (40") Clear Ball
DECAL, Caution-Jacking Cylinder Damage (English Language)
DECAL, Caution-Jacking Cylinder Damage (Chinese Language)
DECAL, Caution-Jacking Cylinder Damage (Spanish Language)
DECAL, Caution-Jacking Cylinder Damage (Italian Language)
DECAL, Caution-Jacking Cylinder Damage (Korean)
DECAL, Warning - Burn Hazard (English Language)
DECAL, Warning - Burn Hazard (Chinese Language)
DECAL, Warning - Burn Hazard (Spanish Language)
DECAL, Warning - Burn Hazard (Italian Language)
DECAL, Warning - Burn Hazard (Korean)
DECAL, Manitowoc Crane Group
DECAL, 18000 Model No. (see Note1)
DECAL, Manitowoc 18000 (see Note1)
MODEL
18000
NAMEPLATE & DECALS
ITEM
PART #
QTY.
40
A11450
A13350
A11451
A13351
A11449
A13349
A13807
A14199
81000744
A15213
81001530
386206
386207
A11590
81000730
A15212
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
41
43
44
54
55
DESCRIPTION OF PART
DECAL, OFF
DECAL, OFF (Chinese Language)
DECAL, ON
DECAL, ON (Chinese Language)
DECAL, Decal Battery Disconnect (English Language)
DECAL, Decal Battery Disconnect (Chinese Language)
DECAL, Decal Battery Disconnect (Spanish Language)
DECAL, Decal Battery Disconnect (Italian Language)
DECAL, Decal Battery Disconnect (Korean)
DECAL, Pump Drive Oil Dipstick
DECAL, Warning-Read Manual (English Language)
DECAL, Warning-Read Manual (Chinese Language)
DECAL, Warning-Read Manual (Spanish Language)
DECAL, Warning-Read Manual (Italian Language)
DECAL, Warning-Read Manual (Korean Language)
DECAL, Engine Oil Dipstick
ROTATING BED JACKS NAMEPLATE/DECALS - OPTION

42
176856
A09064
A09344
176856
81000744
4
4
4
4
4

DECAL, Warning-Crush Hazard Hazard (Chinese Language)
DECAL, Warning-Crush Hazard Hazard (Spanish Language)
DECAL, Warning-Crush Hazard Hazard (Italian Language)
DECAL, Warning-Crush Hazard Hazard (Korean Language)
EUROPE NAMEPLATE/DECALS - OPTION

45
46
47
48
A04559
197151
A09066
A01153
A11623
81000740
177828
A05714
1
1
1
1
1
1
1
1
NAMEPLATE, QSX15 Tier-2 Emission Tag

DECAL, Fire Extinguisher (English Language)
DECAL, Fire Extinguisher (Chinese Language)
DECAL, Fire Extinguisher (Spanish Language)
DECAL, Fire Extinguisher (Italian Language)
DECAL, Fire Extinguisher (Korean Language)
DECAL, CE
DECAL, Sound Power Level 111db
MAX-ER HANGING COUNTERWEIGHT AND MAX-ER WHEELED COUNTERWEIGHT - OPTION:

50
51
53
181503
95494
386218
386219
A11570
81000708
538663
1
4
4
4
4
4
1
DECAL, I.D. - USA Made

DECAL, Danger (Stay Clear) (English Language)
DECAL, Danger (Stay Clear) (Chinese Language)
DECAL, Danger (Stay Clear) (Spanish Language)
DECAL, Danger (Stay Clear) (Italian Language)
DECAL, Danger (Stay Clear) (Korean Language)
DECAL (Max-er) - 59
MAX-ER WHEELED COUNTERWEIGHT - OPTION:

56
58
59
181503
176856
A09064
A09344
A11585
81000716
195270
1
4
4
4
4
4
1
DECAL, I.D. - USA Made (English Language)

DECAL, Warning, Crush Hazard (English Language)
DECAL, Warning, Crush Hazard) (Chinese Language)
DECAL, Warning, Crush Hazard) (Spanish Language)
DECAL, Warning, Crush Hazard) (Italian Language)
DECAL, Warning, Crush Hazard) (Korean Language)
DECAL, Max-er Controls (English Language)
A13438
DECAL, Max-er Controls (Chinese Language)
ASSEMBLY
REVISION
A06702
Y
7 of 8
MODEL
18000
NAMEPLATE & DECALS
ITEM
60
61
PART #
QTY.
A09372
A11598
81001109
195435
A13439
A09373
A11599
81001110
A05204
A09653
A09370
A11633
81001111
1
1
1
3
3
3
3
3
4
4
4
4
4
DESCRIPTION OF PART
DECAL, Max-er Controls (Spanish Language)

DECAL, Max-er Controls (Italian Language)
DECAL, Max-er Controls (Korean Language)
DECAL, Warning (Tipping Hazard) (English Language)
DECAL, Warning (Tipping Hazard) (Chinese Language)
DECAL, Warning (Tipping Hazard) (Spanish Language)
DECAL, Warning (Tipping Hazard) (Italian Language)
DECAL, Warning (Tipping Hazard) (Korean Language)
DECAL, Caution (Tire Inflation) (English Language) (see Note 6)
DECAL, Caution (Tire Inflation) (Chinese Language) (see Note 6)
DECAL, Caution (Tire Inflation) (Spanish Language) (see Note 6)
DECAL, Caution (Tire Inflation) (Italian Language) (see Note 6)
DECAL, Caution (Tire Inflation) (Korean Language) (see Note 6)
#79A LUFFING JIB - OPTION:

64
66
181503
A10003
A10003
A15471
A11648
81001122
1
1
1
1
1
1
DECAL, I.D. - USA Made (English Language)

DECAL,Operating Instructions (English Language)
DECAL,Operating Instructions (Chinese Language)
DECAL,Operating Instructions (Spanish Language)
DECAL,Operating Instructions (Italian Language)
DECAL,Operating Instructions (Korean Language)
#80 BOOM LADDER - OPTION:

69
177837
A09072
A13358
A11588
8100725
1
1
1
1
1
DECAL, Warning (Boom Ladder) (English Language)

DECAL, Warning (Boom Ladder) (Chinese Language)
DECAL, Warning (Boom Ladder) (Spanish Language)
DECAL, Warning (Boom Ladder) (Itallian Language)
DECAL, Warning (Boom Ladder) (Korean Language)
#81 BOOM LADDER - OPTION:

72
177837
DECAL, Warning (Boom Ladder) (English Language)
A09072
A13358
A11588
8100725
1
1
1
1
DECAL, Warning (Boom Ladder) (Chinese Language)

DECAL, Warning (Boom Ladder) (Spanish Language)
DECAL, Warning (Boom Ladder) (Itallian Language)
DECAL, Warning (Boom Ladder) (Korean Language)
ASSEMBLY
REVISION
A06702
8 of 8
Note 1:
-3 Black Letters
-4 White Letters
-5 Clear Letters W/white Outline
Note 2:
Refer to boom and jib rigging drawing for part number
Note 3:
Not Shown
See 175916 for quanities and placement.
Note 4:
Position decal by safety harness anchor.
SECTION 3
OPERATING CONTROLS AND PROCEDURES
TABLE OF CONTENTS
Standard Hand Signals for Controlling Crane Operations . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Luffing Jib Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
1 Crane Mode Select/Confirm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
2 Drum 4 (Boom Hoist) Park Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3 Drum 6 (Luffing Hoist) Park Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4 Boom Hoist and Whip Hoist Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
5 Luffing Hoist and Swing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
6 Normal Limit Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
7 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
8 Mechanical Boom Angle Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
9 Mechanical Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Automatic Jib Stop (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Wind Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
#44 Luffing Jib on #55-79A Boom with 100 foot (30,5 m) Mast . . . . . . . . . . . . . . . . 3-9
Operation Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Operation Not Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
#79A Luffing Jib on #55 or #55A Boom without MAX-ER Attachment . . . . . . . . . . 3-10
Operation Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Operation Not Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
79A Luffing Jib on #55 or #55A Boom with MAX-ER Attachment. . . . . . . . . . . . . . 3-11
Operation Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Operation Not Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-i
OPERATION
SECTION 3
OPERATION
STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS
The following standard hand signals comply with ASME B30.5 - 2007
HOIST. With forearm vertical,

forefinger pointing up, move
hand in small horizontal circle.
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.
USE WHIPLINE (Auxiliary

Hoist). Tap elbow with one hand;
then use regular signals.
RAISE BOOM. Arm extended,

finger closed, thumb pointing
upward.
LOWER BOOM. Arm extended,

fingers closed, thumb pointing
downward.
RAISE BOOM & LOWER LOAD.

With arm extended, thumb
pointing up, flex fingers in and
out as long as load movement is
desired.
LOWER BOOM & RAISE LOAD.

With arm extended, thumb
pointing down, flex fingers in and
out as long as load movement is
desired.
MOVE SLOWLY. Use one hand

to give any motion signal and
place other hand motionless in
front of hand giving the motion
signal (hoist slowly shown as an
example).
SWING. Arm extended point with

finger in direction of swing of
boom.
da0108
3-1
OPERATION
STOP. Arm extended, palm

down, move arm back and forth
horizontally.
EMERGENCY STOP. Both arms

extended, palms down, move
arms back and forth horizontally.
TRAVEL. Arm extended forward,

hand open and slightly raised,
make pushing motion in direction
of travel.
TRAVEL (Both Tracks). Use both

fists in front of body, making a
circular motion about each other,
indicating direction of travel;
forward or backward. (For Land
Cranes Only).
TRAVEL (One Track). Lock the

track on side indicated by raised
fist. Travel opposite track in
direction indicated by circular
motion of other fist, rotated
vertically in front of body. (For
Land Cranes Only).
RETRACT BOOM (Telescoping

Boom). Both fists in front of body
with thumbs pointing toward
each other.
EXTEND BOOM (Telescoping

Boom). One Hand Signal. One
fist in front of chest with thumb
tapping chest.
EXTEND BOOM (Telescoping

Booms). Both fists in front of
body with thumbs pointing
outward.
RETRACT BOOM (Telescoping

Boom). One hand signal. One
fist in front of chest, thumb
pointing outward and heel of fist
tapping chest.
da0109
3-2
DOG EVERYTHING. Clasp

hand in front of body.
OPERATION
3
THIS PAGE BLANK
3-3
OPERATION
3-100
85
90
1
Left Side
of Boom
3-102
50
55
60
65
70
75
80
8
45
5
15
40
35
25
30
20
10
4
6
On Cab Support
Outside Right Window
Item
Identification
1
Crane Mode Select/Confirm Switch
2
Drum 4 (Boom Hoist) Park Switch
3
Drum 6 (Luffing Hoist) Park Switch
4
Boom Hoist Control
5
Luffing Hoist and Swing Control
6
Limit Bypass Switch
7
Digital Display
8
Mechanical Boom Angle Indicator
9
Mechanical Level
See Figure 3-4 for drum identification.
3-101a
FIGURE 3-1
GENERAL OPERATION
LUFFING JIB OPERATING CONTROLS
The instructions in this section supplement the operating

control instructions in the Crane Operators Manual. This
section has two purposes:
See Figure 3-1 for Location of Controls
1 Crane Mode Select/Confirm Switch
To familiarize qualified operators with the location of the

controls used for luffing jib operation.
See Operating Controls in Section 3 of your C rane

Operators Manual for operation of the crane mode switch.
To alert operators to important safety information.
This switch is used to select and confirm the following

modes:
WARNING
Prevent death or serious injury to personnel!
Luffing jib attachment must be installed and operated
by experienced personnel trained in erection and
operation of construction cranes. These personnel
shall read, understand, and comply with instructions in
this manual, in Crane Operators Manual, and in
Luffing Jib Rigging drawings and Capacity Charts.
3-4
LUFFING JIB mode for normal operation.
LJIB STOP mode for extending and retracting the jib

stop positioner cylinders during the luffing jib raising and
lowering procedures.
When the luffing jib mode is selected and confirmed,

LUFFING JIB ON appears on the display as shown in
Figure 3-2. The luffing hoist and boom hoist control handles
switch to the locations shown in Figure 3-1.
If equipped with a MAX-ER attachment, the MAX-ER mode
must also be selected and confirmed. Once selected and
confirmed, the *M on the right end of the display indicates
that the MAX-ER mode is on (Figure 3-2).
Luffing Jib
Mode ON
OPERATION
MAX-ER Mode
ON
Crane Mode LUFFING JIB ON *M
Luffing Jib
Mode ON
LJIB SP Mode
ON
Crane Mode LUFFING JIB ON SP
FIGURE 3-2
FIGURE 3-3
To operate the #79A jib stop positioner cylinders during

luffing jib raising and lowering, proceed as follows:
1.
Select proper #79A luffing jib chart in Rated Capacity

Indicator/Limiter.
2.
Select and confirm luffing jib mode. After confirming this

mode, top line of display should read (see Figure 3-3):
Crane Mode - LUFFING JIB ON
3.
To retract jib stop positioner cylinders, select and

confirm LJIB STOP mode. After confirming this mode,
top line of display should read:
Crane Mode - LUFFING JIB ON SP
SP in this line means that jib stop positioner cylinders
should be retracting (power applied to solenoid).
4.
To extend jib stop positioner cylinders, select and

confirm mode LJIB STOP again. After confirming this
mode, top line should now read:
WARNING
Moving Part Hazard!
If retracted, jib stop positioner cylinders will extend (jib
stops rise) when engine is stopped.
2 Drum 4 (Boom Hoist) Park Switch

3 Drum 6 (Luffing Hoist) Park Switch
4 Boom Hoist and Whip Hoist Control
5 Luffing Hoist and Swing Control
See Operating Controls in Section 3 of crane Operators

Manual for operation of above controls.
6 Normal Limit Bypass Switch

This switch bypasses the limits identified in Table 3-1.
Crane Mode - LUFFING JIB ON
WARNING
SP is gone and power is removed from solenoid.

Cylinders should extend fully.
When bypassing a limit, carefully follow instructions under

Limit Devices topic in this section.
Insert key. Turn CLOCKWISE and HOLD to BYPASS
(disable) reached operating limits. This position allows
functions to be operated beyond the limits.
RELEASE to ENABLE operating limits. This position allows
limits to stop functions in the normal manner.
Remove key to prevent unauthorized operation.
3-5
OPERATION
Table 3-1 Bypassable Limit Identification

Non-European
European
Standard By-pass
Standard By-pass
(Momentary Key Switch)
(Momentary Key Switch)
(past production with quadrant style jib stop)
Boom Up Limit
Yes
Boom Down Limit
Yes
Yes
Block-Up Limit (each drum)
Yes
Yes
Bail Limits - Max and Min (each drum)
Yes
Yes
Rated Capacity Indicator/Limiter
Yes
Yes
Luffing Jib Maximum Up 1
Yes
Yes
Limit
Luffing Jib Maximum UP 2 1

Luffing Jib Down
Yes
Yes
Yes
Yes
Only when boom is below 50.

(current production without quadrant style jib stop)
Boom Up Limit
YES
Boom Down Limit
Yes
Block-Up Limit (each drum)
Yes
Bail Limits - Max and Min (each drum)
Yes
Rated Capacity Indicator/Limiter
Yes
Luffing Jib Maximum Up 1
Yes
Luffing Jib Maximum UP 2 1
Luffing Jib Down 1
Luffing Jib Down 2
Only when boom is below 50.
Cannot be by-passed.
Yes
Yes
Yes
Yes
N/A
N/A
7 Digital Display
Displays boom angle, luffing jib angle, and boom to luffing jib
angle. See Figure 3-5 for identification of each angle:
Boom Angle angle between center line of boom and

horizontal. Monitor this angle when raising boom to
operating angle.
Adjust automatic boom stop to proper angle when

operating with luffing jib. See Automatic Boom Stop in
Section 6 of this manual for adjustment procedure.
-
3-6
85 for #44 or #79A Luffing Jib on 140-180 ft (42,754,9 m) of #55-79A or #55 Boom.
Yes
Yes
Yes
Yes
Yes
87 for #44 or #79A Luffing Jib on 200-340 ft (61,0103,6 m) of #55-79A or #55 Boom.
Luffing Jib Angle angle between center line of jib and

horizontal. Monitor this angle when raising and lowering
jib during operation.
Boom to Luffing Jib Angle angle between center line

of boom and center line of jib. Monitor this angle when
raising boom and jib from ground and lowering boom
and jib to ground.
The digital display also displays system faults and operating

limits for the luffing hoist and all other crane functions. See
Digital Display Readings in the Crane Operators Manual for
a complete list of operating conditions, system faults, and
operating limits.
OPERATION
9 Mechanical Level
Indicates crane levelness from front to rear and from side to
side. Crane levelness can also be viewed in display screen.
4
11
6
2
Automatic Jib Stop (not shown)

When an automatic jib stop is reached, the luffing hoist stops
automatically (brake spring applies) and is inoperable. The
operating limit alert (yellow light and buzzer) comes on and
the digital display indicates which limit has been reached.
Three jib stop limits are provided:
3-103
The appropriate limit bypass switch must be turned to

the bypass position to allow the jib to be raised an
additional 1.2 to 2 to LUFFING JIB MAX UP 2 limit.
5
Drum
Number
1
2
3
4
5
6
Luffing Jib Max Up 1 (maximum working angle) which

automatically stops the luffing hoist when the boom to
luffing jib angle is 168.
Identification
Main Hoist 1 (in boom insert)
Main Hoist 2 (in boom butt)
Whip Line Hoist
Boom Hoist (in mast butt)
Mast Hoist
Luffing Jib Hoist (in boom butt)
Luffing Jib Max Up 2 (maximum angle) which

luffing jib angle is 169.2 to 170.
This limit can be bypassed with the limit bypass switch
only when the attachment is lowered to ground (boom
below 50).
The luffing jib can be lowered after either limit is contacted.

FIGURE 3-4
WARNING
Falling Boom/Jib Hazard!

Do not raise luffing jib above Max Up 2 limit. Structural
damage will occur, possibly causing boom and luffing jib
to be pulled over backwards.
1
3
Make sure luffing jib limits are enabled for normal

operation (bypass switch turned counterclockwise).
Item
1
2
3
4
Description
Horizontal
Boom Angle
Boom to Luffing Jib Angle
Luffing Jib Angle
Luffing Jib Down limit which automatically stops the

luffing hoist when the boom to luffing jib angle is 70.
This limit cannot be bypassed.
The luffing jib can be raised after the limit is contacted.
2
1
3-104
FIGURE 3-5
8 Mechanical Boom Angle Indicator

Shows the angle of the boom in degrees above horizontal.
The boom and luffing jib angles can also be viewed in display
screen.
WARNING
Falling Boom/Jib Hazard!
Do not lower luffing jib below down limit. Structural
damage will occur, possibly causing boom and luffing jib
to collapse.
3-7
OPERATING PRECAUTIONS
P2148
1.
Read and comply with instructions in Liftcrane Luffing

Jib Capacity Charts provided with luffing jib attachment.
Do not operate beyond limits given in capacity charts.
Make sure proper counterweight is installed on crane
and MAX-ER (if equipped).
2.
Read and comply with instructions in this manual and in

Crane Operators Manual.
3.
Read and comply with Maximum Allowable Travel

Specifications in Luffing Jib Capacity Chart Manual.
4.
Make sure luffing jib attachment is installed properly.

Read and comply with instructions in Section 4 of this
manual.
5.
Before raising boom and jib, verify that pressure in jib

stop positioner hydraulic system (see Figure 3-6) is at
proper setting. For detailed instructions, see Section 4 in
this manual.
Main
Strut Stop
Pressure
Gauge
FIGURE 3-7
10. Operate all crane functions slowly and smoothly. Avoid

sudden starts and stops which could side load or shock
load attachment.
11. Do not operate if wind exceeds allowable limits given in
Capacity Charts provided with crane and luffing jib.
P2143
WIND CONDITIONS
Wind adversely affects lifting capacity and stability. The
result could be loss of control over the load and crane, even
if the load is within the cranes capacity.
Boom
Top
WARNING
Pressure
Gauge
FIGURE 3-6
6.
Before raising boom and jib, verify that pressure in main

strut stop cylinders (Figure 3-7). is at proper setting. For
detailed instructions, see Section 4 of this manual. If
pre ssu r e is n ot wit h in sp e cif ied ra n ge , co n ta ct
Manitowoc Service Department for assistance.
7.
Make sure all safety devices block-up limits, boom

and jib angle indicators, boom and jib stops, rated
capacity indicator/limiter are installed and operating
properly. See Section 6 of this manual.
Make sure proper luffing jib capacity chart is selected to
turn on luffing jib mode.
8.
9.
Raise and lower attachment as instructed in Section 4 of

this manual.
Perform all operations with crane on a firm, level,
uniformly supporting surface. Crane must be level to
within 1 ft (0,3 m) in 100 ft (3,1 m).

Judgment and experience of qualified operators, job
planners, and supervisors must be used to compensate
for affect of wind on lifted load and boom by reducing
ratings or operating speeds, or a combination of both.
Failing to observe this precaution can cause crane to tip
or boom and/or jib to collapse. Death or serious injury to
personnel can result.
Wind speed (to include wind gusts) must be monitored by job
planners and supervisors.
Wind speed at the boom or jib point can be greater than wind
speed at ground level. Also be aware that the larger the sail
area of the load, the greater the winds affect on the load.
As a general rule, ratings and operating speeds must be
reduced when:
Wind causes load to swing forward past allowable
operating radius or sideways past either boom
hinge pin.
OPERATION
50 mph (22 m/s) and Above -
#44 Luffing Jib on #55-79A Boom with 100

foot (30,5 m) Mast
Operation Permitted
Boom with 190 - 240 ft (57,9 - 73,2 m) Luffing Jib
Operation is permitted in steady winds or wind gusts up to

the maximum speed given in Table 3-2, provided ratings are
reduced the specified amount.
Lower boom and luffing jib onto blocking at ground level.
Up to 40 mph (18 m/s) Park crane (upper in line with crawlers) with load blocks
and weight balls on ground or secured and position
boom at 75 and luffing jib at 50.
Operation Not Permitted
Operation is not permitted in the areas indicated in Table 3-2.

Observe the following options:
Mast
Up to 50 mph (22 m/s) Park crane (upper in line with crawlers) with load blocks
and weight balls on ground or secured and position
boom at 75 and luffing jib at 50.
Above 50 mph (22 m/s) Haul in boom hoist wire rope just enough to tension mast
straps. Do not raise boom off blocking. Wind can cause
mast stops to collapse if this step is not performed.
Above 75 mph (34 m/s) Lower mast onto blocking at ground level.
Table 3-2
Rating Reductions for Various Wind Speeds and Wind Gusts
Luffing Jib Length ft
(m)
Boom Length ft
(m)
70-120
(21,3-36,6)
130-180
(39,6-54,9)
190-240
(57,9-73,2)
140-180
200-240
260-280
140-180
200-240
260-280
140-180
200-240
260-280
(42,7-54,9) (61,0-73,2) (79,2-85,3) (42,7-54,9) (61,0-73,2) (79,2-85,3) (42,7-54,9) (61,0-73,2) (79,2-85,3)
Maximum Wind
Speed
Percent
Rating Reduction
mph
m/s
15
20
10
25
11
10
50
30
13
10
30
10
60
35
16
10
20
60
20
Above 35 mph
(16 m/s)
OPERATION NOT PERMITTED
For luffing jib operation in winds above 15 mph (7 m/s) with luffing jib positioned above 50, load block from luffing jib point must weigh at
least 15,000 lb (6804 kg). Luffing jib may be blown over backwards if this precaution is not observed. See luffing jib capacity chart for
specific backward stability conditions.
3-9
OPERATION
#79A Luffing Jib on #55 or #55A Boom

without MAX-ER Attachment

without MAX-ER
Operation Permitted
Park crane (upper in line with crawlers) with load block

on ground or secured and position boom at 85 and
luffing jib at 60.

40 mph (18 m/s) and Above Lower attachment onto blocking at ground level.

Mast

without MAX-ER
Up to 50 mph (22 m/s) -
Up to 40 mph (18 m/s) -

luffing jib at 55.
Lower attachment onto blocking at ground level.

Table 3-3
Luffing Jib Length ft
(m)
Boom Length ft
(m)
90-150
(27,4-45,7)
170-230
(51,8-70,1)
250-310
(76,2-94,5)
160-200
(48,8-61,0)
160-200
(48,8-61,0)
160-180
(48,9-54,9)
Maximum Wind Speed
Percent
Rating Reduction
mph
m/s
15
20
10
25
11
60
30
13
30
35
16
60
Above 35 mph
(16 m/s)
Wind speed to be measured at or above boom point elevation. See Luffing Jib Capacity Chart for specific backward stability
conditions.
3-10
OPERATION
79A Luffing Jib on #55 or #55A Boom with

MAX-ER Attachment

with MAX-ER Attachment
Operation Permitted

luffing jib at 55.



40 mph (18 m/s) and Above Lower boom and luffing jib onto blocking at ground level.

Up to 40 mph (18 m/s) -
Up to 30 mph (13 m/s) Park crane (upper in line with crawlers) with load block
luffing jib at 55.
Up to 50 mph (22 m/s) Park crane (upper in line with crawlers) with load block
luffing jib at 45.
30 mph (13 m/s) and Above Lower boom and luffing jib onto blocking at ground level.
Mast
Table 3-4
Luffing Jib
Length ft
(m)
Boom Length
ft
(m)
90-150
(27,4-45,7)
170-230
(51,8-70,1)
160-220
240-280
300-340
160-220
(48,8-67,1) (73,2-85,3) (91,4-103,6) (48,8-67,1)
Maximum
Wind Speed
mph
m/s
15
250-310
(76,2-94,5)
240-280
300-340
160-220
240-280
300-340
(73,2-85,3) (91,4-103,6) (48,8-67,1) (73,2-85,3) (91,4-103,6)
Percent
Rating Reduction
0
40
60
20
10
10
25
11
20
50
60
30
13
10
30
60
35
16
10
30
60
Above 35 mph
(16 m/s)
Wind speed to be measured at or above boom point elevation. See Luffing Jib Capacity Chart for specific backward stability
conditions.
3-11
SECTION 4
SET-UP AND INSTALLATION
TABLE OF CONTENTS
Accessing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Crane Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operating Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Counterweight Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Blocked Crawlers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Rigging Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Luffing Jib Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Identifying Jib Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Handling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Shipping Crane Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Removable Lacings #44 Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Luffing Jib Rigging Guide #44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Assist Crane Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Installing #44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Prepare Boom and Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Install Jib Butt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Install Jib Inserts and Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Complete Upper Jib Point Roller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Connect Jib Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Install Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Install Luffing Hoist Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Raise Main Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Connect Backstay Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Connect Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Set Up Adjustable Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Raise Jib Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Install Load Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Connect Electric Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Install Wind Speed Indicator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Adjust Electronic Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Pre-Raising Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Raising Boom and #44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
In-Line Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Jack-Knife Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Lowering Boom and #44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
In-Line Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Jack-Knife Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Removing #44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Lowering Jib Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Lowering Main Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Remove Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Removing Jib Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4-i
Assist Crane Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing Crane, Boom, and Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Backstay Straps on Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jib Stop Positioner Hydraulic System Operation . . . . . . . . . . . . . . . . . . . . . .
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure For Raising Boom And Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure For Lowering Boom And Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Periodic Check Of Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing #79A Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Jib and Main Strut Butts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Jib Strut Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Luffing Hoist Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Main Strut Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Backstay Straps on Main Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raise Main Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raise Main Strut (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raise Main Strut (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raise Jib Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Jib Strap Equalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect Jib Strut Straps to Equalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Jib Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare Jib Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Jib Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Jib Load Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect Electric Cords/Adjust Electronic Devices . . . . . . . . . . . . . . . . . . . . .
Install Wind Speed Indicator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set Up Jib Stop Positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Raising Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raising Boom and #79A Luffing Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jack-Knife Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lowering Boom and #79A Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jack-Knife Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jack-Knife Lowering Procedure (continued) . . . . . . . . . . . . . . . . . . . . . . . . .
Removing #79A Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Jib Load Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Jib Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Upper Jib Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassemble Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Jib Strap Equalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Butt and First Two inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Jib Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Main Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Main Strut (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store Main Strut Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store Luffing Hoist Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Main and Jib Strut Tops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Jib and Main Strut Butts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Boom and Jib Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Wire Rope from Shipping Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seizing and Cutting Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anchoring Wire Rope to Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Winding Wire Rope onto Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-ii
4-35
4-38
4-38
4-40
4-40
4-40
4-40
4-40
4-42
4-42
4-42
4-42
4-44
4-45
4-46
4-48
4-50
4-52
4-52
4-54
4-54
4-54
4-54
4-54
4-56
4-56
4-56
4-56
4-56
4-57
4-57
4-60
4-62
4-62
4-62
4-64
4-64
4-64
4-64
4-64
4-64
4-64
4-66
4-66
4-66
4-68
4-70
4-72
4-72
4-72
4-72
4-72
4-74
4-74
4-74
4-74
4-75
4-76
Anchoring Wire Rope to Wedge Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Anchoring Wire Rope to Button Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Breaking in Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Rigging Winch Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Load Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Guide Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Duplex Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Reeving Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Load Block Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Load Block Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Duplex Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Guide Sheaves and Drums. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Reeving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
4-iii
SETUP AND INSTALLATION
SECTION 4
WARNING
Avoid Death or Serious injury!
Read and understand instructions in this section before
attempting to install or remove attachment.
Moving Parts/Pinch Points!
Avoid death or crushing injury during crane assembly and
disassembly:
Assembly personnel take every precaution to

prevent injury when working near moving parts.
Maintain communication between operator and

assemblers to avoid accidents.
KEEP UNAUTHORIZED PERSONNEL

WELL CLEAR OF CRANE.
The attachment shall be installed, operated, and removed by

experienced personnel trained in the operation and erection
of construction cranes. These personnel shall read,
understand, and comply with the instructions in this section,
in the Luffing Jib Rigging Drawing, and in the Liftcrane
Luffing Jib Capacity Charts provided with the attachment.
Contact your Manitowoc Crane Care distributor for a detailed

explanation of any procedure not fully understood.
The installation/removal area must be firm, level, and free of
ground and overhead obstructions.
Level = 1% of grade or 1 ft (0,03 m) in 100 ft (30,5 m).

The area selected must be large enough to accommodate
the crane, selected boom and jib length, and movement of
an assist crane.
For #44 Jib:
The maximum combined boom and jib length is 520 ft

(158,5 m).
To prevent lifting equipment from failing and load from

dropping, crane owner/user shall verify following prior to
each lift:
The minimum boom length for use with the jib is 140 ft
(42,7 m). See the capacity chart for boom and jib length
limitations.
All lifting equipment (shackles, hooks, slings, blocks)

has been properly maintained and is safe for use.
For #79A Jib:
All lifting equipment has a capacity equal to or greater

than load to be lifted.
Falling Load Hazard!
GENERAL SETUP AND INSTALLATION
The maximum combined boom and jib length is 650 ft

(198,1 m).
The minimum boom length for use with the jib is 160 ft
(48,8 m). See the capacity chart for boom and jib length
limitations.
This section contains installation and removal instructions for

the luffing jib attachments available for the Model 18000: #44
and #79A.
To allow movement of aerial work platforms and an assist

crane, there must be a minimum of 35 ft (6,1 m) clearance on
both sides of the boom and jib.
For the remainder of this section, luffing jib attachment is

referred to as jib or attachment.
CRANE ORIENTATION
The instructions in this section assume that the crane,

required length of boom and mast, and MAX-ER attachment
(if required) are already installed and ready for luffing jib
installation.
The terms RIGHT, LEFT, FRONT, REAR used in this section

see the operators right, left, front, and rear sides when
seated in the operators cab looking forward with the crawler
motors to the rear.
For #44 Jib, the crane must be rigged as follows:
#55-79A boom.
100 ft (30,5 m) mast.
No MAX-ER attachment.
For #79A Jib, the crane must be rigged as follows:
#55 or 55A boom.
100 ft (30,5 m) mast without MAX-ER attachment.
140 ft (42,7 m) mast with MAX-ER attachment.
ACCESSING PARTS
Some parts of the crane, boom, and jib cannot be reached
from the ground. Take necessary precautions to prevent
falling off the crane, boom, or jib during assembly and
disassembly. Falling from any elevation could result in
serious injury or death.
Owner/user shall provide approved ladders or aerial work

platforms so workers can safely access those areas of crane,
boom, and jib that cannot be reached from ground.
4-1
Adhere to local, state, and federal regulations for handling

personnel and for personnel fall protection
Do not use top of boom or jib as walkways.
The boom and jib components (butts, inserts, tops,

pendants, straps) must be assembled in proper sequence
according to the rigging drawings.
CRANE WEIGHTS
Two tables are provided on the luffing jib rigging drawing:

one table lists the boom sections and backstay pendants
required for various boom lengths; the other table lists the
boom sections required for various jib lengths. Make sure
proper table is referred to. Read and comply with insert and
pendant notes on the rigging drawing.
See Crane Weights in Section 1 of this manual for the

weights of the individual boom and jib components.
LUFFING JIB RAISING PROCEDURE
OPERATING CONTROLS
See the Luffing Jib Capacity Chart Manual for applicable

luffing jib raising and lowering procedures.
Optional boom ladders (stored in boom butt) are available

from Manitowoc. If your crane has ladders, see Section 3 in
Operators Manual provided with crane.
Become thoroughly familiar with the location and function of

all operating controls provided for the crane and attachment.
Read and understand the instructions in Section 3 of this
manual.
Luffing Jib
Angle
C
L Luffing Jib
Horizontal
COUNTERWEIGHT REQUIREMENT
Boom to Luffing
Jib Angle
See applicable Luffing Jib Capacity Charts and Raising

Procedure Charts for counterweight requirements when
operating with jib.
C
L Boom
Horizontal
WARNING
Tipping Hazard!
Boom
Angle
Prevent crane from tipping. Do not operate crane until

proper counterweight is installed.
Horizontal
3-104
BLOCKED CRAWLERS
FIGURE 4-1
To prevent crane from tipping or structural damage to

attachment, all boom and jib combinations must be
raised and lowered over blocked crawlers. See Luffing Jib
Capacity Charts and Raising Procedure Charts for blocked
crawler requirements. Also see Crawler Blocking Diagram in
Luffing Jib Capacity Chart Manual for instructions.
IDENTIFYING JIB COMPONENTS

Jib sections are marked for proper identification as shown in
Figure 4-4, View A (all four chords of each boom or jib
section).
Straps and conn ecting links are m arke d f or prope r
identification as shown in Figure 4-4, View B.
Pendants (when used) are marked for proper identification
as shown in Figure 4-4, View C.
DANGER
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.
RIGGING DRAWINGS
See the end of this section for applicable jib rigging
drawings.
4-2
HANDLING COMPONENTS
Handle boom and jib components with care to avoid
damaging lacings and chords. Lift against chords only, never
against lacings.
Nylon slings should be used to handle components. If wire
rope or chain slings are used, protective covering (such as
sections of rubber tire) must be used between the slings and
the component.
RETAINING CONNECTING PINS
That all trailer loads comply with local, state, and federal
transportation requirements.
That all crane components are properly blocked and

secured so they cannot shift or fall off trailers.
To avoid damage to components:
Connecting pins are retained in various ways:
Snap pins.
Quick-release pins.
Cotter pins.
Keeper plates with cap screws and lock washers.
Use nylon tie-downs to secure components as shown in

Figure 4-2, View A.
Do not operate crane until all connecting pins are installed

and properly retained.
If chain tie-downs are used, install protective covering

(sections of rubber tire) between chain and component
being secured as shown in Figure 4-2, View B.
SHIPPING CRANE COMPONENTS
When securing boom sections, wrap tie-downs over

chords never over lacings. Keep tie-downs as close
to blocking as possible (View A) to prevent bending of
chords.
It is the owner/users responsibility to ensure the following:
P2498
P2499
Chain Tie-Down
Wrapped Over
Boom Chord
Nylon Tie-Down
Wrapped Over
Boom Chord
Protective
Covering
(section of
rubber tire)
View B
FIGURE 4-2
View A
REMOVABLE LACINGS #44 JIB

The 20 ft (6,1 m) and standard 40 ft (12,2 m) #44 inserts
have removable diagonal lacings. These lacings may be
removed to allow for storage of other components during
shipping.
Removable
Diagonal
Lacing
Boom
Insert
7/8-9UNC x 2-1/2 in
Grade 5 Hex Bolt
If removed, removable diagonal lacings must be

reinstalled before operating crane.
1.
Thoroughly clean all dirt from mating surfaces between

lacings and supports on inserts.
2.
Reinstall proper number of removable lacings in each

insert with bolts and stop nuts as shown in Figure 4-4.
3.
Securely tighten nuts.

P835
7/8 in Elastic
Stop Nut
Clean all dirt from between lacings and lacing

supports. Securely tighten nuts.
FIGURE 4-3
4-3
4-100
Manitowoc
Part Number
Boom or Jib
Number
Edge of Strap Part Number

or Link
(both ends)
Chord
XXXXXX
Manufacturing
Code
View B
View A
Manufacturers
Number
Manitowoc
Part Number
PN-277360
SET-3
6X25 EEIP RR IWRC

1&1-4''X19.17'
Length
PO-96858-90
RL-6390B-01
Manitowoc
Purchase Order
Number
Aluminum Tag
(if equipped)
Rope Type
Diameter
Manitowoc
Part Number
View C
Diameter
Manufacturers
Number
Length
Manitowoc Purchase
Order Number
FIGURE 4-4
4-4
THIS PAGE BLANK
4-5
Jib Stops in
Operating Position
Pins in Upper Holes for Operation

Pins in Lower Holes for Shipping and for Handling Jib Stop Assembly
Support this End of Jib Stops (50 lb - 23 kg)
Before Removing Pins from Lower Holes
Jib Stops in
Shipping Position
Shaft with
Keeper Plate
Roller
Jib Stop
Support
View B
4-101
Boom Stop
(both sides)
Jib
Stop
Boom Butt
Wire Rope
Guide
Jib Stop
Lugs
Lower
Catwalks
View A
Rigging Winch
(inside)
Hand
Winch
#44 Jib
Butt
Cable
4-102
Luffing Jib
Wire Rope
Guide
Luffing Jib
Wire Rope
Guide
P1383
Jib Strut
Rest
P1382
Handle
View D
View C
Jib Strut
Pins with
Cotter Pins
FIGURE 4-5
4-6
LUFFING JIB RIGGING GUIDE #44
3.
General
The following installation, raising, lowering, and removal
instructions apply to the #44 luffing jib mounted on a #5579A.
Note that 40 ft (12,2 m) insert with luffing hoist guide

sheaves must be installed next to 10 ft (3,1 m) insert
which is next to boom butt.
4.
Assist Crane Requirements

Either the Model 18000 or an assist crane can be used to
install and remove the jib. If the Model 18000 is used, it must
be in the setup configuration (same as when installing
counterweights and crawler or assembling boom) see
Crane Assembly in Crane Operators Manual for detailed
instructions and capacity limitations.
The jib butt, jib strut, and main strut are shipped from
Manitowoc as an assembled unit. The assembly weighs
approximately 23,250 lb (10 500 kg) and is the heaviest load
to be lifted. Size assist crane accordingly.
Instructions in this section assume an assist crane will

be used.
To allow for the set-up of an assist crane, there should be a
minimum of 35 ft (10,7 m) clearance on one side of the
boom.
Installing #44 Luffing Jib

Lower Boom
1.
If specified in raising procedure chart, travel front

crawler rollers onto blocking.
2.
Swing upper slightly to either side and lower load block

and weight ball onto ground.
3.
Swing boom in-line with crawlers and lower boom point

onto blocking approximately 54 in (1,4 m) high as shown
in Figure 4-5, View A. This will allow you to assemble jib
on blocking approximately 6 in (152 mm) high.
Prepare Boom and Jib

1.
Remove load block from boom point.
2.
Remove upper boom point, if equipped.
Change boom length as necessary to meet job

requirements.
Check that all boom inserts and straps are assembled in

proper sequence according to rigging drawing.
WARNING
Tipping Hazard!
Crane can tip if step 5 is not performed if required.
5.
If specified in raising procedure chart, remove following

items:
Lower boom point from #79A boom top.
Rigging winch and luffing jib wire rope guides from

#44 butt.
6.
Add or remove crane counterweight to comply with

applicable capacity chart.
7.
Remove boom stops, lower catwalk, and wire rope guide

from #44 butt.
8.
Modify #44 butt for use as jib butt as shown on

modification drawings.
9.
Attach jib stop assembly to lugs on jib butt with shafts

and keepers plates (Figure 4-5, View B).
a.
Support jib stops at point shown (50 lb - 23 kg).
b.
Remove pins from lower holes and install them in

upper holes (operating position).
c.
Lower jib stops to operating position.
10. Pin jib strut rest to lugs on jib butt (Figure 4-5, View C).
11. Attach hand winches to jib strut if necessary (Figure 4-5,
View D).
a.
If necessary, install cables and attach to adjustable

straps.
b.
Install handles if removed for shipping.
4-7
Boom
Top
Adapter
Frame
Fixed
Vertical
Pin
View C
Pin with
Cotter Pins
4-104
4-103
Typical Jib
Sections
View B
Removable Lacing (2
each insert)
See Figure 4-3
#79A Boom
Top
Typical
Jib Inserts
40 ft (12,2 m)
#44 Jib Butt
30 ft (9,1 m)
#44 Jib Top
Upper Point
Roller Assembly
4-105
View A
Lower
Boom Point
Jib Hinge Pin

with Keeper Plate
6 in (152 mm)
Blocking
(typical)
Blocking Here so
Distance from Center
of Jib Hinge Pin to
Ground is 54 ft (1,4 m)
View E
Jib
Sections
View D
Upper Pin
with Snap Pins
Installed
4-106
Removable
Horizontal Pin
with Cotter Pins
4-107
Lower Pin
with Snap Pins
Not Installed
FIGURE 4-6
4-8
Install Jib Butt
2.
Check that removable diagonal lacings are securely

fastened to each jib insert (see Removable Lacings
#44 Jib topic and Figure 4-4).
3.
Assemble jib inserts in proper sequence shortest

inserts nearest butt (see Luffing Jib Assembly Rigging
drawing):
See Figure 4-6 for following procedure.

1.
2.
Lift jib butt adapter frame into position at end of boom

top and pin to boom top lugs (View B).
Lift jib butt into position at end of boom top (View A).
Pin jib butt to lugs on boom top with hinge pins. Install
washers as pins are inserted to limit jib butt side play to
1/8 in (3 mm).
3.
Lower jib butt onto blocking approximately 6 in (152 mm)

high.
a.
Lift insert into position and engage top connector

holes in insert with fixed vertical pins in butt as
shown in View C.
b.
Lower insert until bottom connector holes are

aligned and install removable horizontal pins as
shown in View E.
c.
Install blocking approximately 6 in (152 mm) high

under top end of insert.
d.
Repeat steps 3a 3c until all inserts and jib top

have been installed.
Install Jib Inserts and Top

1.
Determine jib length required for lift to be made.
4.
WARNING
Collapsing Jib Hazard!
Lift upper point roller assembly into position at end of

boom top. Pin top connecting holes in upper point to
boom top (View D).
Install removable lacings, if removed, before raising jib.
4-9
Link
(stored)
Link
(to working position)
Strap Storage Pin

(shipping holes each bracket)
Strap
Strap
4-108
View B
Strap Storage Pin

Connecting Pins with
Collars and Retaining Pins (storage holes each bracket)
Bottom
Pin
Upper Jib
Point Roller
From Assist
Crane
Nylon
Slings
View C
4-109
4-110
View A
Retaining
Pin
P1387
Hook
P1386
Main
Strut
Latch
From Assist
Crane
View E
Jib
Strut
View D
Main
Strut
Lifting Lug
(4 each)
Jib
Strut
4-111
View F
Strut Stop
Cylinders
4-10
FIGURE 4-7
Complete Upper Jib Point Roller Installation
3.
Rotate links from storage position to working position.
4.
Install connecting pins, collars, and retaining pins to

connect links to adjacent straps.
5.
Repeat steps at end of each insert.
1.
Attach nylon slings from assist crane to top chords at top

end of jib top (View A).
NOTE:
Assist crane must have sufficient capacity to lift

weight of assembled jib.
2.
Slowly lift jib top until bottom holes in upper jib point
roller are aligned with holes in jib top.
3.
Insert bottom pins to connect upper jib point roller to jib

top (View C).
4.
Lower jib top until rollers are on ground.
5.
Disconnect slings from jib top.
Install Struts
1.
The main strut, jib strut, and adjustable straps can be

shipped as an assembled unit to reduce shipping space.
If struts are assembled, proceed as follows:
a.
Connect chain slings from assist crane to four lifting

lugs on main strut (View F).
b.
Lift strut assembly off transport trailer and place

assembly on ground.
c.
Remove retaining pins connecting main strut to jib

strut (View E). Store pins in jib strut holes once main
strut is removed.
Connect Jib Straps

See Figure 4-7, View B for following procedure.
Jib straps and links are stored on the inserts and jib top for
shipping.
If necessary, lift main strut slightly to loosen pins.
1.
Remove strap storage pins from shipping holes and

install in storage holes.
d.
2.
Remove retaining pins, collars, and connecting pins

from end of straps on adjacent insert.
Lift main strut slightly so that it just lifts off jib strut at
hook and latch (View D).
e.
Swing, boom, and hoist assist crane as required to

disengage latch on main strut from hook on jib strut.
Use care not to hit strut stop cylinders with main

strut.
f.
Place main strut on blocking and disconnect slings.
4-11
From Assist
Crane
Jib
Strut
Adapter
Frame
P1384
Slings
Keeper
Plate
Lifting Lug
(4 each)
View A
Hinge
Pin
Jib
Strut
Boom
Top
P1385
4-112
View B
Jib
Butt
Adapter
Frame
Hinge
Pin
Adapter
Frame
Jib Strut
Support
From Assist
Crane
P1385
Main
Strut
Slings
Keeper
Plate
Lifting Lug
(4 each)
View C
Main
Strut
Jib
Strut
Boom
Top
4-113
View D
Adapter
Frame
FIGURE 4-8
4-12

2.
As pins are installed, install washers to limit side

play of main strut to 1/8 in (3 mm).
Install jib strut, as follows:

a.

lugs on main strut (View B).
Adjust length of rear chain slings so rear end of strut
hangs at least 8 ft (2,4 m) lower than top end of
strut.
b.
c.
Lift jib strut into position at end of adapter frame and

align connecting holes.
d.
Install Luffing Hoist Wire Rope

1.
Select and confirm LUFFING JIB mode.
2.
Place reel of luffing hoist wire rope on ground along right

side of jib near sheave end of struts.
3.
Attach wire rope to sucker line, if installed in strut

sheaves.
Pin jib strut to adapter frame and install keeper

plates (View A).
If sucker line is not installed, reeve free end of luffing

hoist wire rope through strut sheaves and under guide
sheave (right side) on boom top as shown in reeving
diagram on rigging drawing.
As pins are installed, install washers to limit side

play of jib strut to 1/8 in (3,2 mm).
d.
3.
Disconnect slings from jib strut.
4.
Route free end of luffing hoist wire rope through guide

sheaves in 40 ft (12,2 m) insert nearest boom butt.
5.
Securely anchor free end of luffing hoist wire rope to

luffing hoist drum with wedge provided (see Wire Rope
Installation and Maintenance in this section).
Install main strut, as follows:

a.

lugs on main strut (View D).
Adjust length of rear chain slings so rear end of strut
hangs at least 8 ft (2,4 m) lower than top end of
strut.
b.
Lift main strut into position at end of adapter frame

and align connecting holes.
c.
Pin main strut to adapter frame and install keeper

plates (View C).
Disconnect slings from main strut.
Wire rope must spool off bottom of luffing hoist

drum.
6.
Tightly wind excess wire rope onto luffing hoist drum.
7.
Anchor other end of luffing hoist wire rope to right side of

main strut with socket and wedge provided (see Wire
Rope Installation and Maintenance in this section).
4-13
Storage Pin in
Shipping Holes
To Assist
Crane
Basic
Backstay Strap
Erection Pendant
with Shackle
Erection Pendant
Storage Bar
(inside strut)
Backstay Basic
Strap
4-124
View B
Storage
Holes
4-114
Attach Tag
Line Here
View A
Assist Crane
Erection Pendant
(disconnected)
Erection
Pendant
Wedge
Socket
Main
Strut
Erection Pendant
(to Assist Crane)
Erection Pendant
(to Drum 1)
45
P1388
View C
Load Line
From Drum 1
Basic
Backstay
Straps
4-115
Tagline
Backstay Link
on Boom Butt
Backstay Strap
on Boom Insert
Strap Storage Pin Removed

from Top Holes and Stored in
Bottom Holes
Backstay Strap
(stored on boom)
P1389
Strap
Bracket
4-14
Connecting Pin
with Collar and
Retaining Pin
Boom Top
Wire Rope
Guide
Basic
Backstay Strap
(stored on strut)
4-116
View E
View D
View F
Link
Connecting Pin
with Collar and
Retaining Pin
Main
Strut
Stop
4-117
View G
FIGURE 4-9
Raise Main Strut
10. Lower erection pendant from assist crane to vertical and

disconnect assist crane.
11. Slowly haul in load line from Drum 1 to raise jib strut.
Continue to pay out luffing jib hoist wire rope.
Operator must carefully match rate of speed that luffing
hoist wire rope is payed out with speed that load line is
hauled in.
WARNING
Moving Part Hazard!
Do not stand on boom top or jib butt while main strut is
being raised or lowered.
Wait until main strut is stopped and supported by assist
crane or luffing hoist line before climbing onto boom top or
jib butt.
1.
Remove backstay strap storage pins from shipping

holes (View B) and install in storage holes.
Allow straps to rest in storage brackets.
Luffing hoist wire rope must remain slack until strut

is raised to vertical.
CAUTION
Strut Damage!
Too much tension in luffing hoist wire rope can cause
structural damage to strut. Keep luffing hoist wire rope
slack until strut nears vertical.
2.
Attach taglines to backstay basic straps. Taglines should

be at least 20 ft (6 m) long.
12. As strut nears vertical, haul in luffing hoist wire rope just
enough so main strut moves smoothly past vertical.
3.
Disconnect shackles on ends of strut erection pendants

from storage bar in base of main strut.
Jib strut should not rise off jib butt during remaining
steps.
Reconnect shackles to pendants.

4.
Connect chain sling from assist crane to shackle on one

erection pendant (View A).
5.
Hoist and swing with assist crane so erection pendant is

extended vertically above top of main strut.
6.
Connect shackle on other erection pendant to load line

from Drum 1 (View C).
CAUTION
Strut Damage!
7.
8.
9.
13. Continue to slowly pay out luffing hoist wire rope to lower
main strut. Keep load line from Drum 1 slack.
14. Have ground personnel use taglines to guide jib
backstay straps so they do not hit boom lacings.
15. Stop lowering main strut when stops on strut are against
side plates of boom top wire rope guide (View G).
16. Pay out load line from Drum 1 so erection pendant
hangs vertically (View D) and disconnect load line (View
C).
Connect Backstay Straps
Do not attempt to raise main strut with load line from

Drum 1 until step 7 is performed. Structural damage
to strut will occur.
Keep load line from assist crane centered over main
strut while raising strut. Structural damage can occur
if strut is side loaded.
Slowly haul in load line from assist crane to raise main
strut. At same time pay out luffing hoist wire rope.
Raise strut to at least 45 with assist crane and stop
(view D).
See Figure 4-9, Views E and F for following procedure.

1.
Remove strap storage pins from shipping position and

store and in bottom holes in strap brackets.
2.
Remove retaining pins, collars, and connecting pins

from end of each basic backstay strap.
3.
Rotate links from storage position to working position

and pin to ends of basic backstay straps.
4.
Repeat above steps for backstay links between each

boom section.
5.
See View E for connection of backstay link at boom butt.
Slowly haul in load line from Drum 1 until load line is

supporting strut.
4-15
View A
Front of Rotating Bed
Accumulator
Counterbalance
Valve
2,400 psi (165 bar)
Gauge
Coupler
P1633a
Pressure Control
Pilot Valve
2,600 psi (179 bar)
Strut Stop Hydraulic

Cylinder
View C
Cylinder
Relief Valves
2,100 psi (145 bar)
Gauge
Coupler
Hydraulic
Lines
4-118
View B
Jib
Strut
Supply Line to
Jib Strut
Overflow
Tank
Vent
Line
Return Line from Manifold

on Boom Butt
Return Line from Manifold
on Boom Butt
4-119
View D
P1622
Overflow Tank
Couplers
Return Line to Manifold

on Boom Butt
View E
Supply Line to
Jib Strut
Three Hoses
from Jib Strut
Boom Insert
Couplers
P1623
4-16
Boom Top to Jib

Strut Stop Couplers
FIGURE 4-10
Connect Hydraulic Hoses
4.
Connect hydraulic hoses from jib strut to couplers on

boom top (View E).
CAUTION
5.
Start engine.
Strut Damage
If luffing jib will be operated when air temperature is below
32F (0C), drain and refill hydraulic systems (crane and
boom) with Petro Canada Premium Plus hydraulic oil
(MCC #549318). Be sure strut stop cylinders and supply
lines are completely drained before refilling.
For operation below 10F (-12C) use a thinner fluid such
as Petro Canada Premium Arctic 15 (MCC #A03745).
6.
Strut stop cylinders should fully extend, if not already

done.
7.
Check fluid level in overflow tank. Tank should be empty.

If tank is not empty, possible causes include:

The strut stop hydraulic hoses have quick couplers with dust
caps. The dust caps must be removed before making the
connections.
1.
Stop engine.
2.
Connect luffing hoist hydraulic hoses (View A) between

crane and boom butt.
3.
Connect hoses between ends of boom inserts along

entire length of boom (View D).
8.
Wrong oil viscosity for cold weather operation (see

CAUTION above).
Drain line hydraulic connections not made.
Bent or kinked drain line blocking oil flow.
Drain line check valve on transition insert incorrectly

installed.
Attach an accurate hydraulic pressure gauge to coupler

at accumulator on front of rotating bed (View A). Verify
that system pressure is 2,900 psi (200 bar).
All other valves are preset to pressure settings given in
Views B and C.
4-17
Shown Pinned for 100 ft (30,5 m) Jib Length

Connecting
Link
10
Inner
Strap
Outer
Strap
11
4-120
View A
Hole
No.
1
2
3
4
5
6
7
Jib Length
feet (meter)
70 (21,3)
80 (24,4)
90 (27,4)
100 (30,5)
110 (33,5)
120 (36,6)
Hole
No.
8
9
10
130 (39,6)
140 (42,7)
11
Jib Length
feet (meter)
150 (48,8)
160 (48,8)
170 (51,8)
180 (54,9)
190 (57,9)
200 (61,0)
210 (64,0)
220 (67,1)
230 (70,1)
240 (73,2)
View B
Load Pin Shown Locked
in Operating Position
Slide
Pin
Key
Hole
Load
Pin
Inner
Strap
P1395
Hand
Winch
Outer
Access Strap
Hole
Plunger
Cable
(to adjustable strap)
Jib
Strut
Cable
Retaining
Pin
4-121
Storage Hole for

Retaining Pin
Shackle
View D
Jib
Strut
View C
P1384
Pin
Adjustable
Strap
Cable
(from hand
winch)
Jib
Strut
Adjustable
Strap
4-122
View E
4-123
4-18
Locking
Pin
FIGURE 4-11
View F
Set Up Adjustable Straps
Perform following steps at both adjustable straps.
1.
Determine correct pinning location for adjustable strap

b a s e d o n j i b l e n g t h . ( S e e Vi e w A a n d ta b l e i n
Figure 4-11).
2.
Remove load pin from its stored position in adjustable

strap by depressing plunger and sliding load pin toward
wider end of key hole (View B).
The adjustable strap (View A) consists of four major parts: a

connecting link, an inner strap, an outer strap, and a load pin.
The connecting link is pinned to the backstay strap on the
strut. The inner strap is retained inside the outer strap. The
outer strap slides up or down over the inner strap. The load
pin must be installed in the proper key hole in the inner strap
before the jib strut is raised. The length of the jib dictates
which key hole must be used.
The outer rims of the load pin have flanges that hold the pin
in place in the key hole in the inner strap (View B). A slide pin
mounted inside the load pin holds the load pin in place.
Depressing a spring-loaded plunger in the load pin allows
the slide pin to move through the load pin as long as the
plunger is depressed. When released, the plunger engages
one of two grooves in the slide pin to lock the slide pin in
place. Extending the slide pin holds the load pin in place in
the key hole.
DANGER
Remove pin through access hole in outer strap.

3.
Insert pin through access hole in outer strap at required

pinning location.
4.
Depress plunger and slide load pin into narrow end of

key hole. Release plunger.
5.
Check that load pin is tightly locked against narrow end

of key hole (View B).
NOTE:
6.
Make sure locking pin is installed as shown in View E.
7.
Check that cable from hand winch is attached to

adjustable strap (View D).
8.
Check that cable between hand winch and adjustable

strap is snug.
9.
Check that ratchets on hand winches are set to prevent

winches from paying out line.
Crane Collapse!
Install and lock load pins in proper holes of adjustable
straps for jib length in use (Figure 4-11, View A)
If load pin is not tightly locked in operating position,

remove load pin, rotate it 180, and reinstall.
10. Remove retaining pin connecting adjustable strap to jib

strut. Install retaining pin in storage hole (View D).
WARNING
Adjustable Strap Separation!
Make sure adjustable strap locking pin is installed
(Figure 4-11, View E) before raising jib strut.
4-19
View B
Main Strut
Backstay
Straps
Strut Stop
Cylinder
P1630a
Rod
End
Cylinder
Mounting
Lugs
Strut Stop Frame

both Sides of
Boom Top
1
Erection
Pendants
Strut Stop
Cylinder
NO
INTERFERENCE
View C
5
P1631a
Cylinder
Support
Frame
4-125
4
View A
Jib
Strut
Store Erection
Pendants Here
Stored
1/8 in
(3 mm)
3
View D
Hand
Winch
P1396
Jib
Strut
View F
Cable
Storage
Lug
Item
1
2
3
4
5
Description
Washer
Shim
Shim
Support
Stop Block
4-147
View E
Strut Stop
Cylinder
45
4-126
Retaining Pin
(storage hole)
View G
Jib
Strap
P1390
Outer
Strap
Store Locking
Pin Here
Outer
Strap
Inner
Strap
P1397
Cable
View H
4-20
Locking Pin
(erection position)
View J
Pin with Collar

and Retaining Pin
FIGURE 4-12
Raise Jib Strut
c.
See Figure 4-12 for following procedure, unless otherwise

noted.
Reposition stop blocks (5, View E) so distance

between stop blocks and supports (4) is 5 in (127
mm).
CAUTION
WARNING
Moving Part Hazard!
Do not stand on boom top or jib butt while either strut is
being raised or lowered.
Wait until struts are stopped and supported by an assist
crane or luffing hoist wire rope before climbing onto boom
top or jib butt.
NOTE:
Haul in luffing hoist wire rope until main strut is near

vertical and jib strut just starts to rise (View A).
2.
Attach both erection pendants to storage bar on main

strut with shackles on ends of pendants (Figure 4-9,
View A).
3.
Continue hauling in luffing hoist wire rope to slowly raise

jib strut to approximately 45 and stop (View G).
4.
While raising jib strut, observe strut stop cylinder rod

ends. Following adjustments were made at factory and
should not require field adjustment.
Make sure rod ends do not interfere with any part of
strut stop frames (View B).
If interference occurs, readjust washers (1, View C)
and shims (2, View D) until there is NO
INTERFERENCE (cylinders centered in frames).
b.
5.
While raising strut, use mechanical angle indicator

mounted on jib strut to monitor strut angle.
1.
a.
Structural Damage!
Do not raise jib strut above 70 during erection while
boom is on ground. Structural damage to jib strut or strut
stop cylinders will occur. At 70 strut angle, cylinder rods
will have approximately 5 in (127 mm) travel remaining
(Figure 4-13, View B).
Install shims (3, View D) under supports (4) so that

when rollers bottom out in strut stop pockets on
boom top (Figure 4-13, View B) gap is 1/8 in (3 mm)
between supports (4) and underside of cylinders.
Connect adjustable straps to jib straps on jib insert:

a.
Using hand winch, lower adjustable straps to

vertical (View G). Raise or lower strut as needed.
b.
Raise or lower strut as needed to align connecting

holes in inner straps with connecting holes in jib
straps on jib insert.
c.
Pin adjustable straps to jib straps (View J).
6.
With jib straps resting in supports on insert, raise or

lower jib strut so there is no load on locking pin in
each adjustable strap.
7.
Remove locking pins (View H) and store in holes in outer

straps.
CAUTION
Structural Damage!
Inner straps will not extend to proper length if locking pins
are not removed. Structural damage will occur.
8.
Disconnect cables from outer straps (View H) and

connect cables to storage lugs at base of jib strut (View
F).
Use hand winch to tighten cable as needed.
4-21
Jib
Strut
Strut Stop
Cylinder
Main
Strut
Cylinder Rod Roller

Bottomed Out in
Strut Stop Pocket
70Max
5 in (127 mm)
4-127
4-128
View B
FIGURE 4-13
View A
Install Load Lines
Connect Electric Cords
Depending on your lifting requirements, the luffing jib can be

operated with load lines over either jib point, lower or upper.
Connect electric cords to respective junction boxes and

switches. See Boom Wiring and Limits Diagram at end of this
section:
1.
2.
3.
See Capacity Chart for lifting limitations and required

deducts when handling loads from selected locations.
See Wire Rope Specifications Chart in Luffing Jib
Capacity Chart Manual to determine parts of line
required for your job. Size load block accordingly.
Route load line from desired drum through proper guide
sheaves on boom (See Load Line Reeving in this
section).
Jib stop limit switches on jib adapter.
Block-up limit switches.
Load sensors (for attachments without wireless

RCL).
Install Wind Speed Indicator Assembly
4.
If jib will be raised using In-Line Method, install load

block and weight ball from jib points before boom and jib
are raised.
Install wind speed indicator if removed for shipping. Use star

washers to attach mounting bracket to jib top to provide good
a ground (see Wind Speed Assembly drawing at end of this
section).
5.
If jib will be raised using Jack-Knife Method, proceed as

follows:
Connect electrical cable at base of wind speed mounting

bracket.
a.
Reeve load lines through guide sheaves in jib point.
Adjust Electronic Devices
b.
Pull load lines approximately 20 ft (6,1 m) past end

of jib and lay lines on ground.
Adjust electronic devices according to instructions in Section

6 of this manual:
c.
Securely tie off load lines to jib point. Install load

block and weight ball after boom and jib are jackknifed into position just prior to raising jib point
rollers off ground.
Jib stop limit switches.
Boom stop limit switch (to 85 or 87, depending on

boom length, after boom and jib are raised).
Block-up limit switches.
Pre-Raising Checks
WARNING
Run-Away Wire Rope!
For long boom and short jib combinations, wire rope on
boom side of attachment can overhaul unsecured wire
rope on jib side. This could cause personnel injuries and
damage to equipment. Securely tie off load lines to jib
before raising attachment.
4-22
Make the following checks and correct any defects before

raising the attachment.
Lower boom point removed from boom top if required by

raising procedure chart.
Rigging winch and wire rope guides removed from jib

butt if required by raising procedure chart.
Crawlers blocked if required by raising procedure chart.

See Crawler Blocking Diagram for blocking procedure.
All installation steps given in this section performed.
Boom and jib inserts installed in proper sequence

according to rigging drawings.
Upper jib point roller installed.
Boom, jib, and backstay straps installed in proper

sequence according to rigging drawings.
Adjustable jib straps locked in proper position.
All connecting pins installed and properly secured.
Main and jib struts in operating position.
All hydraulic connections made.
Jib stop in operating position.
Jib strut stop cylinders extended and adjusted.
Boom and luffing hoist wire rope anchored properly to

drums, spooled tightly onto drums, and engaged with
proper sheaves (see Rigging Drawings and Wire Rope
Installation and Maintenance in this section).
Load lines anchored properly to drums, spooled tightly

onto drums, and engaged with proper sheaves (see
Reeving Diagrams and Wire Rope Installation and
Maintenance in this section).
Wire rope guard pins, bars, or rollers installed to retain

wire rope in sheaves.
If load line will be installed after boom and jib are

jack-knifed into position, make sure load line going
to jib point is securely attached to end of jib point so
load line cannot fall off jib and boom.
All blocking, tools, and other items removed from boom

and jib.
All blocking, tools, and other items removed from jib

point roller path area.
4-23
4-24
All safety devices installed, electric cords connected,

and limits adjusted (see appropriate adjustments
sections in this manual):
Rated Capacity Indicator/Limiter.
Boom and jib angle indicators.
Automatic boom stop (must be reset for luffing jib

operation after boom and jib are raised).
Automatic jib stops.
Jib and boom block-up limits.
Luffing Jib Raising Procedure Chart reviewed, and

following operations determined:
Raising method in-line or jack-knife.
Required boom to jib angle for jack-knife raising

method.
Raising procedure in this section read and thoroughly

understood.
Proper amount of crane counterweight installed.
Wind within allowable limits for raising boom and jib (see
charts in Luffing Jib Operators Manual).
All lube points greased (see Lubrication Guide in Luffing

Jib Operators Manual).
LUFFING JIB mode selected and confirmed.
ITEM NUMBERS CORRESPOND TO INLINE RAISING PROCEDURE STEPS
2
1
4-129
View A
3
7
3
4-130
View B
6
5
4-132
View D
4-131
View C
When steps 4 and 5 are performed,
jib stop will swing past adapter frame
into proper operating position.
View E
5
4-133
RIGHT
If steps 4 and 5 are not performed, jib

stop will not swing past boom top into
proper operating position.
Damage could occur. Jib stop will not
operate properly.
4-134
160 or
Less
Greater
Than 160
60 or
More
WRONG
FIGURE 4-14
4-25
Raising Boom and #44 Luffing Jib

General
1.
Install load block and/or weight ball (if not already done).
2.
Slowly luff up to raise jib strut until jib straps clear strap
storage brackets on jib and stop.
It will be necessary to use limit bypass switch to luff up if
MAX UP 1 limit is on.
WARNING
Falling Boom And Jib Hazard!
Select and confirm LUFFING JIB mode. Operating in any
other mode with luffing jib attached is prohibited.
Luffing jib limits are disabled when LUFFING JIB mode is
off. Boom and jib could be pulled over backwards.
CAUTION
Structural Damage!
Do not exceed 70 jib strut angle while boom is on ground.
Use mechanical angle indicator on jib strut to monitor strut
angle.
3.
WARNING
Moving Part Hazard!
Warn all personnel to stand clear of jib point rollers while
raising boom and jib.
Use digital display in operators cab to monitor boom angle
and boom to luffing jib angle while raising boom and jib.
In-Line Raising Procedure

NOTE:
It is normal for the following limits to come on

during the raising procedure:
BLOCK UP this fault will go off once the boom and luffing
jib are raised and the load lines/block-up limit chains are
hanging freely.
Slowly boom up to raise boom until jib straps are taut

and stop. Jib point rollers will roll along ground as boom
and jib rise.
Pay out load lines as boom is raised.
CAUTION
Jib Stop Damage!
Jib stop will not swing past boom top to operating position
if steps 4 and 5 are not performed. Damage could occur.
Jib stop will not operate properly.
4.
Continue to slowly boom up to raise boom and jib until

boom angle is 60 or higher and stop.
Pay out load lines as boom is raised.
5.
MAX UP 1 and MAX UP 2 these faults will go off once the

boom to luffing jib angle is less than 168.
Check boom to luffing jib angle. If angle is more than

160, luff down until angle is 160 or less.
Jib stop will swing past boom top into operating position.
It will be necessary to use limit bypass switch to luff
down if BLOCK UP limit is on.
6.
WARNING
Pay out load lines as boom and jib are raised.
When using in-line method:
Do not raise boom and jib combinations longer than

specified on raising procedure chart.
Raise boom to desired operating angle and position

jib at required operating radius before lifting load
block and/or weight ball from ground.
4-26
Raise boom and jib to desired operating angle and

radius.
7.
Travel crane forward until jib point is over load block and/
or weight ball and lift load block and/or weight ball to
desired operating position.
2
2
4-135
4
7
6
9
4-136
12
11
10
4
4-137
13
ITEM NUMBERS CORRESPOND TO JACKKNIFE RAISING PROCEDURE STEPS
13
4-138
FIGURE 4-15
4-27
Jack-Knife Raising Procedure
5.
OPERATOR AND SIGNAL PERSON watch backstay

straps and jib straps along left side of boom and jib as
boom and jib rise.
WARNING
Pay out luffing hoist wire rope (luff down) so jib straps
remain slack.
Tipping Hazard/Structural Damage!
See Raising Procedure Chart to determine BOOM

TO LUFFING JIB ANGLE that boom and jib must be
jack-knifed to before jib can be raised.
Do not raise boom and jib combinations longer than

specified on raising procedure chart.
Monitor angle on digital display as boom and jib are

raised.
Allow backstay straps to float up and down 3 - 6 in (76 162 mm) above strap brackets at top end of boom butt.
Allow jib straps to float up and down 3 - 6 in (76 162 mm) above strap brackets at end of jib top.
6.
CAUTION
Structural Damage!
Do not exceed 70 jib strut angle while boom is on

ground. Use mechanical angle indicator on jib strut to
monitor strut angle.
Avoid side loading as boom and jib are raised.
Disengage swing lock and release swing brake until

boom and jib have been raised to required boom to
luffing jib angle.
NOTE:
MAX UP 1 and MAX UP 2 these faults will go off once the

boom to jib angle is less than 168.
1.
Disengage swing lock and release swing brake.
2.
Slowly luff up until jib straps lift out of strap brackets on

jib and stop.
3.
Slowly boom up.
Falling Jib Hazard/Structural Damage!

Do not lower jib to any boom or jib angle less than
minimum stop (70).
7.
Stop raising boom when boom and jib have been

positioned at required boom to luffing jib angle or jib is
vertical, whichever occurs first. Monitor this angle on
digital display.
8.
Slowly luff up until jib straps start to go into tension and

stop.
9.
Boom up to raise jib point rollers clear of ground, apply

swing brake, and install load block and/or weight ball
(see Install Load Lines in this section).
Untie load lines from jib after installing load block and/or
weight ball.
WARNING
Jib point rollers will roll along ground as boom and jib are
jack-knifed into position.
WARNING
Do not allow jib or backstay straps to become too tight
during raising steps. Crane will tip or structural damage
will result.
Do not allow jib and backstay straps to become too slack
during raising steps. Jib strut could fall onto jib butt.
4-28
Slowly continue with Jack-Knife Raising Procedure

steps 3 - 5.
WARNING

BLOCK UP this fault will go off once the boom and luffing
jib are raised and the load lines/block-up limit chains are
hanging freely.
4.
Jib straps and backstay straps will tighten as boom and

jib rise.
Pay out load lines as boom and jib are raised.

Raise boom to desired operating angle and position jib at
required operating radius before lifting load block and/or
weight ball from ground.
10. Slowly raise boom to desired operating angle. See
Capacity Chart for allowable boom angles.
11. Pay out load lines as boom and jib are raised.
12. Luff up to position jib at required operating radius for
load to be handled.
13. Travel forward as required to position load block and/or
weight ball below jib points and lift load block and/or
weight ball to desired operating position.
ITEM NUMBERS CORRESPOND TO INLINE LOWERING PROCEDURE STEPS
5
See View E
1 4
3
4-140
4-139
View B
View A
When step 5 performed, jib stop

will swing past adapter frame into
proper operating position.
5
4-133
RIGHT
View E
160
or Less
4-141
View C
60 or
More
7
4-142
View D
FIGURE 4-16
4-29
Lowering Boom and #44 Luffing Jib
NOTE:
General
It is normal for BLOCK UP, MAX UP 1, and MAX

UP 2 limits t o come on during the lowering
procedure.
1.
Swing upperworks in line with lowerworks so boom is

over front of crawlers.
2.
Travel crawler rollers onto blocking, if required.
3.

other mode with luffing jib attached is prohibited.
Swing boom and jib slightly to either side of center and

lower load block and/or weight ball to ground.
4.
Swing boom and jib in line with crawlers.
WARNING

WARNING
Moving Part Hazard!
lowering boom and jib.
As defined in the raising procedure chart, one of two
methods can be used to lower the boom and jib depending
on the boom and jib combination: In-Line Method or JackKnife Method. See the chart to determine which method can
be used. Be sure crane is properly configured for
selected method.
NOTE:
CAUTION
Jib Stop Damage!
Jib stop will not rotate to proper storage position if step 5
is not performed.
5.
Position boom at 60 or higher boom angle and lower

luffing jib to 160or less boom to luffing jib angle (View E.
6.
Slowly boom down until jib point rollers contact ground.

It will be necessary to use limit bypass switch to boom
Haul in load lines as boom and jib are lowered but do not
lift load block and/or weight ball off ground.
Use digital display in cab to monitor boom and

boom to luffing jib angles while lowering boom and
jib.
CAUTION
Structural Damage!
Do not exceed 70 jib strut angle while boom is on ground.
Use mechanical angle indicator on jib strut to monitor strut
angle.
In-Line Lowering Procedure

7.
WARNING
Perform Jack-Knife Lowering Procedure steps 712 to

lower boom and jib remaining distance.
Observe boom to luffing jib angles specified on

raising procedure chart.
If required by raising procedure chart, lower boom

and jib over blocked crawlers.
Lower load block and/or weight ball to ground before

4-30
A1275
ITEM NUMBERS CORRESPOND TO JACKKNIFE LOWERING PROCEDURE STEPS
5
3
4
1 3
4-143
9
6
7
4-144
12
10
11
4-145
FIGURE 4-17
4-31
Jack-Knife Lowering Procedure
Monitor angle on digital display.

CAUTION
WARNING
Structural Damage!
Observe boom to luffing jib angles specified on

raising procedure chart. Use digital display in cab to
monitor boom and boom to luffing jib angles.
If required by raising procedure chart, lower boom
and jib over blocked crawlers.
Avoid side loading as boom and jib are lowered.
Disengage swing lock and release swing brake when

jib point rollers contact ground.
6.
Depending on boom and jib combination, jib may be

hanging vertical when rollers contact ground. If this
happens, raise jib (luff up) until jib is a few degrees
forward of vertical.
Lower all load block and/or weight ball to ground

before lowering boom and jib.
WARNING
Moving Part Hazard!
NOTE:
It is normal for the BLOCK UP, MAX UP 1, and

MAX UP 2 limits to come on during the lowering
procedure.
1.
Swing upperworks in line with lowerworks so boom is

centered over front of crawlers.
2.
Travel crawler rollers onto blocking, if required.
3.

lower load blocks and/or weight balls onto ground. Then
swing boom and jib in line with crawlers and apply swing
brake.
WARNING
Do not lower boom and jib to ground until boom has been
positioned at minimum boom angle of 70 and jib has
been positioned at specified boom to luffing jib angle. Use
digital display in cab to monitor boom and boom to luffing
jib angles.
Slowly boom down until jib point rollers contact ground.
It will be necessary to use limit bypass switch to boom

7.
Release swing brake (disengage swing lock) and

continue to lower boom slowly.
Jib point rollers will roll along ground as boom and jib
unfold.
8.
Pay out load lines as boom and jib lower.
9.
Jib straps and backstay straps will slacken as boom and

jib lower.
OPERATOR AND SIGNAL PERSON watch backstay
straps and jib straps along left side of boom jib as boom
and jib lower.
Do not allow straps to become to slack.
Allow backstay straps to float up and down 36 in (76

162 mm) above strap brackets at top end of boom butt.
Allow jib straps to float up and down 36 in (76162 mm)

above strap brackets at end of jib top.
WARNING
WARNING
Falling Jib Hazard!
Do not lower jib to any boom to luffing jib angle less than
minimum stop (70). Structural damage to jib butt will
occur, possibly causing jib to collapse.
Do not allow jib or backstay straps to become too tight

during lowering steps. Crane will tip or structural damage
will result.
Do not allow jib and backstay straps to become too slack
during lowering steps. Jib strut could fall onto jib butt.
4.
Position boom at 70 or higher boom angle.
10. Continue with Jack-Knife Lowering Procedure steps 79

until boom top is resting on blocking at ground level.
5.
Slowly luff down to position jib at required boom to luffing

jib angle (see Raising Procedure Chart for angle).
11. Slowly luff down to lower jib strut until jib straps rest in
strap storage brackets on jib.
4-32
12. Lower struts as described in Removing Jib later in this

section.
Removing #44 Luffing Jib
8.
Lowering Main Strut
Lowering Jib Strut
1.
Disconnect both erection pendants from storage bar on

main strut (Figure 4-7, View A).
2.
Connect one erection pendant to load line from (Drum 1)

(Figure 4-7, View C).
3.
Connect other erection pendant to sling from assist

crane.
WARNING
Moving Part Hazard!
Do not stand on boom top or jib butt while either strut is
being lowered.
Wait until struts have been stopped and are supported by
load line or luffing hoist line before climbing onto boom top
or jib butt during disassembly.
1.
2.
3.
If boom will be removed, disconnect hydraulic hoses

between boom inserts (Figure 4-8, View D). Install dust
caps.
Pay out luffing jib hoist line (Drum 6) to lower jib strut.
Continue lowering strut until jib straps are resting in
strap brackets and adjustable straps are fully retracted
(Figure 4-10, View G). Strut will be at approximately 45.
Remove locking pins from storage holes and install in
adjustable straps (Figure 4-10, View H). Luff up or down
to align holes in straps.
Haul in assist crane load line until erection pendant is

hanging vertically above main struts. Keep pendant
slack.
4.
Disconnect basic backstay straps from backstay straps

on boom (Figure 4-7, View F).
5.
Pin links in storage position on boom (Figure 4-14, View

B).
6.
Attach taglines to end of basic backstay straps. Taglines

should be about 20 ft (6,1 m) long.
7.
Slowly haul in luffing hoist wire rope while paying out

load line from Drum 1 to pull main strut forward.
Disconnect inner straps from jib straps. (Figure 4-10,

View J). Luff up or down to loosen pins.
Match rate of speed that luffing hoist wire rope is

hauled in with speed that load line from Drum 1 is
payed out so strut moves smoothly past vertical
without falling.
Once strut is past vertical, keep luffing hoist wire

rope slack while paying out load line.
Guide basic backstay straps into storage brackets

on side of strut with taglines.
Store pins in inner straps.

4.
Store adjustable straps:

a.
Release ratchet on hand winch (Figure 4-10, View

F).
b.
Disconnect cable from storage lug on jib strut

(Figure 4-10, View F).
c.
Attach cable to lug on adjustable strap (Figure 4-10,

View H).
d.
Remove retaining pin from storage hole in outer

strap (Figure 4-10, View H).
e.
Using hand winch, raise adjustable strap to storage

position (Figure 4-9, View E).
f.
Install retaining pin to secure adjustable strap to jib

strut (Figure 4-9, View D).
g.
Repeat preceding steps 4a 4f for other adjustable

strap.
5.
Lower jib strut onto strut supports (Figure 4-9, View F).
6.
Continue to luff down until main strut comes to rest on

boom top wire rope guide (Figure 4-9, View F).
7.
Disconnect hydraulic hoses from jib strut at boom top

(Figure 4-8, View E). Install dust caps.
Coil hoses and tie them to jib strut for storage.
8.
Lower main strut to approximately 45 and stop

(Figure 4-7, View D).
9.
Haul in assist crane load line until assist crane is

supporting strut.
10. Lower strut with assist crane while keeping luffing hoist
wire rope and load line from Drum 1 slack.
11. Stop lowering main strut when it comes to rest on jib
strut.
12. Remove taglines.
13. Disconnect erection pendants from assist crane and
Drum 1 load line.
Connect pendants to storage bar on main strut for
storage.
14. Install strap storage pins in shipping holes to secure
straps to sides of main strut (Figure 4-7, View B).
Remove Struts
4-33
1.
Remove main strut, as follows:

a.

lugs on main strut (View D).
Rear slings should be 6 - 8 ft (1,8 - 2,4 m) longer
than front slings.
b.
c.
2.
b.
Lift main strut into position over jib strut.
c.
Swing, boom, and hoist assist crane as required to

engage latch on main strut with hook on jib strut
(View D).
Attach taglines to strut so that swing motion can be

controlled when hinge pins are removed.
Use care not to hit strut stop cylinders with main

strut.
Remove keeper plate from both sides of adapter

frame (View C).
d.
Remove retaining pins from jib strut holes (View E).
Lift main strut so slings are taut and hinge pins are
loose.
e.
Align holes in end of main strut with holes in end of

jib strut and install retaining pins (View E).
e.
Remove hinge pins.
f.
f.
Lift main strut away from adapter frame and jib strut,
and place main strut on blocking at ground level.
Lift strut assembly onto transport trailer and

disconnect slings.
g.
Disconnect slings from main strut.
h.
Reinstall hinge pins and keeper plates in adapter

frame for storage.
Remove jib strut, as follows:

lugs on jib strut (View B).
Rear slings should be 6 - 8 ft (1,8 - 2,4 m) longer
than front slings.
b.
c.
Attach taglines to strut so that swing motion can be

controlled when hinge pins are removed.
Remove keeper plate from both sides of adapter
frame (View A).
d.
Lift jib strut so slings are taut and hinge pins are
loose.
e.
Remove hinge pins.
f.
Lift jib strut away from adapter frame and place jib
strut on ground.
g.
Disconnect slings from jib strut.
h.
Reinstall hinge pins and keeper plates in adapter

frame for storage.
4-34

lugs on main strut. Lift strut so it is level.
d.
a.
3.
a.
The main strut, jib strut, and adjustable straps can be

shipped as an assembled unit to reduce shipping space.
To assemble struts for shipping, proceed as follows:
Removing Jib Attachment
WARNING
Collapsing Boom/Jib Hazard!
Improper disassembly of boom and jib sections can cause
boom or jib to collapse onto personnel removing
connecting pins.
Death or serious injury can result if precautions listed
below are not taken:
Lower boom/jib so boom and jib points are supported

on blocking or ground.
Slacken rigging do not attempt to remove

connecting pins while boom or jib is supported by
rigging.
Block below both ends of each boom or jib section

before removing connecting pins.
Stand on outside of boom or jib sections when

removing connecting pins. Never work under or
inside boom or jib sections. Use care not to damage
lacings and chords as pins are knocked out.
Remove jib in opposite sequence of installing jib.

Automatic boom stop must be reset to 85 for MAX-ER
operation without jib.
LUFFING JIB RIGGING GUIDE #79A

General
The following installation, raising, lowering, and removal
instructions apply to the #79A luffing jib mounted on a #55 or
#55A boom.
As shown on the Luffing Jib Assembly drawing, 20 ft (6,1 m)
and 40 ft (12,2 m) inserts from a #79 boom can be used to
make up the desired jib length. However, the jib has a
different 20 ft (6,1 m) butt with a special 20 ft (6,1 m) insert,
and a different top.
The heaviest individual parts to be lifted are the strut tops

which are shipped assembled together. This assembly
weighs approximately 18,500 lb (8 392 kg).
The assist crane must also be capable of handling the
following weights:
Main Strut 50,000 lb (22 680 kg) during strut raising

and lowering. The assist crane must have a hook height
of 110 ft (33,5 m) minimum.
Jib maximum of 100,000 lb (45 360 kg) when lifting jib

point onto the dolly. This is 1/2 the weight of the
maximum jib length.
Assist Crane Requirements

An assist crane is required for jib installation and removal.
4-35
THIS PAGE BLANK
4-36
View C
P1231
6
2
1A
1A
3
2
4-146
4
3
1B
1B
12
View B
Operation
View A
Straps Stored
13
10
4-149
14
View D
4-148
View G
(stored) 8
13
8 (working)
9 (working)
12
Lugs B
(2 places)
Lug A
4
11
4-150
10
4-151
9 (stored
location not visible)
Item
1A
1B
2
3
4
5
6
7
8
Description
Storage Pin (strap stored)
Storage Pin (operation)
Strap Bracket (typical)
Link (typical)
Strap (typical)
Connecting Pin (typical)
Collar (typical)
Retaining Pin (with cotter pins)
Drum 6 Wire Rope Guide
Item
9
10
11
12
13
14
15
16
View F
View E
Description
Pin with Snap Pin
40 ft (12,2 m) #55 Insert with Drum 6
Sheaves
#55 Boom Top
Wire Rope Guide
Connecting Pin with Snap Pins
Link with Pins and Snap Pins (stored)
Counterweight Box
Lug
P2118
15
16
View H
FIGURE 4-18
4-37
Preparing Crane, Boom, and Mast
e.

1.
Lower boom to ground level onto blocking approximately

4 ft (1,2 m) high.
2.
Remove load block.
3.
If installed, remove load block and upper boom point.
4.
Boom point sheave assembly can be installed on boom

point.
5.
Connect unused block-up limit electric cords to

terminating plugs on boom point junction boxes.
6.
If necessary, remove 40 ft (12,2 m) insert and install 40 ft

(12,2 m) insert with Drum 6 sheaves (10, View F).
7.
Raise luffing hoist wire rope guide (8, View F) on boom

insert (10):
8.
4-38
a.
Remove stored pin (9).
b.
Rotate wire rope guide with assist crane as shown.
c.
Using pin (9), pin wire rope guide to Lug A.
Raise boom top wire guide:

a.
Support wire rope guide (12, View D) with sling from

assist crane.
b.
Remove connecting pins (13, View D).
c.
Rotate wire rope guide to working position (View E).
d.
Pin wire rope guide to Lugs B (View E) with pins

(13).
9.
Do not install links and pins (14, View D) for luffing

jib configuration.
Make sure removable strap brackets for luffing jib (18,

Figure 4-21, View J) are installed on main strut butt.
10. If necessary, add lugs (16) for counterweight tie links to

top crane counterweight boxes (15), one on each side,
as shown in Figure 4-18, View H.
Install Backstay Straps on Boom

Starting at butt end of boom, install backstay straps in proper
sequence on boom sections according to Luffing Jib Rigging
Drawing. This step is required only if straps are not stored on
boom sections.
To prevent interference between pins, heads of boom strap

pins must face outboard sides of boom; heads of backstay
strap pins must face inboard as shown in View C.
If the straps are already installed, proceed as follows:
1.
Remove storage pins from top hole (1A, View A) in

brackets (2).
2.
Store pins in bottom holes (1B, View B) in brackets (2).
3.
Rotate links (3) forward and pin to adjacent straps (4,

View B).
4.
Retain connecting pins (5, View B) with collars (6, View

C) and retaining pins (7).
10
12
1
2
11
3
4-152
13
5
(stored)
4
5
(working)
4-164
P2149
Item
1
2
3
4
5
6
Description
Fill Plug
Support Frame
Reservoir, 4.7 gal (17,8 L)
Drain Plug
Jib Stop Positioner
Boom Top
Item
7
8
9
10
11
12
13
Description
Manifold Valve
Pressure Gauge
Pump, Manual
Pump Handle
Accumulator, 5 gal (18,9 L)
Dipstick
Jib Stop
FIGURE 4-19
4-39
Jib Stop Positioner Hydraulic System Operation
CAUTION
Structural Damage!
Read and adhere to these instructions to prevent
structural damage to components.
Positioner cylinders are extended and retracted using
crane mode switch in operators cab. Read Section 3 in
this manual and Section 3 in the crane Operators Manual
for mode selection instructions.
11. Pump until oil level is at low mark on dipstick. Gauge

reading must be 2,450 2,500 psi (169 172 bar).
Record pressure on inspection record.
12. Seal fill and dipstick ports with hydraulic sealant.
Procedure For Raising Boom And Jib

1.
Pump hand pump until pressure gauge reads 2,500 psi

(172 bar).
2.
Disengage safety latch using hand winch in jib top.
3.
Set spring tension adjustment: 8-3/4 in (222 mm)

minimum to 9 in (229 mm) maximum (see Set Up Jib
Stop Positioners topic in this manual).
4.
Signal crane operator to retract cylinders with mode

switch.
5.
Release tension on safety latch cable allowing enough

slack for engagement when cylinders are extended.
Slack must be at safety latch.
6.
Raise boom to where boom to jib angle is 140.
NOTE:
7.
Signal operator to extend cylinders with mode switch.

Cylinders will extend and remain pressurized.
8.
Verify safety latches are latched to prevent cylinders

from retracting.
9.
Continue raising boom and jib to working position.
WARNING
System Under Pressure!
Do not disconnect any part of system until system is
depressurized. Components may shift suddenly, causing
bodily injury.
This procedure requires two persons: one at the

boom top and an operator in the cab.
Initial Setup
1.
Cylinders begin retracted and connected to jib stops.
2.
Verify that accumulator pressure corresponds to

pressure in following table (depending on ambient
temperature).
Ambient Temperature
Procedure For Lowering Boom And Jib

1.
Lower boom and jib. With jib in dolly, boom down until
boom to jib angle is 140.
2.
Release jib safety latch with hand winch in jib top.
3.
Signal crane operator to retract cylinders with mode

switch.
4.

5.
Continue lowering boom slowly verifying that stops do

not engage pins in boom top.
6.
Continue to lower boom and jib to ground.
7.
Signal crane operator to extend cylinders with mode

switch. If cylinders do not extend automatically,
manually pump cylinders to extended position.
Pressure
Interpolate as Required
30F (-1C)
1600 psi (110 bar)
50F (10C)
1665 psi (115 bar)
70F (21C)
1730 psi (119 bar)
90F (32C)
1796 psi (124 bar)
3.
Put 2-1/2 gallons (10 L) of MCC A03745 Arctic 15 prefiltered hydraulic oil in reservoir. Leave fill cap off.
4.
Prime pump by pressuring reservoir slightly with usersupplied air pressure.
5.
Begin pumping hand pump. Bleed cylinder and

accumulator lines. When fluid flows clear, close lines.
6.
Continue pumping hand pump. Cylinders will extend.
7.
When cylinders are fully extended, signal operator to

retract cylinders. with mode switch. Weight of jib stops
will retract cylinders.
8.
Repeat steps 6 and 7 for 3 cycles to expel all air from

cylinders and lines.
9.
Pump hand pump until cylinders are fully extended.
Periodic Check Of Oil Level

See Section 5 of this manual for oil change interval and
instructions.
10. Adjust tank oil level to top mark on dipstick. Dipstick

should rest on tank fitting for proper oil level check.
4-40
7 (stored)
1
4-154
4-153
View A
View B
Blocking
9 (stored)
6
12
4-155
View C
4-157
P2112
P2113
View D
View E
View M
4-156
4-158
11
10
(stored)
1
17
(typical)
View J
View L
P2115
View K
10
(working)
P2508
11
13
9
2
P2114
View F
15 (typical)
14
18
19a
16
4-160
19b
View H
13
14
20
View I
P2124
View G
FIGURE 4-20
4-41
Installing #79A Luffing Jib
NOTE:
Install Jib and Main Strut Butts

Main strut top and jib strut top are shipped together
as shown in View H. Main strut top is above jib strut
top.
1.
Using appropriate slings attached to main strut top (14,

View H), lift jib strut/main strut tops into position at jib
strut butt (2). Adjust slings so butt end of top is higher
than top end.
2.
Position jib strut top (13) so bottom connecting holes in

strut top line up with connecting holes in jib strut butt (2)
3.
Connect jib strut butt (2) to boom top (3) with connecting
pins (4, View D) (pin heads toward outboard side).
Install connecting pins (15, View K) and safety pins (pin

heads facing outboard side).
4.
Lower jib strut top onto blocking 3 ft (0,9 m) high.
3.
Securely fasten keeper plates (5, View D) to pins (4).
5.
Disconnect assist crane from slings. Remove slings.
4.
Temporarily attach end plates (6, View D) over ends of

pins (2). Block top end of jib strut butt approximately 3 ft
(0,9 m) high.
Install Luffing Hoist Wire Rope
NOTE:
1.
2.
Main strut butt (1) and jib strut butt (2) are shipped
together as shown in View A. Main strut butt is
above jib strut butt.
Using appropriate slings, lift jib strut/main strut butts into

position at boom t op (3) and align jib strut b utt
connecting holes (View A).
5.
Lower main strut/jib strut butts onto blocking about 3 ft

(0,9 m) high.
6.
Support main strut butt (1) with slings from assist crane,
and remove shipping pins (9, View A).
7.
Remove pin (8, View A) from strut support A (7).
8.
Rotate strut support A (7) to stored position on jib strut

butt and connect to lugs with pin (8) (View B).
Shipping jib strut top (13) and main strut top (14) assembled
as shown in Figure 4-20, View H allows reeving a sucker line
through the luffing sheaves in the strut tops. See Luffing Jib
Rigging Drawing for wire rope specifications.
Make sure wire rope is properly anchored to Drum 6

(luffing hoist) and tightly spooled onto drum.
Make sure Drum 6 wire rope guide is raised in 40 ft (12,2

m) boom insert.
Make sure wire rope passes under lower sheave and

over upper sheave in 40 ft (12,2 m) boom insert.
Make sure wire rope passes under sheave in boom top

wire rope guide and rollers (17, View J) in main strut
butt.
Pull out upper wire rope guide bar (19a, View I) to the left
about half way. Remove lower wire rope guide bar
completely (19b). If this step is not performed, wire
rope damage can occur when main strut is raised.
Main strut butt is now separated from jib strut butt.

9.
Lift main strut butt about 1 ft (300 mm) clear of jib strut
butt.
10. Store shipping pins (9, View C) in lugs on jib strut butt.
11. Lift main strut butt (1) into position at boom top (3) and
align connecting holes.
12. Using pins (12, View M), connect main strut butt to boom
top.
Do not remove upper wire rope guide bar completely.

You will not be able to reinstall it after main strut is
raised.
13. Remove strut supports B shipping pins (11, View E).

14. Rotate strut supports B (10, View F) to working position.
15. While lowering main strut butt (1), guide saddles in strut
supports B (10) to rest on pins (9, View C) attached to
lugs on jib strut butt.
Route wire rope through proper sheaves as shown in

reeving diagram on Luffing Jib Rigging Drawing.
Pull lead end of luffing hoist wire rope approximately 100

ft (30,5 m) past end of struts and lay on ground. This will
allow strut to be raised to erection position.
Anchor lead end of luffing hoist wire rope to socket (20,

View G) in main strut top (14)
16. Disconnect assist crane from lifting slings.
Install Jib Strut Top

Component Identification for Figure 4-20
Item
1
2
3
4
5
6
7
4-42
Description
Main Strut Butt
Jib Strut Butt
Boom Top
Connecting Pin
Keeper Plate
End Plate
Strut Butt Support A
Item
8
9
10
11
12
13
14
Description
Shipping Pin with Wire Lock
Shipping Pin with Cotter Pins
Strut Support B
Storage Pin with 2 Cotter Pins
Connecting Pin with 2 Cotter Pins
Jib Strut Top
Main Strut Top
Item
15
16
17
18
19a
19b
20
Description
Connecting Pin with Safety Pin
Luffing Hoist Wire Rope
Roller
Wire Rope Guide
Wire Rope Guide Bar (upper)
Wire Rope Guide Bar (lower)
Dead End Socket
7 (stored)
4-161
6
4
7 (working)
4-162
View B
4-163
View C
(working)
6
1
P2116
View D
(stored)
5
4-160
View A
See
Figure 4-20,
View K
9
(stored)
P2118
P2117
View E
View F
24
P2119
9
(working)
4-165
View O
23
19
15
18
21
11
View G
16
10
13
22
14
13
20
12
1
3
P2121
View N
17
P2120
View L
18
19
P2122
160200 ft
(48,861,0 m)
4-166
220360 ft
(67,1109,7 m)
21
View H
15
View M
17
P2123
View J
FIGURE 4-21
4-43
Install Main Strut Top
3.

Connect Main Strut Top to Strut Butt
Rotate links (15, View L) forward and pin to links (14)

using pins (16) stored in links (15) (pin heads facing
outboard side).
Install collars, retaining pins, and cotter pins.
1.
Support main strut top (3, View A) with slings from assist
crane. Adjust slings so butt end of top is higher than top
end.
2.
Remove rear shipping pins (7, View B).
3.
Remove pins (6, View C) from strut support C.
4.
Lift main strut top clear of jib strut top.
5.
5.
Store rear shipping pins (7, View B) in lugs on jib strut

top.
Connect Jib Strut Top to Counterweight
6.
Rotate strut supports C (5, View D) into stored position

and pin to jib strut top with shipping pins (6).
7.
Move strut top slowly to the rear while paying out luffing
hoist wire rope from Drum 6 so that wire rope between
struts pays out smoothly without kinking or binding.
8.
Install bottom and top connecting pins (15, Figure 4-20,

View K) and safety pins.
9.
Remove pins (23, View N) securing adjustable straps

(21) to shipping brackets (22) mounted on strut stop
cylinders (20).
Pins (23) will be used to attach adjustable links to
backstay straps on boom butt.
When sufficient wire rope has been paid out, position

main strut top in front of main strut butt (View O).
NOTE:
4.
Top connecting pins are 2 in (51 mm) in diameter.

Bottom connecting pins are 2-1/2 in (64 mm) in
diameter.
Raise insert until top connecting holes line up and install

connecting pins and safety pins.
WARNING
Falling Equipment Hazard!
Counterweight is required to prevent jib strut from rising
when main strut is raised with luffing hoist.
If counterweight becomes disconnected from jib strut, jib
strut will rise part way and then both struts could fall
forward violently. Minimum capacity required for slings is
25,000 lb (11 340 kg) per side.
1.
1.
Remove shipping pins (10, View H) from strap brackets

(11) and store in hole (12).
2.
Remove shipping pins (18, View J) from straps on main

strut butt. Store in brackets (17, View L).
Remove one top crane counterweight box from each

side of crane counterweight.
Boxes must be equipped with tie link lugs.
2.
Stack counterweight boxes (8, View F), one at a time, at

jib strut top (4, View O).
3.
Secure lifting lugs on top counterweight box (5) to lugs

on jib strut top (4) with shackles and suitable slings (24,
View F).
4.
If desired, front counterweight tie links (9, View G) may

be connected at this time. Do not connect rear
counterweight tie links (9, View E).
10. Disconnect assist crane from slings. Remove slings.

Connect Backstay Straps
If necessary, adjust length of adjustable links (21) for

boom length (View M).

Item
1
2
3
4
5
6
7
8
9
10
11
12
4-44
Description
Main Strut Butt
Jib Strut Butt
Main Strut Top
Jib Strut Top
Strut Support C
Pin with Wire Locks
Pin with Wire Locks
Crane Counterweight Boxes
Counterweight Tie Links
Strap Shipping Pin with Snap Pins
Strap Bracket
Storage Hole for Shipping Pin
Item
13
14
15
16
17
18
19
20
21
22
23
24
Description
Backstay Strap
Link
Connecting Link
Connecting Pin with Collar, Retaining Pin and Cotter Pins
Removable Strap Bracket
Strap Shipping Pin with Cotter Pin
Retaining Pin with Cotter Pins
Strut Stop Cylinder
Adjustable Link
Strap Bracket
Connecting Pin with Collar, Retaining Pin and Cotter Pins
Sling and Shackle
Install Backstay Straps on Main Strut

1.
2.
Install backstay straps on main strut as shown in

Figure 4-22.
Main Strut
4-167
Jib Strut
1
5a
5b
7
Store on
Main Strut
Adjust length and position of straps (14) as shown on

Luffing Jib Rigging Drawing.
8a
10
8b
9
10
11
14
9
12
9
9
13
10
9
Connect to Backstay Straps on Boom Inserts
Connect to Jib Strap Equalizer

and Straps on Jib Inserts
Item Description
Length
1*
Link
50 in
1270 mm
2*
Pin with Collar and Retaining Pin (3 in dia.)
10-1/16 in
256 mm
3
Link (3.375 in dia.)
18 in
457 mm
4
Pin with 2 Collars and Retaining Pins
10-5/8 in
270 mm
5a
Spreader
42-5/16 in
1075 mm
5b
Spreader
27-31/32 in
710 mm
6
Strap
14 ft, 0-5/8 in
4,5 m
7
Link
18 in
457 mm
8a
Spreader
94 in
2,4 m
8b
Spreader
84-1/2 in
2,146 mm
9
Pin with Collar and Retaining Pin (3 in dia.)
6-1/2 in
165 mm
10
Link
8-5/8 in
219 mm
11
Strap
105-1/4 in
2,7 m
12
Link
48 in
1,2 m
13
Adjustable Link
46-1/2 in
1181 mm
14
Strap
17 ft, 10-1/2 in
5.5 m
* These in corresponding Strut Top
NOTE: Links and Straps Hole-to-Hole, Pins are Overall Length
Quantity
4
4
4
8
2
2
8
4
1
1
10/6 main/jib
4/8 main/jib
2
4
1
2
FIGURE 4-22
4-45
Raise Main Strut
See Figure 4-23 for following procedure steps.

1.
Make sure all strap storage pins (4, View B; 5, View C)

on main strut (8) are stored.
2.
Check that strut raising pendants are lying over strut

backstay straps.
3.
Verify that top of jib strut is properly anchored to

counterweight (Figure 4-21, Views E, F, and G).
4.
Check strut stop cylinder to verify the following:
Ambient Temperature
Pressure
Interpolate as Required
Strut stops (1) are fully retracted and retaining pins

(2, View A) are installed.
30F (-1C)
230 5 psi (15,8 0,3 bar)
50F (10C)
240 5 psi (16,5 0,3 bar)
70F (21C)
250 5 psi (17,2 0,3 bar)
90F (32C)
260 5 psi (17,9 0,3 bar)
If difference in strut stop cylinder pressure is greater

than 5 psi (0,3 bar) or pressures are not within limits
specified in the preceding table, contact factory for
assistance.
Strut stops are pinned to strut butt. Do not remove

pin (7, View D).
Precharge pressure on strut stop pressure gauges

(3, View A) corresponds to pressure in the following
table:
P2125
P2121
P2122
6
4
1
View A
View B
View C
4-165
1
Item
1
2
3
4
5
6
7
8
WARNING
Cylinder Movement Hazard
Strut cy linder will extend forcefully if
cylinder rod retaining pin (7, View D) is
re m o v e d a n d c a u s e p e rs o n a l in ju ry.
Extending cylinder will damage strut by
twisting.
P2126
4-46
Description
Strut Stop Cylinder
Retaining Pin with Cotter Pin
Pressure Gauge
Strap Shipping Pin (stored)
Strap Shipping Pin (working)
Storage Hole for Shipping Pin (5)
Cylinder Rod Retaining Pin with Snap Pin
Main Strut
View D
FIGURE 4-23
1
1
6
11
12
1
POSITION
E
POSITION
D
1
POSITION
C
10
P2127
View F
16
P2128
POSITION
B
1
13
POSITION
A
17
4-168
View A
2
View E
6
14
POSITION F
6
13
15 (working)
4-169
P2129
View D
15 (stored)
14
13
View B
P2130
View C
Item
1
2
3
4
5
6
7
8
9
Description
Drum 3 Load Line
Socket
Pin with Cotter Pin
Links
55 USt (50 t) Shackle
Strut Handling Pendants
Link
Pin with Collar and Retaining Pin
Boom Backstay Strap
Item
10
11
12
13
14
15
16
17
Description
Link
Strut Backstay Strap
Pin with Collar and Retaining Pin
Main Strut
Strut Stop
Drum 3 Luffing Hoist Line
Upper Crane Counterweight Box
FIGURE 4-24
4-47
Raise Main Strut (continued)

5.
6.
Connect Drum 3 load line (1) to links (4) as shown in

View E.
Use same socket used to anchor load line to boom

or jib point.
Make sure Drum 3 load line passes over Drum 3

guide sheave in mast.
Make sure Drum 3 load line passes through center

of the slack boom hoist wire rope reeving and over
the boom hoist equalizer (which should be resting
on boom rails).
NOTE:
7.
8.
9.
CAUTION
Attach assist crane to main strut lifting links (4, View E)

with user-supplied 55 USt (50 t) shackle (5, View E).
After the main strut is fully raised, it will be

necessary to lift the boom hoist equalizer slightly to
pass the load line under the equalizer.
Remove pins (8, View E) from links (4) on main strut (13)
and raise links 2 - 3 ft (0,6 - 0,9 m). Store pins (8) in
same holes after links are raised.
Slowly raise pendants (6) until it is taut (POSITION A,
View A). Pay out Drum 3 load line (1), if required.
Continue to hoist pendants (6) to raise main strut (13) to
POSITION B. Pay out Drum 3 load line (1) and luffing
hoist wire rope (16) as strut rises.
Keep pendants (6) vertical during this step.

NOTE:
Control hoist speed by observing upper

counterweight box (17, View A). Upper box must
not lift off lower box during strut raising procedure.
Overload Hazard!
Do not allow upper crane counterweight (17) box to lift off
lower box at any time during strut raising procedure. Load
line and pendants could be overloaded, possibly resulting
in damage.
10. Once main strut is at approximately 45 (POSITION C,
View A), slowly haul in Drum 3 load line (1) while paying
out luffing hoist wire rope (16).
11. Follow with assist crane pay out load line and travel
while performing step 10.
Do not induce any side load in main strut with assist

crane. Load line from assist crane should remain
vertical during strut raising procedure.
12. When main strut is approaching vertical POSITION
D, pay out load line from assist crane so that pendants
(6) and Drum 3 load line (1) start to pull in a straight line.
13. Continue to luff down and haul in Drum 3 load line (1)
while following with assist crane to lower main strut until
backstay straps can be connected (POSITION E).
Watch closely as strut lowers so that load line does

become tangled in boom hoist equalizer. Signal
operator as required.
14. Connect backstay straps (11) to connecting links (10)
using pins (12) (View F).
15. Connect rear tie links (9, Figure 4-21, View E) between
two crane counterweight boxes at jib strut top.
16. Slowly luff up to raise main strut to POSITION F.
17. Remove retaining pins (15, View D) from strut stops
(14).
Support strut stops when removing pins. Strut stops

will swing away from main strut.
18. Store pins (15) in lugs on main strut (13, View C).
Continued On Next Page
4-48
View A
View B
P2132
P2131
9
(shipping)
P2133
9
(working)
8
(shipping)
POSITION G
10
View H
1
P2134
8
(stored)
2
POSITIO
NH
4-170
View C
View G
View F
6
(stored)
View E
View D
6
7
4
P2135
P2136
P2137
5
Item
1
2
3
4
5
Description
Luffing Hoist Line (Drum 6)
Main Strut
Strut Stop
Boom Top
Pin with 2 Cotter Pins
Item
6
7
8
9
10
4
Description
Cylinder Rod Retaining Pin
Lug
Tube Retaining Pin
Strut Locking Pin
Handling Pendants
FIGURE 4-25
4-49
Raise Main Strut (continued)

27. Remove retaining pins (6, View E) and store as shown in

View F.
19. Slowly luff down to lower main strut (2) to rear

POSITION G (View C).
28. Slowly pay put Drum 3 hoist line. Cylinder rods will
extend, allowing strut to rotate forward (View F).
Stop when strut stops (3) are just above boom top (4) as
shown in View D.
29. Store handling pendants (10) and links:

a.
Leave assist crane attached to the links at end of

handling pendants (10).
b.
Lower links with assist crane and pay out Drum 3

hoist line until handling pendants are hanging
vertically between backstay straps.
20. Remove pins (5, View D).
WARNING
Cylinder Movement Hazard
Strut cylinder will extend forcefully if cylinder rod pin (6,
View D) is removed and cause personal injury. Extending
cylinder will damage strut by twisting. Strut may fall.
21. Swing strut stops (3) to rear and position main strut (2)
as needed to align holes in strut stop (3) with lugs (7) on
boom top (View E).
Pendants will lie against cross brace between

straps.
c.
Disconnect Drum 3 hoist line from links and lay hoist

line on top of boom.
d.
Disconnect one handling pendant from links and

allow to pendant to hang vertically.
e.
Use assist crane to lift other pendant (with links)

back up and outside of jib backstay straps. Lower
pendant to vertical and disconnect assist crane from
links.
f.
Repeat step 29e for other pendant.
g.
Reconnect pendant to links and pin links with

handling pendants to jib strut butt.
h.
Use assist crane to lift Drum 3 hoist line into position

behind boom hoist equalizer. Haul in excess line on
Drum 3.
i.
If Drum 3 hoist line will not be used, store it on Drum

3.
22. Pin strut stops (3) to lugs (7) on boom using pins (5)
(View E).
23. Remove tube retaining pins (8, View H) and store as
shown in View G.
24. Remove strut locking pins (9, View A) from stored
position.
25. Insert pins (9) in lower holes on outer stop tube (View B).
Luff up as needed to align holes in strut stops.
26. Pull strut slightly to rear by slowly hauling in Drum 3 hoist
line slightly to remove load on cylinder rod retaining pins
(6, View E).
CAUTION
Strut Damage!
Pulling strut too far to rear will damage strut and/or strut
stop cylinders.
30. Disconnect crane counterweight from jib strut top

31. Disconnect tie links from
(Figure 4-21, Views E and G).
boxes
32. Remove boxes, one at a time, and install. Place one box
on each side of crane counterweight
33. Reinstall wire rope
Figure 4-20, View I).
4-50
counterweight
guide
bars
(19a
and
19b,
70
1
2
4
5
6
P2138
View B
12
6
5
4-171
View A
View D
9
10
11
12
2
View C
P2139
1
P1370
Lift
Here
14
24
Operating
Position
23
22
12
17
20
25
19
13
21
23 22 23
Stored
4-172
View G
4-174
4-173
24
Shipping
Position
P2141
Lift
18
17
View H
15
14
13
View F
16 and 16a
View E
FIGURE 4-26
4-51
Raise Jib Strut
Wrap slings around chords only. Do not use lifting

lugs on butt or inserts and do not lift against lacings.
See Figure 4-26, Views A D for following procedure.

1.
Slowly luff up to raise end of jib strut to desired working

height.
2.
Support links (1) so they cannot fall and remove link

storage pins (3) from shipping holes (View D).
3.
Lower links (1). Store link storage pins (3) in shipping

holes.
4.
Connect links (4), spreaders (7, 8), and jib straps (6) to
jib strut (14) as jib strut is raised (Views B and C).
5.
Attach a 20 ft (6,1 m) long sling to end of each strap (12).

Slings will be used to pull jib strut down later in
procedure.
6.
Slowly luff up to raise jib strut to no higher than 65 to

70 as shown in View A.
Install Jib
Jib assembly is identical to boom assembly. The

following instructions assume that assembly
personnel already know how to assemble the
boom (jib) sections. If in doubt, see Boom Rigging
Guide in Crane Operators Manual.
See Luffing Jib Assembly drawing at end of this
section for proper positioning of jib sections.
1.
Install Jib Butt and First Two Inserts:

a.
Assemble jib butt (13) and first two inserts (19, 21)
on blocking in front of boom.
b.
Using nylon slings and a four point hookup from

assist crane, hook onto butt and first two inserts.
Lift jib butt and inserts into position at end of boom

top (20) as shown in View G.
d.
Guide jib butt as required so jib stops (17) are

outside of jib strut (14) as shown in View F.
e.
Align connecting holes in jib butt (13) with holes in

boom top (20) and install keeper plates (15, View E)
and end plates (16).
f.
Apply Loctite to jib strut and jib butt keeper plate cap
screws. Securely tighten keeper plate screws.
Torque to 100 ft-lb (136 Nm).
g.
Lower jib butt and inserts onto

approximately 8 in (203 mm) high.
Assemble remaining jib inserts and jib top in proper

sequence as shown on Luffing Jib Rigging Drawing.
3.
Unpin jib straps from stored position on inserts and

connect links between straps.
4.
Raise jib top wire rope guide:
See Figure 4-26, View H for following procedure.

a.
Remove links (22) and pins (23) from storage.
b.
Support wire rope guide (24) with slings from assist

crane.
c.
Remove pins (23) from lugs (25).
d.
Raise wire rope guide (24) to operating position.
e.
Pin links (22) to wire rope guide (24) and to lugs (25)
with pins (23). Wire rope will rub on jib point if
links are not installed.
f.
Store extra two pins (23) in link storage lugs.

Item Description
Item Description
1
Links (4)
14
Jib Strut (1)
2
Pin w/Collar and Retaining Pin (2)
15
Keeper Plate (2)
3
Link Storage Pin (2)
16
Pin (2)
4
Link (2)
16a End Plate with Cap Screws (4)
5
Pin w/Collar and Retaining Pin (4)
17
Jib Stop
6
Strap (4)
18
Jib Stop Support
7
Spreader (2)
19
20 ft (6,1 m) Jib Insert with Bracket Lugs*
8
Spreader (1)
20
Boom Top
9
Link (2)
21
20 ft (6,1 m) or 40 ft (12,2 m) Insert*
10
Link (4)
22
Link (2)
11
Pin w/Collar and Retaining Pin* (4)
23
Pin with Snap Pins (6)
12
Jib Strap (2)
24
Wire Rope Guide
13
Jib Butt (1)
25
Lug (2)
Number in parenthesis ( ) equal quantity.
* See Luffing Jib Assembly drawing for quantity and installation location.
4-52
blocking
2.
See Figure 4-26, Views E G for following procedure.

NOTE:
c.
Lift
11
26
P2146
10
11
12
10
25
4
Working
11
7
7
6
8
View C
4
Stored
11
4-176
4-175
25
View B
22
3
1
View A
4-177
14
16b
20
17
19
View D
View F
P2147
P2144
23
19
19
24
21
P1378
View E
View G
P2149
13
Working
15
14
13
Stored
4-178
15
View H
16a
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
Jib Insert (typical)
Jib Top
Strut Strap
Strap Support Bracket
Pin with Cotter Pins
Jib Strap (outside)
Strap Storage Pin
Jib Strap (inside)
Equalizer
Pin with Cotter Pin
Links with Connecting Pin, Collar
and Retaining Pins
Jib Stop Positioner
Pin with Cotter Pin
Item
15
16a
16b
17
18
19
20
21
22
23
24
25
26
Description
Pin with Cap Screw and Lock Washer
Lug (Boom Top)
Lug (Jib Stop)
Jib Stop
Jib Stop Support (see Figure 4-26)
Jib Stop Cable
Cable Sheave
Shackle
Dolly
Sight Glass
Tire Inflation Valve
Upper Boom Point
FIGURE 4-27
4-53
Install Jib Strap Equalizers
e.
Remove jib stop positioner (13) from storage (View

H).
f.
Pin jib stop positioner (13, View G) to lug (16a) on

boom top and to lug (16b) on jib stop (17).
g.
Disconnect assist crane.
h.
Tighten eyebolt until positioner safety latch spring is

tensioned to approximately 9 in (229 mm) long.
See Figure 4-27, View B for following procedure.

1.
Remove strap support brackets (4) from stored position

and install in working position.
2.
Rest outside strap (7) on top of strap storage pin (8)

(installed in strap support on insert).
3.
Rest inside strap (9) on top of pin (5) (installed in strap

support bracket).
4.
Remove pins (11) from equalizer (10).
5.
Lift equalizer (10) into position at ends of straps (7 and

9).
6.
Pin equalizer to straps (7 and 9) with pins (11).
2.
Route cable (19, Figure 4-27, View G) through cable

sheaves (20) on jib stop and in boom butt and pin cable
to jib stop.
3.
Connect other end of cable to cable from hand winch as

shown in View F.
Connect Jib Strut Straps to Equalizers
Prepare Jib Dolly
1.
Check following items each time dolly (22, View D) is used:
2.
Using assist crane connected to slings on strut straps (3,

View A), pull jib strut forward and down until strut straps
can be connected to equalizer links.
Pay out luffing hoist wire rope as strut is pulled forward.
NOTE:
3.
Jib strut is not heavy enough to overhaul luffing

hoist wire rope. Approximately 15,000 lb (6 804 kg)
of pull is required.
Pin strut straps (3) to equalizer links (12, View B) with pin
heads facing outside of jib.
Complete Jib Assembly

1.
Install jib stop positioner, one side at a time:
See Figure 4-26, View F for steps a - c in following

procedure.
a.
Attach assist crane to lifting lug on jib stop (17, View

F).
b.
Support jib stop with assist crane and unpin jib stop
support (18) from jib butt.
c.
Pin support to jib stop for storage.
1.
Tire pressure at inflation valve (24, View E). Inflate to

112 psi (7,7 bar).
2.
Oil level in wheel hubs. Fill, if required, to FULL ring in

sight glass (23, View E). Use same gear oil used in drum
planetaries on crane.
Install Jib Dolly

See Figure 4-27 for following procedure
An assist crane capable of lifting half the weight of the jib is
required for the following procedure. A fork-lift truck is
required to handle the upper jib point.
1.
Attach slings from assist crane to end of jib top.
2.
Lift jib top with assist crane.
3.
Install upper jib point:
See Figure 4-27 for steps d - h in following procedure.

d.
4-54
Loosen spring tension on positioner safety latch

only enough to allow removal of pins (14 and 15,
View H).
a.
Using a fork-lift truck, lift upper jib point (25, View C)

into position at jib top.
b.
Pin upper jib point to jib top with pins (26, four
places).
c.
Remove fork-lift truck.
4.
Position dolly (22, View D) under upper jib point (25) with
the longest guide forward and to the right.
5.
Lower jib top so upper point engages saddles in dolly.
6.
Disconnect assist crane.
View C
View B
View D
P2143
11
12
P2145
P2143
P2156
4-177
7
(unlatched)
View A
8-3/4 9 in
(222-229 mm)
7
(unlatched)
1 ft (305 mm)
Slack Here
(minimum)
10
5
8
4
9
(extended)
Item
1
2
3
4
5
6
P2149
View F
Description
Jib Insert (typical)
Jib Top
Hand Winch
Cable
Cable Sheave
Junction Box
Item
7
8
9
10
11
12
9
(retracted)
View E
P2150
Description
Safety Latch
Spring
Hydraulic Cylinder
Jib Stop
Pump Handle
Pressure Gauge
FIGURE 4-28
4-55
Install Jib Load Line
Install Wind Speed Indicator Assembly
Route load lines through proper guide sheaves on boom

butt, on boom top, and in jib strut. The position of the guide
sheaves in the strut must match the guide sheaves on the
boom top.
Install wind speed indicator if removed for shipping. Use star

washers to attach mounting bracket to jib top to provide good
a ground (see Wind Speed Assembly drawing at end of this
section).
Pull load lines approximately 40 ft (12,19 m) past end of jib

and lay them on ground. Securely fasten load lines to jib
point. Install load block after boom and jib have been jackknifed into position and dolly has been removed.
Connect electrical cable at base of wind speed mounting

bracket.
NOTE:
Load block(s) will be installed after boom and jib

are jack-knifed to required angle.
WARNING
Falling Wire Rope Hazard!
rope on jib side of attachment. Wire rope could fall off
boom. Securely fasten load line to jib point before raising
attachment.
Set Up Jib Stop Positioners
1.
Pump hand pump (11, View C) until pressure gauge (12)

reads 2500 psi (172,3 bar).
2.
Using hand winch (3, View D) in jib top, disengage

safety latch (7, View F) in jib butt.
3.
Adjust safety latch spring tension if necessary (View F).
4.
Signal crane operator in operators cab to retract

positioner cylinders. Weight of jib stops retracts
cylinders (9, View E).
Connect Electric Cords/Adjust Electronic Devices

1.
2.
Connect electric cords to respective junction boxes and

switches. See Boom Wiring Diagram at the end of this
section.
Angle indicator on jib butt.
Jib stop limit switches on boom top.
Block-up limit reel in jib butt.
Block-level sensor switches.
Jib stop positioner electrical valve.
For hard-wired load links (if equipped): install load

link, associated links, and swivel. Route and secure
load link cord so that during erection and operation
the link can pivot without pulling on the cord or
interfering with other parts.
Connect all unused electric cords to proper terminating

plugs on junction boxes.
NOTE:
3.
4-56
Block-up limit electric cords will be connected to

limit switches after boom and jib are jack-knifed to
required angle.
Adjust electronic devices according to instructions in

Section 6 of this manual:
Boom stop.
Luffing jib stop limit switches.
Jib angle indicator.
Block-level sensor switches (in this section).
WARNING
Structural Damage!
Raising boom and jib with jib stop positioner cylinders
extended will result in structural damage. Be sure
cylinders are retracted.
5.
Using hand winch (3, View D) in jib top, release tension

on safety latch cable (4).
6.
Pay out additional cable and pull cable through jib as

needed to provide at least 12 in (305 mm) slack at
safety latch. Slack is needed to allow latch engagement
when cylinders are extended.
Pre-Raising Checks
Make the following checks and correct any defects before
raising the attachment.
All installation steps given in this section performed.
Boom and jib inserts installed in proper sequence

according to Rigging Drawings.
Boom, jib, and backstay straps installed in proper

sequence and unpinned from storage positions.
All connecting pins installed and properly retained.
Boom and luffing hoist wire rope anchored properly to

drums, spooled tightly onto drums, and engaged with
proper sheaves. Make sure rope guard pins, bars, or
rollers are installed to retain wire rope in sheaves.
Main strut raised and strut stop tubes pinned in

operating position.
Main strut cylinders pressurized.
Jib stop positioner cylinders retracted.
Load lines anchored properly to drums, spooled tightly

onto drums, and engaged with proper sheaves. Make
sure rope guard pins, bars, or rollers are installed to
retain wire rope on sheaves.
LUFFING JIB mode selected and confirmed.
WARNING
Load line going to jib point is securely attached to end of

jib so load line cannot fall off jib and boom.

other mode with luffing jib attached is prohibited. Jib stop
positioner cylinders are extended and will cause structural
damage.
All blocking, tools, and other items removed from boom

and jib and from dolly travel path.

All safety devices installed, electric cords connected,

and limits adjusted.
Raising Boom and #79A Luffing Jib
Raising instructions in this section read and thoroughly

understood.
General
Proper amount of crane counterweight and, if required,

MAX-ER counterweight installed.
ALL boom and jib combinations must be raised and lowered

using Jack-Knife Method. See the Liftcrane Luffing Jib
Capacities Chart to determine the following:
Wind within allowable limits for raising boom and jib.
All lubrication points greased.
Counterweight Requirements (crane and MAX-ER).
Boom to Luffing Jib Angle.
Maximum Boom and Jib Lengths Raised or Lowered:

-
Over end of blocked crawlers.
Over end or side of unblocked crawlers.
4-57
THIS PAGE BLANK
4-58
CIRCLED NUMBERS CORRESPOND TO

JACK-KNIFE RAISING
PROCEDURE STEPS
View A
View B
4
4
4-179
4-180
9
8
9
View C
12
4
7
10
14
140
4-182
11
4-181
View D
15
17
16
19
19
15
19
4-183
View E
4-184
View F
Figure 4-29
4-59
Jack-Knife Raising Procedure
4.
Pay out load line as boom and jib are raised.
Circled numbers in Figure 4-29 correspond to numbered

steps in the following procedure.
5.
Jib and backstay straps will tighten as boom and jib rise.
Signal person, watch jib straps and jib point dolly along
left side of jib as boom and jib are raised. Do not allow jib
point to rise off dolly.
WARNING
Moving Part Hazard!
WARNING
Warn all personnel to stand clear of jib point dolly while

raising boom and jib.
Tipping Hazard!
Death or severe crushing injuries will occur if personnel

come into contact with dolly.
Do not allow jib straps to become too tight during raising

steps. Crane will tip or structural damage will result.
Do not allow jib straps to become too slack during raising
steps. Straps will bounce against jib inserts, possibly
resulting in damage.
WARNING
Tipping Hazard!
Signal operator to pay out luffing hoist wire rope (luff

down) so jib straps remain slack. Do not allow straps to
become too slack or they will bounce against jib inserts.
Keep jib straps 2-1/2 3-1/2 ft (0,76 1,07 m) above
strap supports at end of jib top.
Determine BOOM TO LUFFING JIB ANGLE that boom

and jib must be jack-knifed to before jib can be raised (see
Raising Procedure Chart). Crane will tip or structural
damage will result if specified angle is not adhered to.
Monitor angle on digital display as boom and jib are
raised.
CAUTION
Structural Damage!
Avoid possible structural damage to boom and jib from
side loading as boom and jib are raised:
Disengage swing lock and release swing brake until boom
and jib have been raised to required boom to luffing jib
angle.
Retract jib stop positioner cylinders before beginning to
raise boom and jib.

6.
Continue slowly with Jack-Knife Raising Procedure.
7.
Stop raising boom when boom to jib angle is 140.

Monitor this angle on digital display.
8.
Signal crane operator to extend positioner cylinders with

mode switch. Cylinders will extend and remain
pressurized.
9.
Verify that safety latches are in position and will prevent

cylinders from retracting.
10. Continue slowly with Jack-Knife Raising Procedure.

NOTE:

BLOCK UP this fault will go off once the boom
and luffing jib are raised and the load lines/block-up
limit chains are hanging freely.
MAX UP 1 and MAX UP 2 these faults go off once
boom to luffing jib angle is less than 169.2 to 170.

1.
Determine boom to luffing jib angle that boom and jib

must be raised to before jib can be raised (see Liftcrane
Luffing Jib Capacities Chart).
2.
Signal crane operator to retract positioner cylinders with

mode switch.
3.
Disengage swing lock, release swing brake and slowly

boom up.
Jib point dolly will roll along ground as boom and jib are
jack-knifed into position.
4-60
11. Stop raising boom when boom and jib have been
positioned at required boom to luffing jib angle. Monitor
this angle on digital display.
WARNING
Falling Jib Hazard!
Do not position boom and jib at any boom to luffing jib
angle less than minimum stop (70). Structural damage to
jib butt will occur, possibly causing jib to collapse.
When boom and jib are at proper angle, jib stop saddles
will be in position to automatically engage pins in boom
top.
12. Slowly luff up until jib straps start to go into tension and
stop.
13. Apply swing brake, boom up to raise jib point clear of

dolly, and remove dolly.
WARNING
14. Install load blocks or weight ball (see Load Block

Reeving in this section.

Load lines going up boom can overhaul load lines going
down jib. Do not untie load lines from jib until load blocks
or weight balls have been installed. Load lines can fall off
boom if this precaution is not followed.
WARNING
Do not lift load blocks or weight balls off ground until boom
has been raised to desired operating angle and jib has
been positioned at required operating radius for load to be
handled. Structural damage can occur and attachment
can collapse if this precaution is not observed.
15. Slowly raise boom and jib to desired boom angle (see
capacity chart for boom angles).
16. Pay out load line as boom and jib are raised.
17. Position jib at required operating radius.
18. Travel forward until load blocks and/or weight balls are
directly below jib point.
19. Lift load blocks and/or weight balls to desired position.
4
3
1
2
4-186
4-185
View A
View B
4
5
4-187
View C
Figure 4-30
4-61
Lowering Boom and #79A Luffing Jib

DANGER
General
ALL boom and jib combinations must be raised and lowered
using Jack-Knife Method. See the Liftcrane Luffing Jib
Capacities Chart to determine the following:

Do not lower boom and jib to ground until boom has been
positioned at minimum angle of 85 and jib has been
positioned at specified boom to luffing jib angle. Crane will
tip, or structural damage will occur, possibly causing
attachment to collapse.
Counterweight Requirements (crane and MAX-ER).
Boom to Luffing Jib Angle.
Maximum Boom and Jib Lengths Raised or Lowered:
2.
Raise boom to a minimum angle of 85.
Over end or side of blocked crawlers.
3.
Over end or side of unblocked crawlers.
Position jib at required boom to luffing jib angle (see

Liftcrane Luffing Jib Capacities Chart).
Monitor angles given in following procedure on digital

display.
Jack-Knife Lowering Procedure
DANGER
Moving Part Hazard!
Warn all personnel to stand clear of jib point dolly while
Death or severe crushing injuries will occur if personnel
come in contact with tires.
NOTE:
Item numbers in Figure 4-30 correspond to

numbered steps in following procedure.
It is normal for the BLOCK UP, MAX UP 1, and
MAX UP 2 limits to come on during the lowering
procedure.
1.

lower load block or weight ball onto ground. Then swing
boom and jib to desired position with relation to crawlers
and apply swing brake.
Adhere to raising and lowering limitations given in

Liftcrane Luffing Jib Capacities Chart.
WARNING
Do not allow boom to luffing jib angle to become less than
70. Structural damage to jib can occur.
CAUTION
Structural Damage!
Side loading can cause structural damage to boom and jib
as boom and jib are lowered.
Disengage swing lock and release swing brake when jib
point rollers contact ground.
CAUTION
Jib Point Damage!
Do not allow upper jib point to contact ground while
lowering luffing jib. Damage will occur.
4.
Slowly lower boom until upper jib point is approximately

6 ft (1,8 m) off ground.
It will be necessary to use limit bypass switch to lower
boom if BLOCK UP limit is on.
5.
WARNING
Remove load blocks or weight balls:
a.
Lower load block or weight ball onto ground before

lowering boom and jib. Structural damage can occur and
attachment can collapse if this precaution is not observed.
Remove block-up limit weights and chains and

connect block-up limit electric cords to terminating
plugs on junction boxes.
b.
Securely fasten load lines to jib point so load lines

cannot fall off boom and jib.
4-62
WARNING
6.
Check dolly oil level and tire pressure (Figure 4-27, View
F).
7.
Using a fork-lift truck, lift jib point dolly into position under
jib top. Lower boom (and jib) so upper jib point engages
saddles in dolly (see Figure 4-27, View F).
Falling Wire Rope Hazard!

rope on jib side of attachment. Wire rope could fall off
boom. Securely fasten load lines to jib point before
removing load blocks or weight balls.
10
11
4-188
View C
140
12
4-182
View B
14
15
9
13
8
4-180
4-187
View A
View D
17
4-179
16
18
View E
4-189
View F
Figure 4-31
4-63
Jack-Knife Lowering Procedure (continued)

8.
9.
10.
11.
12.
13.
Release swing brake (disengage swing lock) and slowly

boom down. Jib point dolly will roll along ground as
boom and jib are lowered.
Boom down until boom to luffing jib angle is 140 (View
A).
Pay out load lines as boom and jib are lowered.
Release jib safety latch with hand winch (3, Figure 4-27,
View D) in jib top.
Signal crane operator to retract positioner cylinders with
the mode switch. Weight of jib struts will retract cylinders
(View C).
Continue to boom down slowly.
Pay out load lines as boom and jib are lowered.
Signal person, watch jib stops to verify that stops do not
engage pins in boom top.
16. Boom down until connectors between jib butt and first jib
insert are approximately 6 in (150 mm) from ground.
17. Make sure jib straps lower into strap supports at ends of
inserts.
18. Signal crane operator to extend cylinders with the mode
switch. Cylinders will extend (View F) and remain
extended.
Removing #79A Jib

Remove Jib Load Line
Jib load line will be used to lower main strut later in the
removal procedure. Haul in load line on Drum 3 until end of
line is near boom hoist equalizer.
Remove Jib Dolly

Reverse installation steps to remove jib dolly (Figure 4-27).
Do not lower jib onto ground.
Remove Upper Jib Point

1.
2.
3.
CAUTION
Jib Stop Damage!
Do not luff down if jib stops will engage pins in boom top.
Jib stops can be damaged.
14. Jib straps will slacken as boom and jib lower (View D).
Signal person, watch jib straps along left side of jib as
boom and jib are lowered. Do not allow straps to
become too slack or they will bounce against jib inserts.
Signal operator to haul in luffing hoist wire rope (luff up)
so jib straps remain 2-1/2 3-1/2 ft (0,76 1,07 m)
above strap supports at end of jib top. Do not allow jib
straps to go into tension.
WARNING
Tipping Hazard!
Do not allow jib straps to become too tight during lowering
steps. Crane will tip or structural damage will result.
Do not allow jib straps to become too slack during
lowering steps. Strap connectors will bounce against jib
inserts, possibly resulting in damage.
Support upper point with fork-lift truck.

Remove connecting pins (7, Figure 4-27, View E)
Lower jib onto blocking approximately 6 in (150 mm)
high.
Boom down as required so jib sections are parallel to
ground.
Remove Jib
Jib removal is identical to boom removal. The following
instructions assume that assembly personnel already know
how to disassemble the boom (jib) sections. If in doubt, see
Boom Rigging Guide in Crane Operators Manual
WARNING
Tipping Hazard!
Jib sections can collapse when connecting pins are
removed.
Block both ends of each jib insert before removing
connecting pins.
Never work under or inside jib sections that are not
securely blocked.
Disassemble Jib
NOTE:
15. Continue to boom down approximate boom to luffing jib

angle shown in View D and stop booming down and
luffing up.
Luff up or down as required to position jib straps 2-1/2
3-1/2 ft (0,76 1,07 m) above strap supports at end of jib
top.
4-64
1.
2.
3.
Do not disassemble butt and first two inserts at this

time.
Remove jib top and all but two inserts next to jib butt.
Disconnect jib straps. Store links as shown in
Figure 4-21, View J.
Store straps on jib sections.
4.
Remove wind speed indicator from jib top to prevent

damage during shipping.
b.
Remove nuts, star washers, and bolts from base of

wind speed mounting bracket.
a.
c.
Store indicator assembly in a safe place on crane.
Disconnect electrical cable at base of wind speed.
View B
P2140
2
9
8
4
4-172
11
View A
View C
14
15
12
16
11
13
P2141
P2142
View E
View D
17
20
11
18
(inside boom)
12
4-190
9
13
(stored)
20
17
18
4-153
View F
Item
1
2
3
4
5
6
7
8
9
10
Description
Strap Support Bracket
Equalizer
Jib Strut Straps
Link
Jib Strap (outside)
Strap Retaining Pin (outside strap)
Pin with Cotter Pin
Jib Strap (inside)
Pin with Cotter Pin
Strap Retaining Pin (inside strap)
Item
11
12
13
14
15
16
17
18
19
20
Description
Pin
Jib Stop Positioner Cylinder
Jib Stop
End Plate with Cap Screws
Keeper Plate
Pin
Bracket A
Lug B
Lug C
Figure 4-32
4-65
Remove Jib Strap Equalizers
Remove Butt and First Two inserts
1.
Luff down to lower jib strut (View A).
1.
Raise jib strut to approximately 70.
2.
Guide strut strap equalizers (2, View B) into strap

support brackets (1) as jib strut is lowered.
2.
Store jib stop positioner cylinders (View F):
3.
Disconnect jib strut straps (3, View A) from equalizer

links (4, View B). Strut straps will swing to rear.
NOTE:
Store connecting pins in holes of jib strut straps (3).

4.
Support outside jib strap (5, View B) with assist crane

and remove connecting pin (7) from strap bracket.
5.
Remove strap retaining pin (6).
6.
Lower strap (5) into outside strap bracket. Store strap in

bracket with retaining pin (6).
7.
Support inside jib strap (8) and remove connecting pin

(7).
8.
Set strap on pin (9) in strap support bracket (1).
9.
Remove equalizer (2).
10. Rotate strap bracket forward (View C).
b.
Rotate support bracket (1) 180.
c.
Repin bracket (1) to jib butt with pin (11) and pin to
storage lug with pin (9).
13. Remove strap retaining pin (10, View C) and store

support bracket.
14. Store inside strap (8) in inside strap bracket with
retaining pin (10).
b.
Remove pin (12) from lug on jib stop and store in

clevis on positioner top.
c.
Remove pin (17, View E) from lug (20).
d.
Rotate positioner so pin (12) slides into bracket (18,

View F).
e.
Using pin (17), connect bottom of positioner to lug

(18) as shown in View F.
4.
Remove end plates (15, View D), keeper plates (16) and
pins connecting jib butt to boom top. Store pins and
keeper plates in boom top holes after butt and inserts
are removed.
5.
Remove jib butt and inserts. Guide jib butt as required so

jib stops do not hit lacings.
6.
Disassemble inserts from butt, if desired.
Lower Jib Strut

1.
Slowly luff down to lower luffing jib.
2.
As luffing jib is lowered, disconnect links (4), spreaders

(7, 8), and jib straps (6) from jib strut (Figure 4-26, Views
B and C).
15. Store connecting pins (7) in holes on jib straps.

16. Store strap support bracket on jib butt.
Support cylinder (13) to prevent its dropping when

pins are removed.
Using nylon slings from assist crane, hook onto butt and
first two inserts. Wrap slings around chords only. Do not
use lifting lugs on butt or inserts and do not lift against
lacings.
12. Store strap support brackets (1, View C):

Remove connecting pin (11).
a.
3.
11. Lower inside strap (8) into inside strap bracket.
a.
Disconnecting hydraulic hoses is not necessary.
Do not remove links (1)

3.
Lower jib strut onto blocking approximately 3 ft (0,9 m)

high.
Place blocking at front of butt just behind connecting
pins.
4.
4-66
Store links as shown in Figure 4-26, View D.
Hook from
Assist Crane
View A
14
P2132
View B
19
P2131
9
(shipping)
15
13
View I
16 18
Hole C
P2128
17
9
(working)
9
(working)
10
P2133
Outer
Tube
3
8
1
2
Hole D
View H
Inner
Tube
4-170
View C
11
P2117
View G
6
(stored)
12
Hole B
View F
View D
View E
Holes A
6
7
P2135
4
P2136
P2137
FIGURE 4-33
4-67
Lower Main Strut
Use same socket used to anchor load line to boom

or jib point.
Make sure Drum 3 load line passes under Drum 3

guide sheave in mast.
Make sure Drum 3 load line passes through center

of boom hoist wire rope and over top of boom hoist
equalizer.

1.
Anchor end of jib strut to counterweight:

a.
Remove one top crane counterweight box from

each side of crane counterweight.
Boxes must be equipped with tie link lugs.
b.
Stack counterweight boxes (11, View D), one at a

time, at jib strut top.
c.
Secure lifting lugs on top counterweight box (11) to

lugs on jib strut top with shackles and suitable slings
(12, View D). Minimum capacity required for slings
is 25,000 lb (11 340 kg) per side.
d.
Connect counterweight boxes with tie links as

shown in Figure 4-21, View G (four places).
6.
Pin strut handling pendants (10, View I) to link (16).
7.
Slowly pull main strut back until Holes A in strut stop are
aligned.
CAUTION
Strut Damage!
Pull strut back only until holes are aligned. Pulling strut
further back may damage strut to strut stops.
8.
Remove pin (6) from Hole B and insert in Hole A so

cylinders cannot extend (View E).
9.
Pay out Drum 3 load line so line is slack.
WARNING
Falling Strut Hazard!
Do not disconnect crane counterweight (11) from jib strut
until all remaining steps are performed. Counterweight is
required to prevent jib strut from rising when main strut is
lowered.
If counterweight is not connected to jib strut, jib strut will
rise part way and then both struts could fall forward
violently.
2.
Luff down until luffing hoist wire rope is slack.
3.
Unpin handling pendants and links from lugs on main

strut butt.
4.
Attach 55 USt (50 t) shackle (14, View I) and hook from

assist crane to links (15).
5.
Connect Drum 3 load line (19, View I) to link (16) with

load line socket (17).
10. Luff up as needed to remove load from pins (9, View B).
11. Remove pins (9, View B) from lower holes and store in
upper holes (View A).
12. Luff down to retract strut stop tubes.
13. Remove tube retaining pins (8, View G) from Hole A and
insert in Hole B.
14. Luff up slightly to remove load from strut stop pins (5,
View F).
15. Remove pins (5) and luff up until stops can be swung to
strut (View E).
Continued on Next Page

Item
1
2
3
4
5
6
7
8
9
10
4-68
Description
Luffing Hoist Line (Drum 6)
Main Strut
Strut Stop
Boom Top
Cylinder Rod Retaining Pin
Lug
Tube Retaining Pin
Strut Locking Pin
Handling Pendants
Item
11
12
13
14
15
16
17
18
19
Description
Crane Counterweight Boxes
Sling and Shackle
Shackle (user-supplied)
Links
Link
Socket
Pin with Cotter Pin
Drum 3 Load Line
2
2
3 (working)
5
P2129
View H
3
(stored)
20
4-191
View A
4
4
12
12
P2130
12
View G
4
POSITION E
POSITION C
POSITION D
3
12
6
11
POSITION B
9
POSITION 13
A
10
View F
P2127
8
4-192
16
View B
6
A
14
16
15
18
17
B
P2123
View E
P2120
View D
P2122
View C
Figure 4-34
4-69
Lower Main Strut (continued)

16. Remove retaining pins (3, View G) from lugs on main
strut (2).
17. Pin strut stops (1) to main strut (View H).
18. Luff down to lower main strut until strut backstay straps
(11) can be disconnected (POSITION E, View B).
Guide boom backstay straps (8) into strap brackets (10,
View F) on boom.
19. Remove pins (7, View F) to disconnect adjustable links
(6) from connecting links (9) and boom backstay straps
(8).
Store pins (7) in adjustable link (6). Store links (9) with
boom backstay straps (8).
20. Disconnect rear tie links on counterweight boxes (13) as
shown in Figure 4-21, View E.
21. Raise strut handling pendants (12) with assist crane so
links and hook from assist crane are slightly higher than
top of main strut.
Pay out Drum 3 load line while raising pendants
23. As main strut nears vertical POSITION D tighten

pendants (12) and Drum 3 load line (4) so main strut
moves forward smoothly past vertical without dropping
(View B).
24. Continue to luff up while following with assist crane
pay out load line and travel until main strut is at
approximately 45 (POSITION C).
25. Slacken Drum 3 load line (4) and raise pendants (12) to
vertical POSITION B while luffing up.
26. Continue to lower main strut with assist crane while
luffing up until main strut comes to rest on jib strut
POSITION A. Guide strut straps into strap brackets as
strut comes to rest on jib strut.
Allow luffing hoist wire rope (5) to slacken as strut is
lowered, but do not allow wire rope to kink or jump off
sheaves.
27. Lower pendants (10, Figure 4-25, View I) and links (15,
Figure 4-25, View I) to storage position on main strut
butt. Unpin socket (17) from link (16) and pins links (15)
to main strut butt.
28. Remove counterweight (11) from end of jib strut, one at
a time.
22. Slowly luff up to raise main strut while paying out Drum 3
load line and following with assist crane.
29. Disconnect strut top straps (14) from strut butt straps
(15). Store connecting pins in holes on strut top straps.
Do not induce any side load in main strut with assist

crane. Load line from assist crane should remain vertical
during strut lowering procedure.
30. Rotate connecting links (9, View D) to stored position.

Remove strap shipping pins (16) from holes B and install
in holes A as shown in View D.
CAUTION
Overload Hazard!
Do not allow crane counterweight (13) to rise off ground at
any time during strut lowering procedure. Load line and
pendants could be overloaded, possibly resulting in
damage.
31. Remove strap shipping pins (16, View C) from holes A

and install in holes B to secure strut straps to main strut
top.
32. Pin adjustable links (6) to brackets (18) with connecting
pin (7) as shown in View E. If necessary, adjust link (6) to
shorter length (Figure 4-21, View M) before pinning.

Item
1
2
3
4
5
6
7
8
9
4-70
Description
Strut Stop
Main Strut
Drum 3 Load LIne
Luffing Hoist Line
Adjustable LInk
Pin with Collar and Retaining Pins
Boom Backstay Strap
Connecting Links
Item
10
11
12
13
14
15
16
17
18
Description
Strap Bracket
Strut Backstay Straps
Strut Handling Pendants
Counterweight
Backstay Strap (strut top)
Backstay Strap (strut butt)
Strap Shipping Pin
Link
Strap Bracket
Main Strut
Fully Lowered
Jib Strut Supported

with Slings from
Assist Crane
Sling Attached to Lugs

in Jib Strut Top
4-194
4-193
Boom Top and

Required Inserts
Supported on
Blocking
Figure 4-35
Backstay Straps
Connected
Main Strut
Fully Raised
Raise and Lower Jib
Strut as Required
4
Jib Straps
Disconnected
4-195
Jib Inserts
Supported on
Blocking as Required
Figure 4-36
4-71
Store Main Strut Top
Changing Boom and Jib Length
DANGER
1.
Support main strut top (3, View A) with slings from assist
crane.
2.
Remove bottom and top pins (Figure 4-20, View H)

connecting strut top to strut butt.
Boom and jib sections can collapse when connecting pins

are removed.
3.
Move strut top slowly forward while hauling in luffing

hoist wire rope so that wire rope between struts pays out
smoothly without kinking or binding.
Block or support ends of boom and jib sections with

slin g s f r o m an ass ist cra ne be f or e r e mo vin g
connecting pins.
4.
Rotate strut supports C (5, View D) to working position

(View C) and pin main strut top to jib strut top with
shipping pins (6).
Never work under or inside boom or sections that are

not securely blocked or supported with slings from an
assist crane.
5.
Lower butt end of main strut top and pin to jib strut top
with pins (7, View A).
Boom
Store Luffing Hoist Wire Rope

1.
Disconnect wire rope from socket (20, Figure 4-20, View

G) in end of main strut. Store socket with main strut.
To prevent parts from collapsing and possible death or

serious injury to personnel, observe following safety
precautions when changing boom length:
2.
Spool luffing hoist wire rope onto Drum 3 for storage.
Know weight of what you are lifting and size assist crane
and all lifting slings accordingly.
Lower and pin boom hoist equalizer to rails on boom

insert. Do not disconnect boom straps until this step
is performed. Equalizer could slide off rails.
Lower main strut fully. Perform Lower Main Strut steps

218.
Connect slings from assist crane to both sides of jib strut

and hoist so slings are just taut. Do not disconnect
backstay straps until this step is performed.
Do not attempt to handle boom with equalizer pinned to

rails. Structural failure will result and boom will fall.
If desired, a sucker line can be attached to end of

luffing hoist wire rope and spooled through sheaves in
struts as luffing hoist wire rope is removed. This practice
will make it easier to install the luffing hoist wire rope
next time.
Remove Main and Jib Strut Tops

Main strut top and jib strut top are shipped together as shown
in Figure 4-20, View H.
Reverse assembly steps under Install Jib Strut Top topic to
remove strut tops.
Remove Jib and Main Strut Butts
Handle boom only with nylon slings securely attached to

chords as close to end of inserts as possible. Do not lift
against lacings or lifting lugs on inserts.
Main strut butt and jib strut butt are shipped together as
shown in Figure 4-20, View A.
Reverse assembly steps under Install Jib and Main Strut
Butts topic to remove strut butts.
Do not cantilever more than 40 ft (12,2 m) of insert from

end of inserts being lifted. Attach nylon slings to both
inserts as shown in Figure 4-37.
Do not disconnect assist crane from jib strut until all of

following steps are performed:
4-72
Boom length changed.
Boom straps connected to boom hoist equalizer and

equalizer unpinned from rails.
Backstay straps pinned to main strut.
Main strut fully raised. Perform Raise Main Strut steps

1628.
Jib
To prevent parts from collapsing and possible death or

serious injury to personnel, observe following safety
precautions when changing jib length:
Know weight of what you are lifting and size assist crane
and all lifting slings accordingly.
Handle jib only with nylon slings securely attached to

chords as close to end of inserts as possible. Do not lift
against lacings or lifting lugs on inserts.
Do not cantilever more than 40 ft (12,2 m) of insert from

end of inserts being lifted. Attach nylon slings to both
inserts as shown in Figure 4-37.

It is okay to change the jib length with the struts positioned,
as follows:
Main strut fully raised. Do not disconnect backstay

pendants.
Jib straps disconnected from jib strut straps.
Jib strut raised and lowered as required to provide

clearance. Do not raise strut above 70 or lower strut
to point that it contacts jib butt.
Slings from
Assist Crane
Boom Insert Handling Shown;

Jib Insert Handling Similar
4-196
Boom
Inserts
Boom Insert
Supported on Blocking
FIGURE 4-37
4-73
WIRE ROPE INSTALLATION

NOTE:
Wire rope installation instructions from various

Original Equipment Manufacturers (OEM) are
provided at the end of this section. If a conflict
exists between the following instructions and the
OEM instructions, the OEM instructions apply.
Reel
Drum
Brake
Wire Rope Storage

Store wire rope in coils or on reels off the ground or floor in a
clean and dry indoor location. If outdoor storage is
necessary, the wire rope must be covered with a protective
wrapper. Keep the wire rope away from acids, fumes, and
other corrosives. Keep the wire rope away from heat that can
dry out the lubricant. If the storage period will be long,
lubricate the wire rope and perform periodic inspection given
in this section at least monthly.
Top to Top
OR
Bottom to Bottom
Reel
Brake
Drum
Removing Wire Rope from Shipping Reel

FIGURE 4-39
A925
CAUTION!
Wire Rope Damage!
Shipping reel must rotate when wire rope is unwound.
Attempting to remove wire rope from a stationary reel can
result in a kinked wire rope, and wire rope will be ruined.
1.
Mount wire rope shipping reel on a shaft supported at

both ends by jacks or blocks as shown in Figure 4-38.
Shipping
Reel
Drum
Shaft
3.
Avoid a reverse bend when winding wire rope onto

drum: wind from top of reel to top of drum or from bottom
of reel to bottom of drum as shown in Figure 4-39.
4.
Avoid dragging wire rope in dirt or around objects that

can scrape, nick, cut, or crush wire rope.
Seizing and Cutting Wire Rope

Apply tight seizings of annealed wire to the ends of all wire
rope. If not done, the rope wires and strands may slacken.
This action will result in overloading of some strands and
underloading of others. Bird caging and breakage of the wire
rope can occur.
Before cutting wire rope, apply seizings on both sides of the
point where the cut will be made. Then cut the wire rope with
a torch, rope cutter, or abrasive cut-off wheel.
Jack or
Blocks
See Figure 4-40 for:
A925
2.
4-74
Number of seizings to be applied to the ends of wire

rope and to both sides of the point where a cut will be
made.
Proper application method. Each seizing should be one

rope diameter long.
FIGURE 4-38
Provide a brake at shipping reel (see Figure 4-39) so
wire rope can be wound tightly onto drum.
A925
Wire Rope Type
Seizings
Required
Preformed
Non-preformed
22 mm Diameter or Smaller
Non-preformed
26 mm Diameter or Larger
WARNING!
Wire rope can be pulled out of drum if following steps are
not taken.
Place free end of seizing wire in valley between two stands.

Then wind seizing wire over free end as shown. Finally, twist
and pull two ends of seizing wire together until seizing is tight.
Install straight wedge so corrugated side is against

wire rope.
Install wedge so end of wire rope extends past end of

wedge, but not out of drum socket.
Make sure seizing is not under wedge. Remove

seizing if it interferes with assembly.
View A Rope Diameter 1 in (26 mm) and Larger
Wind seizing wire around wire rope as shown. Then twist two
ends of seizing wire together at center of seizing. Alternately
twist and pull ends until seizing is tight.
Straight Wedge
Outside Drum
Wire
Rope
Hole in
Drum Flange
View B Rope Diameter Smaller than 1 in (26 mm)
FIGURE 4-40
Seizing
Dont Allow End of

Wire Rope to Extend
Out of Socket Opening
Seizing
Anchoring Wire Rope to Drum

Use the correct wedge part number for the size of wire rope
being used; see parts drawing for the boom hoist drums or
for the load drum shaft to obtain the correct part number.
1.
Assemble wire rope and wedge to drum socket.
2.
Tighten wedge, rapping back of wedge with a brass drift

pin and hammer.
Straight Wedge
Inside Drum
Wire
Rope
FIGURE 4-41
4-75
Winding Wire Rope onto Drum

See Drum and Lagging Chart in Capacity Chart Manual for
correct size of drum laggings, if used.
Wraps of First Layer Tight Against

Drum and Against Each Other
Wedge
P448
See Wire Rope Specifications Chart in Capacity Chart

Manual for correct type, size, and amount of wire rope to be
installed on load drums.
See Boom Rigging Drawing at end of this section for correct
type, size, and amount of wire rope to be installed on boom
hoist drums.
1.
Carefully inspect drums and all rope guides, rollers, and

sheaves for wear or damage that can cause wire rope to
wear or be cut. If defects cannot be fixed, replace faulty
parts.
2.
Apply tension to wire rope as it is wound slowly onto

drum.
First wrap must be tight against drum flange for
approximately three-fourths of drum diameter (see
Figure 4-42).
3.
View A
First Wrap Tight Against

Flange for 3/4 of Diameter.
Voids and Loose Wraps in First Layer

Cause Severe Wear of Wire Rope.
P449
Tap adjacent wraps against each other with a soft metal

or wooden mallet.
Use extreme care not to put twists or turns in wire rope;
allow rope to assume its natural lay.
CAUTION!
Wire Rope Damage!
Voids or spaced wraps in first layer (Figure 4-42, View B)
will permit moveme nt an d a wedging action with
subsequent layers. Wedging action will cause crushing
and abrasion of wire rope.
Never allow wire rope to cross wind on drums.
4-76
View B
FIGURE 4-42
Anchoring Wire Rope to Wedge Socket
NOTE:
6.
WARNING
Use Right Method A only if wire rope clip is small

enough to be securely tightened to dead end. Right
Method C is only for a Terminator wedge socket
After socket is pinned in place, hoist load slowly so

wedge seats tight. Do not shock load socket and wedge.
Inspect all parts prior to use. Do not use parts that are
cracked or otherwise defective.
Remove minor nicks, burrs, or rough edges from

socket, wedge, or pin by lightly grinding. Do not
reduce original dimensions by more than 10%.
Do not reinstall shipping material (bolt, plastic strap or

wire) in hole of wedge or socket after assembling.
Discard these materials because they can prevent
wedge from tightening in socket.
Only use a wedge and socket which are correct size

for wire rope being used. Do not mix and match parts
from one assembly with parts from another assembly.
Terminator wedge has go and no-go holes to
check for proper rope size.
Attach wire rope clip to dead end of wire rope after

assembling wire rope to wedge and socket.
If dead end of wire rope is welded, seize end of wire

rope and cut off weld before assembling to wedge
and socket. Weld will not allow strands of wire rope to
adjust around bend of wedge, resulting in high
strands and wavy rope. This condition can seriously
weaken attachment.
WARNING
Wire rope can break if following precaution is not
observed:
Do not attach dead end of wire rope to live end of wire

rope with wire rope clip. Wire rope clip will transfer
load from live side of wire rope to dead end, seriously
weakening attachment.
Anchoring Wire Rope to Button Socket

1.
Remove pin from socket.
2.
Install button end of load line in socket.
3.
Pin socket to anchor point.
4.
Securely tighten locking screw.

A1263
Pin
Button

1.
Assemble wire rope and wedge to socket so live end of

wire rope is in a straight line with socket pin hole. Do not
assemble WRONG as shown.
2.
Allow dead end of wire rope to extend past end of socket

amount shown.
3.
Allow wire rope to assume its natural lay.
4.
Pull against wedge and live end of wire rope enough to

tighten wedge in socket.
4
Load
Line
Use a brass hammer to seat wedge and wire rope as

deep into socket as possible.
5.
Button
Socket
Locking
Screw
(behind)
Button Socket Assembly
FIGURE 4-43
Attach a wire rope clip to dead end of wire rope using

one of the RIGHT methods shown. Rope clip will aid in
preventing wire rope from being pulled out of socket.
4-77
Wire Rope/Clip
0.875
1.0
1.125
1.25
Size inch (mm)
(22,23)
(25,4)
(28,58)
(31,75)
Torque * ft/lbs
225
225
225
360
(kN/m)
(0,30)
(0,30)
(0,30)
(0,49)
* Tightening torque values shown are based on threads being
clean, dry and free of lubrication.
Seizing
6 to 9 Rope Diameters
for Conventional Rope
OR
20 Rope Diameters for
Rotation Resistant Rope
Dead End
Rope Clip
Live End in
Straight Line
with Socket
Rope
Clip
Standard 6 to 8 Strand Wire Rope

Minimum of 6 rope diameters,
but not less than 6 in (152 mm).
Rotation Resistant Wire Rope
Minimum of 20 rope diameters,
but not less than 6 in (152 mm).
Rope
Clip
Tail Length
Short Piece
of Wire Rope
Right!
Method A
Socket
Terminator
Wedge
Wedge
Do not reinstall any shipping material
(bolt, plastic strap, or wire) in hole of
wedge or socket after assembling.
Right!
Method B
Right!
Method C
ALL ARE DANGEROUS AND PROHIBITED!
A925
WRONG
Rope Backward
WRONG
Rope Backward
WRONG
Dead End Clipped
to Live End
Breaking in Wire Rope

After installing a new wire rope, break it in by operating it
several times under light load and at reduced speed. This
practice allows the wire rope to form its natural lay and the
strands to seat properly.
NOTE:
4-78
Wire rope will stretch during the break-in period,

reducing the wire ropes diameter as the strands
compact around the core.
WRONG
Dead End Clipped
to Live End
WRONG
Wedge Backward
FIGURE 4-44
The dead wraps of wire rope on the drum can become slack
during operation, even if the utmost care is used during
installation of the wire rope. This slackening is caused by the
normal stretch that occurs in a new wire rope under tension
and periodically throughout the wire ropes life from release
of the load.
When slackness is noted, tightly wind the dead wraps of wire
rope onto the drum. If left uncorrected, a wedging action with
subsequent layers will occur and the resultant abrasion may
cause broken wires in the dead wraps.
PAD EYE USAGE FOR WIRE ROPE

REEVING
3.
Inspect pad eye prior to each use. Replace it if:
Original dimensions have changed (Figure 4-45).
Cracks or breaks exist in metal or weld.
General
Some rotation-resistant wire rope supplied by Manitowoc is
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.
Safety
1.
For No. 1.5 pad eye, do not exceed 4,45 kN single line
pull.
2.
Make sure sucker line and rope clips are rated for at
least 4,45 kN line pull.
WARNING
Flying Part Hazard!
Pad eye on end of wire rope has been provided for
reeving purposes only. Any other use is neither
intended nor approved.
Pad eye can break and fly apart with considerable force if
it is overloaded, not used properly, or not maintained
properly.
Rope
Clips
Sucker
Line
Sucker
Line
Pull Sucker Line with

Winch or
Fork-Lift Truck
Sucker
Line
Wire
Rope
Wire Rope
from Drum
Pad
Eye
Pad
Eye
P1519
A1189
Boom Point
Sheaves
Pad
Eye
Wire
Rope
Load Block
Sheaves
E
No. 1.5
Pad Eye
G
D
C
Item
A
B
C
D
E
F
G
Inch
0.63
0.25
1.00
0.44
1.13
0.16
1.31
mm
16,00
6,35
25,40
11,18
28,70
4,06
33,27
FIGURE 4-45
4-79
RIGGING WINCH OPERATION

A802
If your crane is equipped with the optional rigging winch in

the boom butt, see Rigging Winch Operation topic in the
Operators Manual for the crane. Also see drawing at the end
of this section.
Duplex
Hook
0-30
LOAD LINE REEVING - #44 LUFFING JIB
0-30
Load Blocks
Shackle
See the Luffing Jib Assembly Drawings at the end of this

section for a complete list of load blocks and weight balls
available for this crane.
Load
FIGURE 4-46
Wire Rope Specifications

WARNING
Use only a hook-and-weight ball or load block with a
capacity equal to or greater than load to be handled.
Avoid overloading bearings in load block sheaves. Attach
load to duplex hook so load hangs straight.
Load block can fail if overloaded, allowing load to fall.
See Wire Rope Specifications chart in Capacity Chart

Manual for the following load block reeving information:
Parts of line required to handle desired load.
Wire rope length required for various boom/jib lengths

and parts of line.
Maximum spooling capacity of load hoists.
Wire Rope Installation

Guide Sheaves
See Figure 4-47 and 4-48 for guide sheave identification and
location of components in the lower and upper boom points.
Once the wire rope is routed through the guide sheaves, be
sure to install rope guard pins, bars, and rollers to retain rope
on guide sheaves. Wire rope and sheaves can be
damaged if rope is not properly retained on sheaves.
See Wire Rope Installation in this section for following

instructions:
Anchoring wire rope to drum.
Installing wire rope on drum.
Anchoring wire rope to wedge socket.
Reeving Diagrams
Duplex Hook
See Figure 4-49 for #44 Luffing Jib reeving diagrams.
Attach the load so it is balanced equally on the hook. Lifting

slings must be within angles given in Figure 4-46 to achieve
maximum hook capacity. The duplex hook has a hole to
which an optional shackle can be attached as shown in
Figure 4-46.
WARNING
Exercise care when block is standing in vertical

position (Figure 4-50), as the potential for tipping
exists. Potential causes of tipping are unstable work
area, boom movement and the reeving process.
If work area is unstable, lay block flat on side plate.
WARNING
Limit load to be handled with shackle to capacity of load
block or shackle, whichever is less.
Load block or shackle can fail if overloaded, allowing load
to fall.
4-80
12
4-197a
13
14
#44 LUFFING JIB
15
18
3
16
17
7
2
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
10
11
16
17
18
Description
Drum 3 Whip Line in Crane
Guide Sheaves in Mast
Guide Sheaves in Jib Strut
Guide Sheaves in Jib Top
For Luffing Hoist Only
Wire Rope Guide on Boom Top
Guide Sheaves in40 ft (13,1 m) Insert
Guide Sheaves in 10 ft (3,0 m) Insert
Drum 1 Hoist in 10 ft (3,0 m) Insert
Drum 5 Luffing Hoist in Boom Butt
Drum 2 Hoist in Boom Butt
Wire Rope Guide (see page 4-83)
Lower Jib Point (see page 4-83)
Upper Jib Point (see page 82)
Dead-End Wedge Socket
with RCL Load Cell Link
Hook-and-Weight Ball
Load Block
Wireless Receiver from Boom Top
4-198
FIGURE 4-47
4-81
#44 UPPER
JIB POINT
1
2
3
2-Part
1-1/8 in (28 mm)
Wire Rope
1-Part
1-1/8 in (28 mm)
Wire Rope
6
6
5
4-199
Item
1
2
3
4
5
6
7
8
Description
Pin with Cotter Pin
Link
Pin with Cotter Pin
Load Cell - 70,000 lb (31 751 kg)
Wedge Socket 1-1/8 in (28 mm)
Link
Pin with Cotter Pin
Swivel Weight Ball
4-200
4-82
Drum 3
Whip
See
NOTE 5
Drum 1
Hoist
JIB TOP
GUIDE SHEAVES
4-202
Bolt
Clamp
LOWER JIB
POINT
SHEAVES
Nuts
Lock Washer
4-203
Tighten each side equally to provide an

equal gap. See NOTE 1 for torque value.
4-201
S2
S1
S3
S4
S6
S8
S5
S7
S9
#44 LOWER JIB POINT
Location of Guide Sheaves with Lead Line

Going to Point Sheave Indicated
Drum 1
NOTE 1: Position clamps hand tight against sheave bearing.

Before torquing bolts, check that sheave turns freely.
Torque bolts lubricated with S.A.E. 20 oil to 120 ft-lb
(163 Nm).
Lead Line
Routed to
Sheave
Dimension B
NOTE 2: This location requires sheave bearing to be snug

against jib top side plate as shown at Dimension B.
S9
0.62 in (16 mm) NOTE 2
NOTE 3: This location requires two clamps as shown at

Dimension A.
S8
2.06 in (52 mm) NOTE 3
S7
4.75 in (121 mm) NOTE 3
S6
10.44 in (265 mm) NOTE 3
NOTE 4: Position guide sheave at this location for whip line

operation over upper jib point. Use two clamps.
NOTE 5: Install rope retaining pin in this hole.
Drum 3
Lead Line
Routed to
Sheave
Dimension A
S4
10.69 in (272 mm)

NOTES 3 & 4
S3
5.00 in (127 mm) NOTE 3
S2
2.06 in (52 mm) NOTE 3
S1
0.62 in (16 mm) NOTE 2
FIGURE 4-48
4-83
* Wire
Rope
Guide
Lower
Jib
Point
4-204
Load
Block
2 PART
4 PART
6 PART
#44 LUFFING JIB
8 PART
10 PART
12 PART
* See Figure 4-48 for

Guide Sheave Location
= Location of Weight for
Block-Up Limit Control
14 PART
16 PART
18 PART
FIGURE 4-49
4-84
THIS PAGE BLANK
4-85
LOAD LINE REEVING - #79A LUFFING JIB
Wire Rope Specifications
Load Block Identification
See Wire Rope Specifications chart in Capacity Chart

Manual for the following load block reeving information:
See the Luffing Jib Assembly Drawings at the end of this

section for a complete list of load blocks and weight balls
available for this crane.
WARNING
Use only a hook-and-weight ball or load block with a
capacity equal to or greater than load to be handled.
Avoid overloading bearings in load block sheaves. Attach
load to duplex hook so load hangs straight.
Load block can fail if overloaded, allowing load to fall.
Parts of line required to handle desired load.
Wire rope length required for various boom lengths and

parts of line.
Maximum spooling capacity of load hoists.
Wire Rope Installation

See Wire Rope Installation in this section for instructions:
Installing wire rope on drums.
Anchoring wire rope to drums.
See Figure 4-52 and Figure 4-53 for dead-end locations and
components in the lower and upper boom points.
Load Block Handling
Guide Sheaves and Drums
Each load block as two lifting lugs as shown in Figure 4-50,

View A.
See Figure 4-54 for identification of the load drums and

guide sheaves.
The load blocks can be stood up for reeving as shown in

Figure 4-50, View B.
Once wire rope is routed through the guide sheaves, be sure

to install rope guard pins, bars, and rollers to retain the wire
rope on the sheaves. Wire rope and sheaves can be
damaged if rope is not properly retained on sheaves.
Duplex Hook
Attach the load so it is balanced equally on the hook. Lifting
slings must be within angles given in Figure 4-51 to achieve
maximum hook capacity. The duplex hook has a hole to
which an optional shackle can be attached as shown in
Figure 4-51.
Reeving
See Figure 4-55 and Figure 4-56 for load block reeving.
Reeving the load block in any manner other than shown can
result in excessive block twist.
CAUTION
WARNING
Limit load to be handled with shackle to capacity of load
block or shackle, whichever is less.
Load block or shackle can fail if overloaded, allowing load
to fall.
4-86
Wire Rope Damage!

Do not hoist load block closer to boom point than shown
on Load Block Reeving charts. Improper fleet angle or
contact with other parts can damage wire rope.
Lifting Lugs
WARNING
4-205
Exercise care when block is standing in vertical

position, as the potential for tipping exists.
Potential causes of tipping are unstable work area,
boom movement and the reeving process.
If work area is unstable, lay block flat on side plate.
4-206
Shackle
(optional)
View B
Reeving Position
View A
FIGURE 4-50
Duplex
Hook
0-30
0-30
Load
Shackle
A802
FIGURE 4-51
4-87
Two Drum
1-1/8 in (28 mm) Rope
One Drum
1-1/8 in (28 mm) Rope
1
Item
1
2
3
4
5
6
Dead End
Dead Ends
7
One Drum
1-1/4 in (32 mm) Rope
2
5
4-207
Dead End
Two Drum
1-1/4 in (32 mm) Rope
Description
Pin with Cotter Pin
Load Cell (70 k)
Link
with Pin and Cotter Pin
Bushing 3 inch OD x 2-9/32 inch ID
(76 mm OD x 56 mm ID)
Button Socket 1-1/4 in (32 mm) with
Pin and Cotter Pin
Dead End Lug - Optional
See
Figure 4-43
#79A LOWER JIB POINT
Dead Ends
FIGURE 4-52
1-1/8 in (28 mm)
Wire Rope
#79A UPPER JIB POINT
1
2
3
1
3
6
4-209
7
1-1/4 in (32 mm)
Wire Rope
9
10
11
12
Description
Pin with Cotter Pin
Link
Pin with Cotter Pin
Load Cell - 70,000 lb (31 751 kg)
Link
Pin with Cotter Pin
Swivel (25 USt)
Button Socket 1-1/8 in (28 mm) or
1-1/4 in (32 mm) Wire Rope with Pin
Link
Pin with Cotter Pin
Swivel Weight Ball
FIGURE 4-53
4-208
4-88
Item
1
2
3
4
5
6
7
8
A08237
11
10
6
10
7
#79A Luffing Jib
Item
1
2
3
4
5
6
7
8
9
10
11
5
4
Description
Drum 1 Hoist (in boom insert)
Drum 2 Hoist (in boom butt)
Drum 3 Whip (in crane)
Guide Sheaves in Boom
Guide Sheaves in Mast
Boom Top Wire Rope Guide
For Luffing Hoist Only
Guide Sheaves in Strut
Jib Top Wire Rope Guide
To Lower Jib Point
Upper Jib Point
1
2
4-210
FIGURE 4-54
4-89
4-211
SINGLE HOIST DRUM REEVING

#79A Top
Lower Boom
Point
Boom Top Wire

Rope Guide
See NOTE
See NOTE
4 Part
9 Sheave Block
2 Part
9 Sheave Block
See NOTE
See NOTE
8 Part
9 Sheave Block
6 Part
9 Sheave Block
NOTE Dead end wire rope at standard upper boom point

dead-end lug. Standard upper boom point MCC
#A08516 is required for 1-1/8 in (28 mm) and 1-1/4 in
(32 mm) wire rope.
10 Part
9 Sheave Block
Dead-End Socket
Two-Block Weight
FIGURE 4-55
4-90
4-212

#79A Top
14 Part
9 Sheave Block
12 Part
9 Sheave Block
4
18 Part
9 Sheave Block
16 Part
9 Sheave Block
20 Part
13 Sheave Block
22 Part
13 Sheave Block

4-91
4-213

#79A Top
24 Part
13 Sheave Block
28 Part
15 Sheave Block
26 Part
13 Sheave Block
30 Part
15 Sheave Block
4-92
4-214
TANDEM HOIST DRUM REEVING

#79A Top
8 Part
9 Sheave Block
12 Part
9 Sheave Block
16 Part
9 Sheave Block
20 Part
13 Sheave Block
24 Part
13 Sheave Block
28 Part
15 Sheave Block
FIGURE 4-56
4-93
BLOCK LEVEL SENSOR ADJUSTMENT
The sensors were adjusted at the factory and need to be

readjusted only when a new sensor is installed or the
position of a sensor is changed.
General
The block level sensors (Figure 4-57) ensure that the load
block remains level when two load lines Drums 1 and 2
are routed to the load block over the #79A luffing jib top.
NOTE:
This block level sensor is only on cranes without

wireless communication. On cranes with wireless
communication, the controller adjusts block level
automatically (see Crane Diagnostics, Block Level
Sensor topic in Section 3 of Operators Manual).
The sensors monitor guide sheave rotation speed. The

craness programmable controller uses signals from the
sensors to equalize the rotation speed of the drums so the
load block remains level.
Sensor Adjustment
1.
If necessary, attach mounting bracket to guide sheave

frame with cap screws.
2.
Loosen jam nut securing sensor to bracket.
3.
Turn sensor in or out to obtain specified dimension

between end of sensor and wall of sheave.
4.
Tighten jam nut.
5.
Check for proper operation without load. Drums should

operate at same speed and load block should remain
level.
Readjust sensor if required.
Sensor #2
#79A
Boom
Sensor
Sheave
Sensor #2
#55 & 55A
Boom
Mounting
Bracket
Sheave
for Drum 1
Sheave for
Drum 2
0.39 in (9,906 mm)

MAXIMUM
Sensor
Sheave for
Drum 6
Sheave for
Drum 3
Jam
Nut
4-215
Front View
of Boom Top Guide Sheaves
FIGURE 4-57
4-94

RIGGING, RAISING PROCEDURES, ELECTRICAL WIRING & WIRE ROPE DATA
Drawing A07766
01/30/2007
Luffing Jib Asm, #44 Luffing Jib
04/14/2004
Luffing Jib Raising Procedure
06/19/2008
01/31/1997
Control Wiring, Boom & Limits

Load Block Conversion
08/01/1996
05/01/2002
Bridon Tech Bull Rotation Resist Ropes

Crosby Terminator Wedge Socket Warning and Application Instructions
Raising & Lowering

Chart 8542A
Electrical Assembly
Drawing A05580
Drawing 184433
OEM Wire Rope Data
TBRR192
P/N2010170
08132008
12 10 9
12 10 9 28
12 10 9
30
12 10 9 28
30
R67 R60 R59

B
27
7
A
4 19
14 14
17 15 13
34
35
R183
R184
R185
R98
65
64
63
R138
R130
20
11
22
105
or
106
Add Washers Item 2 to Each

Side to Center And Prevent
Side Play In Boom Top.
Max Side Play Allowed
33
102 or 103 or 104 or 107
0.12" (3 mm).
No Washers on Outboard
Side of Adapter
160' Jib Shown
7
1
31
7 1
R181
R200
R158
R141
R140
R148
R153
R147
88
87
86
85
75
71
31
R2 R4
29
15 14
23 or 24 25
26
R201
R89
R163
R161
R159
R157
74
73
72
32
12 10 9
12 10 9 28
R78
R77
R76 C
R86
R74
R73
R72
12 R150
10 R149
9 R139
91
95 94 92
90
95 94 92
89
81 80 79
12 10 9
7
12 10 9 28
1
13 14
34
Eng Rev
01-31-07
B
8
R6 R7
17
R1
R10
35
2
R197
R198
R199
34
R8
Typical
R201
26
R183
R184
R185
R5 R9
23 or 24 25
R200
2 R1
R2
66
R120
ASSEMBLY
A07766
R97
49 48 47
38
42 41 39
50 180' Boom
Shown
46
R107
37 40
R100
LUFFING JIB, #44 LUFFING JIB
Group F
REVISION
1 of 22
Jib Strut
Sheaves
7
6
Main Strut
Sheaves
9
4
11
13
10
14
3
12
Main Strut
Dead End
Wire Rope Guide

Assem. on Boom
Rigging Assem.
Wire Rope Guide

Assem. on Boom
Rigging Assem.
Wire Rope Guide

Assem. on Boom
Rigging Assem.
Luffing Jib Hoist
(Ref. A04331)
Luffing Jib Hoist Reeving

Diagram For 14 Part Line
1700' (500 m) of 1.00" Constructex
(Part A14127) - B.S. = 125,000
R29
R18
R17
R21
R20
R19
R62
R28
R61
R63
R58
View A
Rotated: 23.4 CW
ASSEMBLY
REVISION
A07766
2 of 22
R64
R65
R67
R60
R59
R66
27
R58
32
19
17
32
R63
R58
28
28
28
33
R61
R67
R60
R59
33
19 29
17
150' Jib
27
31
30 28
100' Jib
24 25 or 23
R61 R63
R58
11
R67
R60
R59
32
28
27
19
17
30 28
R61
R63
11
R67
R60
R59
R58
28
31
29
24 25 or 23
33
19
17
140' Jib
30 28
31
90' Jib
24 25 or 23
R61 R63
R58
19
17
11
R67
R60
R59
32
30
28
24 25 or 23
6
R61
R58
11
19
17
130' Jib
28
28
33
31
R63
R67
R60
R59
27
29
80' Jib
24 25 or 23
R61 R63
R58
R67
R60
R59
19 29
17
11
28
32
24 25 or 23
6
R61
27
R63
R58
28
33
17
120' Jib
11
R67
R60
R59
19
70' Jib
24 25 or 23
R61
R63
R58
R67
R60
R59
ASSEMBLY
A07766
19
17
11
5
32
24 25 or 23
11
5
28
33
110' Jib
24 25 or 23
Recommended #44 Luffing Jib Assembly

Note: See Table on page 22 For Alternate combinations
11
3 of 22
REVISION
R61 R63
R67
R60
R59
R61 R63
R58
R67
R60
R59
28
32
32
27
19
17
28
29
28
33
33
160' Jib
24 25 or 23
R61 R63
R58
19
17
11
R67
R60
R59
32
28
28
30
31
28
33
32
33
170' Jib
24 25 or 23
R61 R63
R58
11
R67
R60
R59
28
27
19
17
29
32
32
28
28
30
28
33
31
33
180' Jib
24 25 or 23
R61 R63
R58
11
R67
R60
R59
32
28
19
17
28
33
33
32
32
28
33
190' Jib
24 25 or 23
R61 R63
R58
11
R67
R60
R59
28
32
28
32
27
19
17
29
28
33
33
32
28
33
200' Jib
24 25 or 23
11
5
ASSEMBLY
REVISION
A07766
4 of 22
R58
19
17
32
28
32
28
32
30
28
31
33
R61 R63
R67
R60
R59
28
33
33
210' Jib
24 25 or 23
R61 R63
R58
11
R67
R60
R59
28
27
19
17
29
32
28
32
28
28
30
31
28
33
33
32
33
220' Jib
24 25 or 23
R61 R63
R58
11
R67
R60
R59
32
28
33
33
28
33
32
28
19
17
28
32
32
33
230' Jib
24 25 or 23
R61 R63
R58
11
R67
R60
R59
28
32
27
19
17
29
28
32
32
28
28
33
33
33
32
28
33
ASSEMBLY
REVISION
5 of 22
A07766
240' Jib
24 25 or 23
11
5
38
50
46
R100
R107
62
R89
88 89
66
Backstay Straps
R147
R120
R138
R86
Boom Straps
R201
R200
26
140' Boom
50
38
62
66
71
88 89
75
Backstay Straps
46
R100
R181
R89
Boom Straps
R147
R107
R130
R120
R86
R201
R200
R138
26
160' Boom
50
38
62
66
71
88 89 90 91
75
Backstay Straps
46
R100
R181
R107
R120
R130
50
62
R157
R107
71
R120
R158
75
88 89
R130
R138 R147
200' Boom
96
97
REVISION
A07766
6 of 22
26
R89
R86
Boom Straps
R171
R172
R167
#55/79A Boom Assembly

(Reference Boom Rigging Assembly 100' Mast - A05379)
ASSEMBLY
R201
R200
R181
R153
Backstay Straps
46
R100
66
R86
Boom Straps
R147
R138
180' Boom
38
R89
R201
R200
R181
26
50
38
62
66
71
R120
R107
97
97
96
R138 R147 R171
R130
38
62
50
71
66
R172
R167
R171
R167
R171
R120
R107
R130
R86
97
R201
R200
R172
26
R181
R167
96
88 89 90 91
75
R172
97
96
Backstay Straps
46
R89
Boom Straps
280' Boom
R100
96
Backstay Straps
46
R100
97
96
88 89
75
R89
R86
Boom Straps
R138 R147 R157
R158
R171 R172
R171
R201
R172
R200
26
260' Boom
38
50
62
66
R153
71
88 89
75
R120
R107
R181
R167
96
97
97
96
Backstay Straps
46
R100
R167
R89
R86
Boom Straps
R130
R138 R147 R171
240' Boom
R167
R172
R171
R201
R172
R200
26
50
38
62
66
R107
R120
R130
97
96
88 89 90 91
75
Backstay Straps
46
R100
71
R181
R167
R86
R89
Boom Straps
R138 R147 R157 R158
R171
R201
R200
R172
26
220' Boom
R153
R167
R181
#55/79A Boom Assembly

(Reference Boom Rigging Assembly 100' Mast - A05379)
ASSEMBLY
REVISION
A07766
B
7 of 22

8
28
9
10
12
9
10
12
9
10
12
9
10
12
32
32
28
R51
R77 R78
R76
R77 R78
R86
R86
R73
R72 R74
28
28
28
9
10
12
9
10
12
9
10
12
9
10
12
30
30
9
10
12
9
10
12
9
10
12
9
10
12
30
30
9
10
12
9
10
12
9
10
12
9
10
12
R60 R59
R67
R58
R59 R60
R67
R58
View B-B
REVISION
A07766
8 of 22
R89
91
28
28
28
R72 R74
91
10
9 12
92
94 95
10
9 12
92
94 95
89
92
94 95
80
79 81
90
89
92
94 95
80
79 81
75
85
86 87
72
73 74
88
75
85
86 87
72
73 74
66
72
73 74
63
64 65
71
66
72
73 74
63
64 65
50
63
64 65
47
48 49
62
50
63
64 65
47
48 49
38
47
48 49
46
38
47
49 48
27
27
ASSEMBLY
R73
39
41 42
View C-C
39

1
27 30 or 32
Stored
Position
1
9 10 12
9 10 12
Boom Stop
28
Connectors And
Chord Members
Not Shown
Insert
Deflector Sheave
Insert
Lower
Catwalk
Rigging Winch
Pendant Strap Stowage

(Typical on 10, 20 or
40' Insert)
#44 Jib
Jib Top
Adjustable
Strap
Jib
Strut
Allows Pendulum
Stop (Item 17)
to Swing By
Boom Top
Jib Stop
Main
Strut
Jib Butt
Adapter
Boom Top
200' Offset
At Higher Jib Offset

Angles, The Stop
Contacts Boom Top
Here
600'
1600'
View R - Correct Method
Boom Inserts
Mast
Drum 4
Drum 5
Drum 3
Drum 1
Drum 6
Boom Butt
Drum 2
Warning - Structural Damage

If The Jib Offset Angle Is Not Increased
to 20 After a 60 to 20 Boom Angle, Then the
Pendulum Stop Cannot Swing Past the Boom
Top as Shown.
12
Offset
12
Component Identification
25
View S - Incorrect Method
55
ASSEMBLY
REVISION
A07766
B
9 of 22

100' Jib Position
Approx. Shipping Position Weight = 23,245 Lb
Shipping Width = 8' 3" w/ Winch Handles Removed
16
110' Jib Position

120' Jib
Position
70' Jib Position

80' Jib
Position
90' Jib Position

130' & 140' Jib Position
Slide Pin Load Pin
Slide Pin
Load Pin
190'&
200'& Jib Position
210'
220', 230'& 240'
Jib Position
170'&
180' Jib Position
150'&
160' Jib Position
R63
View D
Shipping And Handling
Locked Operating
Unlocked Adjustment
Plunger Handle
Position
Position
(To Be Removed After
Pin Is In Place)
(Box Section Removed For Clarity)
View P
Shown In 160' Jib Position
16
17
34
R181
26
23
or
24 25
View E
19
29
16
17
35
R94
R23
34
26
R181
23
or
24 25
R94
Drum 3 Attached to
Erection Pendant
29
19
View F
Assist Crane Attached

to Erection Pendant
(item R94) Up to 45
To Remove, refer to
Operation Manual.
R89
R94
35
16
Tag Line
Wire Rope
Guide
17
34
R181
View G
ASSEMBLY
REVISION
A07766
10 of 22
26
View P
23 or 24 25
19
R89
R30
R33
R58
Stowed
R94
R64 Must Be In
R65 Position As
Shown
35
View J
See View J
16
17
19 4
26
R181
23
or
29
24 25
Warning: Do Not Exceed 70 Jib Strut Angle
During Erection While Boom
is on The Ground. Watch That The
Jib Strut Cylinders Do Not Fully Retract.
View H
R89
17
34
Handling Pin
Stowed Position
Erection Position
35
34
R58
See Views
L, M & N
18
17
View T
27
R181
R33
Adjustable
Links
19
View L
View K
R65 Erection
R64 Position
R58
R67
R60
R59
Erection Position
R33
27
19
26
23
or
24 25
Storage/Working
Position
R65
R64
R58
R67
R60
27
R59
View M Storage / Working

Position
19
4
29
R65
R64
R58
R67
R60
R59 27
19
View N
ASSEMBLY
REVISION
A07766
B
11 of 22
Greasing Aux Drum Sheave

1: Raise or lower jib until aux drum sheave is in the center
of it's saft and grease groove is completely covered by sheave.
2: Pump grease through grease zerk in boom butt.
3: Before initial boom raising, connect grease line sections
and pump grease through line until grease begins to come
out of grease hone in shaft.
Aux Drum Sheave
Grease
Line
Grease Groove
Grease
Line
Grease Zerk
for Aux Drum Sheave
View T-T
View U-U
Boom Butt
INSERT ASSEMBLIES REQUIRED FOR VARIOUS BOOM LENGTHS

ITEM NO.
R107
BOOM LENGTH
FEET
METERS
140
160
180
200
220
240
260
280
42.7
48.8
54.9
60.9
67.1
73.2
79.2
85.3
ASSEMBLY
REVISION
A07766
12 of 22
R120
R130
R138
R153
R167
INSERT
INSERT
INSERT
INSERT
INSERT
INSERT
ASSEMBLY
ASSEMBLY
ASSEMBLY
ASSEMBLY
ASSEMBLY
ASSEMBLY
#55 BOOM
#55 BOOM
#55 BOOM
#55 BOOM
#79 BOOM
#79 BOOM
10' 0" (3.05 m) W/SHEAVES 20' 0" (6.10 m) TRANSITION 20' 0" (6.10 m) 40' 0" (12.19 m)
ITEM R106 40' 0" (12.19 m) ITEM R129
55/79
ITEM R152
ITEM R166
ITEM R119
40' 0" (12.19 m)
ITEM R139
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
1
0
1
0
1
0
0
0
0
1
1
2
2
3
JIB LENGTH
INSERT
10' 0"
(3.05 m)
ITEM 29
INSERT
20' 0"
(6.10 m)
ITEM 31
INSERT
40' 0"
(12.19 m)
ITEM 33
STRAP
9' 4-3/4"
(2.86 m)
ITEM 27
STRAP
19' 4-3/4"
(5.91 m)
ITEM 30
STRAP
39' 4-3/4"
(12.00 m)
ITEM 32
PIN
TIMBER
ITEM 1
ITEM 7
ADJUSTABLE
STRAP
LENGTHS
BOOM
SUPPORT
LINK
ITEM 28
COLLAR
PIN
PIN
ITEM 9
ITEM 10
ITEM 12
POSITION
STRAP
LENGTH
FEET
METERS
70
23.3
70
580.00
80
24.4
80
557.87
90
27.4
90
539.75
100
30.5
100
524.88
110
33.5
0
OR
0
2
OR
0
0
OR
1
0
OR
0
4
OR
0
0
OR
2
8
OR
4
2
OR
2
8
OR
4
8
OR
4
8
OR
4
8
OR
4
110
512.38
120
36.6
1
OR
1
2
OR
0
0
OR
1
2
OR
2
4
OR
0
0
OR
2
12
OR
8
3
OR
3
12
OR
8
12
OR
8
12
OR
8
12
OR
8
120
501.75
130
39.6
130
140
42.7
12
12
12
12
12
140
150
45.7
0
OR
0
2
OR
0
1
OR
2
0
OR
0
4
OR
0
2
OR
4
12
OR
8
4
OR
4
12
OR
8
12
OR
8
12
OR
8
12
OR
8
150
160
48.8
1
OR
1
2
OR
0
1
OR
2
2
OR
2
4
OR
0
2
OR
4
16
OR
12
5
OR
5
16
OR
12
16
OR
12
16
OR
12
16
OR
12
160
170
51.8
12
12
12
12
12
170
180
54.9
16
16
16
16
16
180
190
57.9
0
OR
0
2
OR
0
2
OR
3
0
OR
0
4
OR
0
4
OR
6
16
OR
12
6
OR
6
16
OR
12
16
OR
12
16
OR
12
16
OR
12
190
200
61.0
1
OR
1
2
OR
0
2
OR
3
2
OR
2
4
OR
0
4
OR
6
20
OR
16
7
OR
7
20
OR
16
20
OR
16
20
OR
16
20
OR
16
200
210
64.0
16
16
16
16
16
210
220
67.1
20
20
20
20
20
220
70.1
0
OR
0
2
OR
0
3
OR
4
0
OR
0
4
OR
0
6
OR
8
20
OR
16
8
OR
8
20
OR
16
20
OR
16
20
OR
16
20
OR
16
230
73.2
1
OR
1
2
OR
0
3
OR
4
2
OR
2
4
OR
0
6
OR
8
24
OR
20
9
OR
9
24
OR
20
24
OR
20
24
OR
20
24
OR
20
240
230
ASSEMBLY
REVISION
13 of 22
A07766
240
484.75
471.88
461.63
450.13
441.13
ADDITIONAL PARTS REQUIRED FOR VARIOUS JIB LENGTHS
MODEL
18000
LUFFING JIB RIGGING

#44 Luffing Jib on #55/79A Boom with 100' Mast
ITEM
PART #
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
78292
137502
160720
172298
172960
174211
178905
179840
179862
179863
179915
179959
195197
195198
195204
195208
195209
195666
A00228
A02735
A04331
A05312
2
as req.
2
4
1
1
2
2
4
4
1
4
2
4
2
2
1
2
2
2
1
1
DESCRIPTION OF PART
PIN
WASHER
PIN
PIN
LUFFING JIB LOWER POINT ROLLER ASSEMBLY
LUFFING JIB UPPER POINT ROLLER ASSEMBLY
TIMBER
STRAP
COLLAR
PIN
TOP, 30' Boom/Jib (9.14 m) (see O-539)
PIN
SHAFT
PLATE, Keeper
SHAFT
PIN
JIB STOP ASSEMBLY
PIN
SUPPORT, Jib Strut
SIGN, Boom
LUFFING JIB HOIST ASSEMBLY
ROLLER ASSEMBLY (see Note 1)
JIB BUTT MOD. (1 PIECE)

23
171230
BUTT, #44 BOOM/JIB 40' (see Note 2) (see O-539)
JIB BUTT MOD. (2 PIECE)

24
25
171283
171284
1
1
BUTT, #44 Boom Lower Section (40') (see Note 2) (see O-539)
BUTT, #44 Boom Upper Section (40') (see O-539)
ADAPTER FRAME, #79A BOOM

26
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
A07488
171825
194986
396319
429010
562176
612721
710308
A06896
A07485
A07600
A07623
1
6
6
2
6
8
12
12
1
4
6
1
ADAPTER FRAME ASSEMBLY

PLATE, Keeper (3/4" thick)
PIN, Keeper (5" dia. x 10-7/8" long)
PIN, Dowel Roll (1/8" x 5/8" long)
FITTING, Grease
PIN, Cotter (1/2" x 9" long)
SCREW, Hex Cap (3/4-10 x 2-1/4" long, grade 5)
WASHER, Lock (3/4")
ADAPTER FRAME, #79A Boom (machining)
PIN, Cotter (5-1/32" dia. x 12-3/8" long)
BAR, Square (3/4" CF 1018)
BRACKET, Limit Switch
#44 INSERT, 10' (3.1 M)

1
7
27
28
78292
178905
179837
192250
4
1
2
4
ASSEMBLY
REVISION
A07766
14 of 22
PIN
TIMBER
STRAP, Boom Support (10')
LINK, Boom Support
MODEL
18000
LUFFING JIB RIGGING

ITEM
PART #
QTY.
9
10
29
12
179862
179863
179912
179959
4
4
1
4
DESCRIPTION OF PART
COLLAR
PIN
INSERT, 10' (3.05 m) (see O-539)
PIN
#44 INSERT, 20' (6.1 M)

1
7
30
28
9
10
31
12
78292
178905
179838
192250
179862
179863
179913
179959
4
1
2
4
4
4
1
4
PIN
TIMBER
LINK, Boom Support
COLLAR
PIN
INSERT, 20' (6.10 m) (see O-539)
PIN
#44 INSERT, 40' (12.2 M)

1
7
32
28
9
10
33
12
78292
178905
179839
192250
179862
179863
179914
179959
4
2
2
4
4
4
1
4
PIN
TIMBER
LINK, Boom Support
COLLAR
PIN
INSERT, 40' (12.19 m) (see O-539)
PIN
1
4
1
2
2
7
2
2
2
2
2
1
2
1
2
1
1
2
2
2
4
8
JIB STRUT ASSEMBLY

WASHER, Flat (see Note 3)
BOOM ANGLE INDICATOR ASSEMBLY
PLATE, Keeper
SHEAVE ASSEMBLY (see Note 4)
PIN
COLLAR
COLLAR
PIN
PIN
WELDMENT, Jib Strut (see O-539)
SPACER
SPACER
SPACER
SHAFT
SHAFT
LINK
PIN
PIN
STOP, Cylinder
PIN
JIB STRUT
34
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
R27
R28
R29
R30
R31
R32
194160
144435
168779
169810
171250
171964
174149
178460
179862
179863
179959
194159
194910
194915
194976
194977
194978
194979
194980
194981
194982
194985
ASSEMBLY
REVISION
A07766
B
15 of 22
MODEL
18000
LUFFING JIB RIGGING

ITEM
PART #
QTY.
DESCRIPTION OF PART
R33
R34
194997
195005
2
1
CABLE ASSEMBLY (60')

SPACER
R35
R36
R37
R38
R39
R40
R41
R42
R43
R44
R45
R46
R47
R48
R49
R50
R51
R52
R53
R54
R55
R56
195006
195194
195195
225105
225111
546052
546054
612451
612353
614033
631528
709440
710302
710304
A00070
A00072
A00306
A00355
A00874
A01617
A01624
A02831
1
2
2
2
1
8
6
6
8
4
4
6
8
10
2
1
2
2
4
2
2
2
GUARD, Rope
PIN
PLATE, Keeper
NUT, Bearing Lock (see Note 6)
WASHER, Bearing Lock
NUT, Hex (1/4-20)
NUT, Hex (3/8-16UNC)
SCREW, Cap (3/8-16UNC - 2B x 5/8" long)
SCREW, Hex Cap (1/4-20 x 3/4" long)
SCREW, Hex Cap (3/8-16 x 4" long)
ROLLER, Sheave (1/4" dia.) (see Note 7)
WASHER, Flat (3/8")
WASHER, Lock (1/4")
WASHER, Lock (3/8")
ROLLER
TUBE, Round
HYDRAULIC CYLINDER ASSEMBLY
WINCH
SHIM, 3/32" (13 GA.)
SUPPORT
SHIM PACK
SUPPORT, Keeper Plate
194869
194861
179862
179959
194864
194865
194872
194966
194967
194968
194992
195350
2
2
2
2
2
2
2
4
2
2
2
2
STRAP ASSEMBLY
STRAP, Adjustable Length Jib Weldment
COLLAR
PIN
LINK, Strap
EXTENSION, Strap
PIN, Strap Adjust
COLLAR
PIN
PIN
PIN
HANDLE
STRAP
R57
R58
R59
R60
R61
R62
R63
R64
R65
R66
R67
R68
MAIN STRUT
35
R69
R70
R71
R72
R73
R74
194162
139133
169810
171964
179862
179863
179959
1
2
1
7
2
2
2
ASSEMBLY
REVISION
A07766
16 of 22
MAIN STRUT ASSEMBLY

PIN
PLATE, Keeper
COLLAR
PIN
PIN
MODEL
18000
LUFFING JIB RIGGING

ITEM
PART #
QTY.
R75
R76
R77
R78
R79
R80
R81
R82
R83
R84
R85
R86
R87
R88
R89
R90
R91
R92
R93
R94
R95
R96
194161
194682
194683
194684
194880
194907
194908
194909
194910
194911
194914
194979
194987
194988
194993
194994
195004
225105
225111
276935
624779
646246
1
2
2
2
1
1
1
2
1
1
2
2
2
1
2
10
1
2
1
2
2
1
DESCRIPTION OF PART
MAIN STRUT, Weldment (see O-539)
PIN
COLLAR
PIN
SHAFT
LINK ASSEMBLY
SPACER
SPACER
SPACER
SHAFT
PIN
LINK
ROLLER
ROLLER
STRAP
PIN
SPACER
NUT, Bearing Lock (see Note 6)
WASHER, Bearing Lock
PENDANT
PIN, Shackle (2-1/4" dia.)
WEDGE, Socket (1" Wire Rope) (see O-890)
OPTIONAL WIRE ROPE GUARD FOR CE CODE

36
A06120
GUARD, Wire Rope for CE Code
BOOM RIGGING (A05379)

R97
A04342
MAST ASSEMBLY (100')
EQUALIZER ASSEMBLY
EQUALIZER
R98
A06258
BUTT, 20' (6.10 M) #55 BOOM

R99
R100
R101
R102
R103
R104
R105
37
38
39
40
41
42
43
A05403
1
20' BUTT ASSEMBLY, #55 Boom
A05447
1
BUTT, , 20' (machining) (see O-573)
A04989
2
BOOM STOP ASSEMBLY
A04329
1
DRUM ASSEMBLY, Main Hoist
193481
1
PIN PULLER ASSEMBLY
A06649
2
PIN, Upper Male Connector
168179
1
INDICATOR, Boom Angle
Luffing Jib Equipped (see Note 8)
A04331
1
LUFFING DRUM ASSEMBLY
A07498
2
LINK, #55 Boom Strap
A07517
2
PIN, 1 Hole w/Hd
A06344
2
PAWL ASSEMBLY, Luffing Drum
A06150
2
PIN, 2 Hole
A06151
2
COLLAR
562105
4
PIN, Cotter (1/4" x 1-1/2" long)
ASSEMBLY
REVISION
A07766
B
17 of 22
MODEL
18000
LUFFING JIB RIGGING

ITEM
PART #
QTY.
DESCRIPTION OF PART
INSERT, 10' (3.05 M) #55 BOOM

R106
R107
R108
R109
R110
R111
R112
R113
R114
R115
R116
R117
R118
44
45
46
47
48
49
50
51
A05381
1
INSERT ASSEMBLY, 10' (#55 Boom)
A05448
INSERT, 10' (machining)(see O-573)
A04329
1
DRUM ASSEMBLY, Main Hoist
631099
2
SHEAVE
563640
4
PIN, Safety
A07561
2
PIN, 1 Hole w/Hd
A06099
2
PIN, 1 Hole w/Hd
A06649
2
PIN, Upper Male Connector Locking
A06173
1
FRAME, Drum/Sheave (machining)
A06175
2
SHAFT
A06176
2
GUARD, Rope
A06540
4
PIN, Frame
A06361
2
PENDANT
562045
4
562105
8
A05198
2
STRAP, 10' (2" x 3-3/4") (#55 Boom)
A06149
4
PIN, 1 Hole w/Hd
A06150
4
PIN, 2 Hole
A06151
4
COLLAR
A06457
4
LINK, #55 Boom
A07565
2
PIN, 2 Hole (5/8" dia. x 9-7/8" long)
INSERT, 40' (12.19 M) #55 BOOM

R119
R120
R121
R132
R123
R124
R125
R126
R127
R128
52
53
54
55
56
57
58
59
60
61
A05387
1
INSERT ASSEMBLY, 40' (#55 Boom) (see Note 9)
A05451
1
INSERT, 40' (machining) (see O-573)
194123
2
TIMBER
A07561
2
PIN, 1 Hole w/Hd
A06099
2
PIN, 1 Hole w/Hd
A06649
2
PIN, Upper Male Connector Locking
548342
8
NUT, Lock NE (3/8-16)
563640
2
PIN, Safety (1/4" O.D. x 5" long)
612480
8
709703
16
WASHER, Flat (1/32")
171497
2
PLATE, End
172169
1
SHEAVE (24" dia.)
563803
4
PIN, Snap (3/8" x 2-1/4" long)
612657
4
SCREW, Hex Cap (5/8-11 x 1" long, grade 5)
710307
4
WASHER, Lock (5/8")
A06399
1
WIRE ROPE GUARD ASSEMBLY, Luffing Line
A06586
2
GUARD, Wire Rope
A06659
1
SHAFT (4-1/2" O.D. x 9-15/32" long)
562045
8
532105
8
ASSEMBLY
REVISION
A07766
18 of 22
MODEL
18000
LUFFING JIB RIGGING

ITEM
PART #
QTY.
62
63
64
65
66
67
68
A05197
A06149
A06150
A06151
A06457
A07033
A07034
2
4
4
4
4
2
2
DESCRIPTION OF PART
STRAP, 40' (2" x 3-3/4") (#55 Boom)
PIN, 1 Hole w/Hd
PIN, 2 Hole
COLLAR
LINK, #55 Boom
PIN, 2 Hole (5/8" dia. x 6" long)
INSERT, 20' (6.10 M) #55 BOOM

R129
R130
R131
R132
R133
R134
R135
R136
69
70
71
72
73
74
75
76
77
A05383
1
INSERT ASSEMBLY,20' (#55 Boom)
A05449
1
INSERT, 20' (machining) (see O-573)
A06651
4
ROLLER
A06653
4
PIN, Roller
194123
2
TIMBER
A07561
2
PIN, 1 Hole w/Hd
A06099
2
PIN, 1 Hole w/Hd
563640
2
PIN, Safety
562045
8
562105
8
A05196
2
STRAP, 20' (#55 Boom) (2" x 3-3/4")
A06149
4
PIN, 1 Hole w/Hd
A06150
4
PIN, 2 Hole
A06151
4
COLLAR
A06457
4
LINK, #55 Boom
A07033
2
A07034
2
PIN, 2 Hole (5/8" dia. x 6" long)
TRANSITION INSERT, 40' (12.19 M)

R137
R138
R139
R140
R141
R142
R143
R144
R146
R147
R148
R149
R150
R151
78
79
80
A05400
1
TRANSITION INSERT ASSEMBLY, 40'
A05459
1
TRANSITION INSERT, 40' (machining)(see O-573)
170799
2
PIN
179862
2
COLLAR (3" dia. x 1" long)
179959
2
PIN (1/2" dia. x 4-1/8" long)
194123
2
TIMBER
562043
4
PIN, Cotter (1/8" x 1" long)
562085
4
A06099
2
PIN, 1 Hole w/Hd
A06683
4
LINK, Eq to #79 Boom Strap
A06944
2
PIN, 1 Hole w/Hd (2-1/4" dia. x 6-9/32" long)
A06947
2
A07161
2
COLLAR (6" dia. x 1-3/4" long)
A07561
2
PIN, 1 Hole w/Hd
78292
4
PIN
179862
2
179863
2
ASSEMBLY
REVISION
A07766
B
19 of 22
MODEL
18000
LUFFING JIB RIGGING

ITEM
PART #
QTY.
81
82
83
84
85
86
87
88
89
179959
562045
562085
562105
A06149
A06150
A06151
A07111
A07112
2
8
4
4
2
2
2
2
4
DESCRIPTION OF PART
PIN (1/2" dia. x 4-1/8" long)
PIN, 1 Hole w/Hd
PIN, 2 Hole
COLLAR
STRAP, 55/79 Transition
LINK, 55/79 Transition
INSERT, 20' (6.10 M) #79 BOOM

R152
R153
R154
R155
R156
R157
R158
R159
R160
R161
R162
R163
R164
R165
90
91
92
93
94
95
194086
1
193412
1
INSERT, 20' (see O-562)
193888
2
PIN
193889
2
PIN
193886
2
PIN
179838
2
STRAP
192250
4
LINK, Strap
179863
4
PIN, Strap
78292
4
PIN, Strap Bracket
179862
4
COLLAR
194123
2
TIMBER
179959
4
PIN
194377
4
ROLLER
194378
4
PIN
179838
2
STRAP
192250
4
LINK, Strap
179863
4
PIN, Strap
78292
4
PIN, Strap Bracket
179862
4
COLLAR
179959
4
PIN
INSERT, 40' (12.19 M) #79 BOOM

R166
R167
R168
R169
R170
R171
R172
R173
R174
R175
R176
R177
R178
194087
193413
193888
193889
193886
179839
192250
179863
78292
179862
194123
179959
194377
1
1
2
2
2
2
4
4
4
4
2
4
4
ASSEMBLY
REVISION
A07766
20 of 22

INSERT, 40" (see O-562)
PIN
PIN
PIN
STRAP
LINK, Strap
PIN, Strap
PIN, Strap Bracket
COLLAR
TIMBER
PIN
ROLLER
MODEL
18000
LUFFING JIB RIGGING

ITEM
R179
96
97
98
99
100
101
PART #
QTY.
DESCRIPTION OF PART
194378
4
PIN
179839
2
STRAP
192250
4
LINK, Strap
179863
4
PIN, Strap
78292
4
PIN, Strap Bracket
179862
4
COLLAR
179959
4
PIN
TOP, #79A BOOM

R180
R181
R182
R183
R184
R185
R186
R187
R188
R189
R190
R191
R192
R193
R194
R195
R196
R197
R198
R199
R200
R201
R202
R203
R204
R205
R206
A05401
A05460
78292
179862
179863
179959
193888
193889
194123
548342
562085
562106
563640
612480
709703
A05882
A06074
A06149
A06150
A06151
A06348
A06349
254555
546053
562045
710303
A02735
1
1
2
4
4
4
2
2
1
4
8
4
2
4
8
1
1
2
2
2
2
4
20
20
4
20
2
BOOM TOP ASSEMBLY, #79A

TOP, Boom (machining)(see O-562)
PIN
PIN (1/2" dia. x 4-1/8" long)
PIN
PIN
TIMBER (3-1/2" x 3-1/2")
NUT, Lock NE (3/8-16)
PIN, Safety (1/4" O.D. x 5" long)
WASHER, Flat (3/8")
GUIDE ASSEMBLY, Wire Rope
BOOM POINT ASSEMBLY
PIN, 1 Hole w/Hd
PIN, 2 Hole
COLLAR
STRAP (28' 2-15/16")
LINK (10")
SCREW, Machine (5/16-18 x 1-1/4" long, ZC Steel)
NUT, Hex (5/16-18 ZC)
WASHER, Lock (5/16")
SIGN, Boom Manitowoc (37" x 96")
OPTIONAL PARTS
102
103
104
105
106
107
A07773
A07752
237074
236505
A00816
A14753
500T HOOK ASSEMBLY (see O-1209)

250MT HOOK ASSEMBLY (see O-1224)
SWIVEL HOOK ASSEMBLY, 30T
250 M Tonne Hook Assembly (O-1409)
ASSEMBLY
REVISION
A07766
B
21 of 22
MODEL
18000
LUFFING JIB RIGGING

ITEM
PART #
QTY.
DESCRIPTION OF PART
Note 1:
If boom top does not have lugs to support roller assembly A05312 (item 22), use
roller assembly A00678 in place of A05312.
Note 2:
#44 2-piece butt requires modification 417346.

#44 1-piece butt requires modification 417345.
Note 3:
Shim cylinder lugs to center cylinder rod end on boom top cylinder guides.
Note 4:
28 mm wire rope.
Note 5:
1" wire rope.
Note 6:
Tighten locknuts efficiently to clamp bearing inner race.
Note 7:
For 1/4" wire rope.
Note 8:
Items required for adding luffing jib to existing equipment or use same items from
insert assemblies for machines with luffing jib equipped.
Note 9:
With wire rope guides for luffing jib.
O-539, O-562, O-573, O-890, O-1208, O-1209, O-1224, O-1225, O-1409

ASSEMBLY
REVISION
A07766
22 of 22

Manitowoc, Wisconsin 54220 U.S.A.
18000
Luffing Jib No. 44 On Boom No. 55-79A with 100 Ft. Mast No. 56
Recommended boom and luffing jib raising and lowering procedure.

Machine must be equipped with 528,000 Lb. (239 500 kg) crane counterweight and 320,000 Lb. (145 150 kg) carbody
counterweight. Refer to luffing jib rigging assembly No. A07766 for boom and luffing jib make-up of inserts, straps, struts and strut
raising procedure and miscellaneous parts, etc.
Two methods may be used to raise and lower boom and luffing jib combinations, depending on length.
A. Standard (In-Line) Method
Haul in luffing hoist line (luff up) until adjustable jib straps are raised to clear strap stowage brackets on luffing jib (approx. 50 to
68 degree jib strut to horizontal angle). Do not exceed 70 degree jib strut to horizontal angle. Check jib strut position by viewing
angle indicator. Slowly raise boom to tighten luffing jib suspension while jib point rollers are allowed to roll on ground. After
luffing jib suspension is tight, boom and luffing jib can then be raised simultaneously using only the boom hoist. Raise boom to
60 degrees or greater. If boom to luffing jib angle is more than 160 degrees, lower luffing jib to obtain this angle to allow jib stop
to engage (see caution). Boom and luffing jib can then be set to desired operating angle and radius. Luffing jib radius must be
within capacity chart before swinging over side of machine. Reverse this procedure when lowering boom and luffing jib.
CAUTION: Failure to lower luffing jib to 160 degree boom to luffing jib angle will not allow luffing jib stop to engage.
Structural damage may result.
The following combinations may be raised and lowered using this method.
Maximum Boom And Luffing Jib Lengths Lifted Unassisted Using

Standard (In-Line) Method
Boom
Length
Feet
140
160
180
200
220
240
Meters
42.7
48.8
54.9
61.0
67.1
73.2
Over End of
Blocked Crawlers
Over Side of
Crawlers
Luffing Jib No. 44

Feet
Meters
70 - 240
21.3 - 73.2
70 - 240
21.3 - 73.2
70 - 210
21.3 - 64.0
70 - 180
21.3 - 54.9
70 - 150
21.3 - 45.7
70 - 110
21.3 - 33.5
Luffing Jib No. 44

Feet
Meters
70 - 240
21.3 - 73.2
70 - 240
21.3 - 73.2
70 - 210
21.3 - 64.0
70 - 170
21.3 - 51.8
70 - 120
21.3 - 36.6
70 - 80
21.3 - 24.4
Load blocks, hook and weight ball on ground until boom and luffing jib
are erected.
S/N: 18005910
8542-A, 4-14-04/GA
Page 1 of 2

Manitowoc, Wisconsin 54220 U.S.A.
18000
Luffing Jib No. 44 On Boom No. 55-79A with 100 Ft. Mast No. 56
B. Jack-Knife Method
Longer boom and luffing jib combinations must be raised and lowered using jack-knife method.
Haul in luffing hoist line (luff up) until adjustable jib straps are raised to clear strap stowage brackets on luffing jib (approx.
50 to 68 degree jib strut to horizontal angle). Do not exceed 70 degree jib strut to horizontal angle. Check jib strut position by
viewing angle indicator. Slowly raise boom while jib point rollers are allowed to roll on ground. Tension should be applied to
luffing jib hoist to keep adjustable jib straps off luffing jib during boom raising. Boom up until boom to luffing jib angle
reaches value specified in table or jib is vertical, whichever occurs first. Tighten luffing jib suspension with luffing jib hoist.
Boom and luffing jib are then raised together using boom hoist until boom reaches desired boom operating angle. Luffing jib
radius must be within capacity chart before swinging over side of machine.
Position boom at 70 degrees or greater prior to lowering luffing jib. Lower luffing jib until boom to luffing jib angle reaches
value specified in table. Lower boom until luffing jib point is just above ground. If luffing jib is hanging vertical, raise luffing
jib a few degrees forward of vertical. Continue to lower boom while luffing jib rolls along ground. Keep enough tension on
luffing jib hoist to keep adjustable jib straps off luffing jib and lower boom to ground.
CAUTION: Do not under any condition allow boom to luffing jib angle to become less than 70 degrees.
The following boom and luffing jib combinations require jack knifing to a specified boom to luffing jib angle for raising and
lowering.
Maximum Boom And Luffing Jib Lengths Lifted Unassisted Using Jack-Knife Method
Over End of
Blocked Crawlers
Boom
Length
Feet
180
200
220
240
260
280*
Meters
54.9
61.0
67.1
73.2
79.2
85.3
Luffing Jib No. 44

Feet
220 - 240
190 - 240
160 - 240
120 - 240
70 - 240
70 - 240
Meters
67.1 - 73.2
57.9 - 73.2
48.8 - 73.2
36.6 - 73.2
21.3 - 73.2
21.3 - 73.2
Over Side of
Crawlers
Boom to
Luffing Jib
Angle
Degrees
90
90
90
90
70
70
Luffing Jib No. 44

Feet
220 - 240
180 - 240
130 - 240
90 - 240
Meters
67.1 - 73.2
54.9 - 73.2
39.6 - 73.2
27.4 - 73.2
Load blocks, hook and weight ball on ground until boom and luffing jib are erected.
* Remove lower boom point.
8542-A, 4-14-04/GA
Page 2 of 2
S/N: 18005910
Boom to
Luffing Jib
Angle
Degrees
90
90
90
70
Eng Rev
06-19-08
ASSEMBLY
REVISION
A05580
I
1 of 20
CONTROL WIRING, BOOM & LIMITS
Group F
ASSEMBLY
REVISION
A05580
2 of 20
ASSEMBLY
REVISION
A05580
I
3 of 20
ASSEMBLY
REVISION
A05580
4 of 20
ASSEMBLY
REVISION
A05580
I
5 of 20
ASSEMBLY
REVISION
A05580
6 of 20
ASSEMBLY
REVISION
A05580
I
7 of 20
ASSEMBLY
REVISION
A05580
8 of 20
ASSEMBLY
REVISION
A05580
I
9 of 20
ASSEMBLY
REVISION
A05580
10 of 20
ASSEMBLY
REVISION
A05580
I
11 of 20
ASSEMBLY
REVISION
A05580
12 of 20
ASSEMBLY
REVISION
A05580
I
13 of 20
ASSEMBLY
REVISION
A05580
14 of 20
MODEL
18000
CONTROL WIRING
Boom & Limits
ITEM
Part #
QTY.
DESCRIPTION OF PART
1
546054
4
NUT, Hex (3/8 -16UNC-2B)
2
591121
1
REEL, Cable
3
612456
4
SCREW, Hex Cap (3/8 -16UNC-2A x 1-1/4 long)
4
667042
36
STRAP, Stay (8 max dia) (see Note 6)
5
710304
4
WASHER, Lock (3/8)
6
81000194
1
CABLE, Electric Boom PWR/COMM WBM 150440
8
A15346
1
LINK, Load Cell 70K Wireless (2.4 GHz) (see Note 10)
9
A15488
1
LINK, Load Cell 70K Wired (see Note 10)
10
A15486
1
CABLE, Electric Load Link (20 long)
11
A15368
1
TRANSCEIVER (2.4 GHz, 125K baud) (see Note 11)
12
81000201
1
CABLE, Electric Boom Jumper WBMJ8 (see Note 11)
14
546052
4
NUT, Hex (1/4 -20UNC)
15
612363
4
SCREW, Hex Cap (1/4 -20UNC x 2 long)
16
710708
4
WASHER, Lock (1/4, int. shakeproof)
ADD FOR #55 OR #55A BOOM TOP
18
624633
1
SHACKLE, Anchor (5/16, round pin)
19
667007
6
STRAP, Stay (see Note 7)
20
669280
6
STUD, Wire Tie (see Note 7)
21
A18332
8
WASHER, Lock External Countersink (1/4") (see Note 9)
23
A08627
1
CONTROLLER, Boom Node
24
81000196
1
CABLE, Electric Block-Up Limit
25
142403
1
WEIGHT
26
A06154
1
SWITCH ASSEMBLY
27
334101
1
CHAIN, Straight Link (12 long)
28
A18331
4
NUT, KEPS (M-1.0 zinc)
29 7126151256
4
SCREW, Hex Serrated Flange (M6 x 25)
ADD FOR #79A BOOM TOP
31
142403
1
WEIGHT
32
A06154
1
SWITCH ASSEMBLY
33
334101
1
34
A18331
4
35 7126151256
4
36
624633
1
37
667007
6
38
669280
6
39
A18332
8
41
A08627
1
CONTROLLER, Boom Node
42
81000196
1
ADD FOR SINGLE HOIST DRUM REEVING - LOWER POINT WITH 10 OR LESS PARTS OF LINE
(#55, #55A, OR #79A BOOM/JIB TOPS)
44
144853
1
PIN
45
A15357
1
BRACKET, Block Up Limit
ADD FOR UPPER BOOM POINT OR UPPER JIB POINT (REF. 170419)
(NEW CONSTRUCTION)
47
48
93657
142403
1
1
BLOCK, Lift (single part line)

WEIGHT (multi part line)
ASSEMBLY
REVISION
A05580
I
15 of 20
MODEL
18000
CONTROL WIRING
Boom & Limits
Part #
ITEM
QTY.
DESCRIPTION OF PART
49
162273
1
WEIGHT
50
168091
1
LUG
51
170120
2
BRACKET
52
195749
1
SWITCH ASSEMBLY
55
334101
2
57
546054
11
58
612456
11
59
624633
3
SHACKLE, Anchor
60
667007
3
61
669280
3
62
710304
11
WASHER, Lock (3/8)
63
81000196
1
ADD FOR #79A UPPER LUFFING JIB POINT OR UPPER BOOM POINT - #55, #55A, OR #79A (REF. A08516)
65
93657
1
66
142403
1
67
162273
1
WEIGHT
68
168091
1
LUG
69
A04984
2
BRACKET
71
195749
1
SWITCH ASSEMBLY
73
334101
2
75
546054
11
76
612456
11
77
624633
3
SHACKLE, Anchor
78
667007
3
79
669280
3
80
710304
11
WASHER, Lock (3/8)
81
81000196
1
ADD FOR #79A LUFFING JIB OR #79A FIXED JIB
84
85
88
90
91
92
94
95
96
97
98
99
100
101
103
104
105
106
142403
A06154
334101
A18331
546054
591121
7126151256
612456
624633
667007
667042
669280
A18332
710304
A07759
A08628
A07068
A06179
1
1
1
4
4
1
4
4
1
3
12
3
8
4
1
1
1
1
ASSEMBLY
REVISION
A05580
16 of 20
WEIGHT
SWITCH ASSEMBLY
REEL, Cable
WASHER, Lock (3/8)
CABLE, Electric Luffing Jib WLJ3K325
CONTROLLER, Boom/Luffing Jib Node
CABLE, Electric Boom Extension WBNE18
MODEL
18000
CONTROL WIRING
Boom & Limits
ITEM
Part #
QTY.
DESCRIPTION OF PART
ADD FOR #44 LUFFING JIB

(NEW CONSTRUCTION)
112
142403
1
WEIGHT
113
195749
1
SWITCH ASSEMBLY
116
334101
1
118
A18331
4
119
546054
4
120
591121
1
REEL, Cable
122 7126151256
4
123
612456
4
124
624633
1
126
667042
12
128
A18332
8
129
710304
4
WASHER, Lock (3/8)
131
81000191
1
CABLE, Electric Boom PWR/COMM WBM250
132
A08628
1
CONTROLLER, Boom/Luffing Jib Node
133
81000192
1
CABLE, Electric Block-Up Limit (6 long)
134
81000195
1
CABLE, Electric Boom Extension PWR/COMM WBNE18
135
A06191
1
JIB STOP ASSEMBLY, Automatic #44 Luffing Jib
ADD FOR #44 UPPER LUFFING JIB POINT (REF. 174211)
(NEW CONSTRUCTION)
138
93657
1
139
142403
1
140
162273
1
WEIGHT
141
168091
1
LUG
142
170120
2
BRACKET
143
174713
2
PLATE, Mounting
144
195749
1
SWITCH ASSEMBLY
146
334101
2
148
546054
6
149
612456
6
150
624633
3
SHACKLE, Anchor
151
667007
3
152
669280
3
153
710304
14
WASHER, Lock (3/8)
154
81000193
1
155
710304
6
SCREW, Cap (3/8-16 UNC-2A x 7/8 Long)
ADD FOR #79A LUFFING JIB
157
A15542
1
JIB STOP ASSEMBLY, Automatic #79A Luffing Jib
158
81000198
1
CABLE, Electric Luffing Jib Stop
ADD FOR UPPER BOOM POINT (170419 REF.) (EXISTING FIELD - 555, 777, 888, 999, M250, 2250)
163
81000196
1
ADD FOR EXTENDED UPPER BOOM POINT
165
166
167
93657
142403
162273
1
1
1

WEIGHT
ASSEMBLY
REVISION
A05580
I
17 of 20
MODEL
18000
CONTROL WIRING
Boom & Limits
ITEM
Part #
QTY.
168
169
170
171
172
173
175
176
168091
170120
174713
A06154
A10556
334101
624633
667007
1
2
2
1
1
3
4
8
DESCRIPTION OF PART
LUG
BRACKET
PLATE, Mounting
SWITCH ASSEMBLY
SWITCH ASSEMBLY
SHACKLE, Anchor
177
669280
8
178
667042
8
STRAP, Stay
180
81000199
1
181
81000202
1
182
477339
1
CABLE, Harness Extension Micro-Change (19.7 long)
184
546054
12
185
612456
12
186
710304
12
WASHER, Lock (3/8)
ADD FOR 55, 55A, OR 79A LOWER BOOM POINT OR LOWER JIB POINT WITH TANDUM (2 DRUM) REEVING
189
190
A15488
81000200
1
1
ASSEMBLY
REVISION
A05580
18 of 20
LINK, Load Cell 70k Wired

CABLE, Electric (load link - 20')
Note 1:
Block-up limit control is intended as a protective device. It is not to be used as a hoist

distance control for specific job applications.
Note 2:
Periodic checks should be made to insure that block-up limit control is functioning properly.
Note 3:
CAUTION: Block-up limit control system may not function at machines maximum single
line speed - carefully check each machine for maximum safe line speed.
Note 4:
For blocks without actuator brackets see modification dwg 184433 customer furnished.
Note 5:
When a locking swivel is placed in the wire rope dead end, allow extra length in chain
equal to length of the locking swivel added.
Note 6:
Attach cable to boom or jib by using straps at approximately 10 ft intervals.
Note 7:
Attach cable to boom top or jib top between junction box and switch by using weld studs
at approximately 1 to 2 ft intervals.
Note 8:
For Receptacles Equipped With Shorting Plugs:

Shorting plugs must be plugged in whenever receptacle is not being used.
Note 9:
Electrical enclosures are to be mounted as shown in view G-G, View H-H, View K-K and
view L-L. Torque the KEPS nuts tight to establish less than .01 ohms between frame and
enclosure receptacle shells. All enclosure mounting bolts must be electrically common to
one another ( less than .o1 ohms).
MODEL
18000
CONTROL WIRING
Boom & Limits
ITEM
Part #
QTY.
DESCRIPTION OF PART
Note 10: The basic bill of material contains one wired load link (item 9) and one wireless load link
(item 8). The wired load link (item 9) is typically used on the lower point (even multi-parts
of line) and the wireless load link (item 8) is typically used on the upper point (single or two
part line).
One additional wired load link (1 item 189) is required and used on the lower boom point or
lower jib point for tandem drum operation.
Note 11: Transceiver (item 11) and cable WBMJ8 (item 12) are mounted on the jib top for luffing jib
or fixed jib applications.
ASSEMBLY
REVISION
A05580
I
19 of 20
MODEL
18000
CONTROL WIRING
Boom & Limits
ITEM
Part #
QTY.
ASSEMBLY
REVISION
A05580
20 of 20
DESCRIPTION OF PART
TECHNICAL
BULLETIN
BRIDON AMERICAN
280 New Commerce Boulevard Wilkes-Barre, PA 18706
Telephone: (570) 822-3349 1-800-521-5555
FAX: 1-800-233-8362
Website: http://www.bridonamerican.com
E-mail: [email protected]
Form No. TBRR-192
Rotation Resistant Ropes

Rotation Resistant Ropes are defined as stranded ropes
designed to generate reduced levels of torque and rotation when
loaded, and are comprised of an assembly of two or more layers
of strands laid helically around a center. The direction of lay of the
outer strands being opposite to that of the underlying layer.
Rotation Resistant Ropes are grouped into the following
categories based on construction:
Rotation Resistant Rope category 1: Stranded rope
constructed in such a manner that it displays little or no tendency
to rotate, or, if guided, transmits little or no torque, has at least
fifteen outer strands and comprising an assembly of at least three
layers of strands laid helically over a center in two operations, the
direction of lay of the outer strands being opposite to that of the
underlying layer (i.e. Endurance Dyform 34LR, Endurance 35LS).
A
B
C
D
E
A. Endurance 19; B. Endurance 8RR; C. Dyform-18;
D. Dyform-34LR; E. Endurance 35LS

constructed in such a manner that it has significant resistance to
rotation, has at least ten outer strands and comprising an
assembly of two or more layers of strands laid helically over a
center in two or three operations, the direction of lay of the outer
strands being opposite that of the underlying layer (i.e.
Endurance Dyform 18, Endurance 19).
constructed in such a manner that it has limited resistance to
rotation, has no more than nine outer strands and comprising an
assembly of two layers of strands laid helically over a center in
two operations, the direction of lay of the outer strands being
opposite to that of the underlying layer (i.e. Endurance 8RR).
While this properly defines the ropes, it does not tell the complete
story about a commonly misunderstood and often misused
product.
All of these ropes have specific operating and performance
characteristics and some have limitations. An overview of certain
operating characteristics shows the following:
Endurance
19
Multiple Part
Reeving
Single Part
Reeving
Endurance
8RR
Endurance Endurance
Dyform-18 Dyform 34LR
& 35LS
DIAGRAMATIC ILLUSTRATION OF ROTATION

VARIOUS ROPE CONSTRUCTIONS
6 X 36 IWRC
ROTATION
ENDURANCE 8RR
DEGREES/M
+
ENDURANCE 19/DYFORM-18
ENDURANCE 35LS/DYFORM-34LR
ROPE TENSION
15%
xMBL
20%
xMBL
MBL = MINIMUM BREAKING LOAD
STANDARD APPLICATIONS
No
Yes
Yes
Yes
Mobile Cranes and Overhead Hoists: Endurance

19 and Endurance 8RR
Yes*
Yes*
Yes*
Yes
Mobile Cranes and Overhead Hoists: Endurance

Dyform-18
Swivels
No
No
No
Yes
Strength
Low
Low
High
Highest
Preformed
Yes
Yes
Partially
No
Multiple Layer
Winding
Yes
Yes
Yes
Yes
Prevention of
Block Spinning
N/A
Good
Much Better
Best
More detail and further explanation of these characteristics and limitations will be
covered in the following discussions.
*These ropes should be limited to a maximum fall of 150 times the rope diameter
(i.e. 1/2 rope x 150 = 75) when used single part, or rope distortion and damage
may occur.
Tower Cranes and Various Hoisting Applications:

Endurance Dyform 34LR and Endurance 35LS
All Rotation Resistant Ropes can be used in a
variety of other applications, but the specific
application and the operating requirements should
be carefully reviewed by BAC Technical Services or
a qualified person before a recommendation can
be made.
BRIDON AMERICAN
SEIZING AND CUTTING
HANDLING/INSTALLATION
Because Rotation Resistant Ropes can be difficult to properly

identify by sight, it is recommended that all Rotation Resistant
Ropes be tightly seized with wire, strand or tape; or welded
before cutting. It is important that all Rotation Resistant Ropes be
prevented from unlaying when cut regardless of construction.
General guidelines for seizing and welding are shown in detail
below. Endurance 35LS and Endurance Dyform 34LR should
have welded ends and not seized ends.
Rotation Resistant Ropes must have properly seized, or welded

ends. They must be installed without inducing twist or turn. They
must not be kinked, and they must have the proper tail length at
the wedge socket.
PREFORMED/NON-PREFORMED
Rotation Resistant Ropes are special ropes and are produced
with special manufacturing techniques to meet all of the required
operating parameters of the ropes. To prevent confusion as to
which are preformed, partially preformed and non-preformed,
Bridon American attaches a warning tag on Rotation Resistant
Ropes to indicate that they should always be properly seized
when cut.
WEDGE SOCKETS
All Rotation Resistant Ropes can be used with standard wedge
sockets. Certain precautions must be taken. All Rotation
Resistant Ropes should be tightly seized with wire, strand or
tape; or welded to prevent loss of rope lay at the dead end. Loss
of rope lay will change the operating characteristics of the ropes
and can cause high strands and rope distortion.
The dead end should be a minimum length of 20 rope diameters
for all Rotation Resistant Ropes with either welded or seized
ends. A wire rope clip may be attached to the dead end.
NOTE: Two seizings are recommended for non-preformed rope (two rope
diameters in length), and one seizing for preformed rope (one rope
diameter in length).
WELDED ENDS
A welded rope end can facilitate the installation of a Rotation
Resistant Rope in a wedge socket. A welded rope end combined
with a tail of less than 20 rope diameters can cause rope
distortion. If the proper tail length is used, a welded end is
acceptable.
Capped welded end.
SWIVELS
Tapered and welded end.
BAC recommends that Endurance 19, Endurance 8RR, and

Endurance Dyform-18 not be dead ended into a swivel, unless
used under specific conditions and with specific limitations.
Endurance Dyform 34LR and Endurance 35LS may be used with
a swivel in any application, but when used in multiple part reeving
a swivel is not necessary, therefore not recommended. All
Rotation Resistant Ropes will rotate to some extent under load.
Excessive rotation will cause imbalance and reduction in
strength. Under a shock load or overload condition, the strength
of these ropes can be reduced as much as 50%.
BAC does recognize that there are certain applications where
safety or operating requirements demand the use of a swivel with
Rotation Resistant Ropes. In these cases, it is mandatory that the
design factor be strictly followed, the ropes are not shock loaded,
BRIDON AMERICAN
and the ropes are frequently inspected by a qualified person.

BAC recommends that each application requiring the use of a
swivel with Rotation Resistant Ropes be reviewed and approved
by a qualified person.
There has been some confusion about swivels attached between
the rope and the dead end attachment point and swivels below
the traveling block (between the block and the load). For the
purpose of the previous discussion, we are referring to the swivel
attachment between the rope and the dead end attachment point.
Most swivels below the traveling block are not anti-friction ball
bearing swivels.
MULTIPLE PART REEVING
Endurance 19 ropes are not recommended for multiple part
reeving. These ropes do not perform well and tend to become
imbalanced when used in this manner. Endurance 8RR,
Endurance Dyform-18, Endurance Dyform 34LR, and Endurance
35LS are more stable constructions and can be used in multiple
part reeving.
SINGLE PART HOISTING
All Rotation Resistant Ropes can be used in single part hoisting.
However, the limitations of single part hoisting must be
understood. Rotation Resistant Ropes will develop torque when
a load is applied and rotation of the load can occur. The amount
of rotation depends on many factors.
Endurance 8RR, Endurance 19, and Endurance Dyform-18 when
used single part should be limited to a maximum fall of 150 x rope
diameter (i.e. 1/2 x 150 = 75) or distortion and damage may
occur.
If the loads being handled under all operating conditions are
within the recommended design factors, the amount of rotation
should not cause problems. If the rope is shock loaded or loaded
beyond the recommended design factor, rotation of the rope will
be a problem. As stated previously, when Rotation Resistant
Ropes rotate, the strength of the rope is reduced. If the rotation is
severe enough, the rope can fail or rapidly develop broken wires
and wear in the inner rope where it can be difficult to detect.
FLEET ANGLES
FIXED
SHEAVE
ODD PART REEVING

Odd part reeving such as 3, 5 or 7 part can cause problems if the
traveling block is not properly aligned. While a greater number of
parts, reeved in an even number will require slower hoisting
speeds, it can prevent problems. If odd part reeving is necessary,
the dead end at the traveling block should be attached to the
center of the block rather than at the side of the block (see
opposite, top). An odd part reeving system can cause the
traveling block to be suspended and hang at an angle. This
misalignment will induce twist into the rope during operation by
the rope climbing the flange or rolling into the sheaves of the
traveling block during hoisting.
FLOATING
SHEAVE
1/2MIN
11/2MAX
LEFT
FLEET
ANGLE
SMOOTH
FACE
DRUM
1/2MIN
11/2MAX
RIGHT
FLEET
ANGLE
Because
Rotation
Resistant
Ropes
develop less torque
under load than a
standard 6 strand
rope, there can be a
problem with rope
pileup
and
poor
spooling unless a
proper fleet angle is
maintained. The fleet
angle becomes even
more important with
the Rotation Resistant
ropes
such
as
Endurance Dyform
34LR and Endurance
35LS. A fleet angle of
1/2 to 1-1/2 is
recommended for all
Rotation
Resistant
Ropes.
BRIDON AMERICAN
CABLING GRAPH
RETIREMENT CRITERIA
Field research jointly conducted by the Wire Rope Technical

Board and the Power Crane and Shovel Association has shown
that cabling of the rope parts in a multiple part reeved hoisting
arrangement is controlled by several factors. The following
calculations and graphs can be used to determine when and if
cabling will occur on multiple part reeved hoisting arrangements.
Recommended retirement criteria for all Rotation Resistant

Ropes are 2 broken wires in 6 rope diameters or 4 broken wires
in 30 rope diameters (i.e. 6 rope diameters for a 1 diameter rope
= 6).
The graph illustrates two dimensional ratios. They are:

1. L/S = Length of fall per unit rope spacing.
2. D/d = Average pitch diameter of traveling and crown block
sheave per unit rope diameter.
Various constructions of rope shown on the graph indicate the
limited conditions for torsional stability with the angular
displacement of the hoist block to a maximum of 90 degrees.
When the operating conditions for a particular installation give a
resultant above the appropriate band, then cabling of the falls will
most likely occur. If the operating conditions give a resultant
below any particular band, the cabling of the falls will most likely
not occur. If the operating conditions for any particular installation
fall within the band, cabling is unpredictable.
Distortion of Rotation Resistant Ropes, as shown above, can be
caused by shock load/sudden load release and/or induced
torque and is the reason for immediate removal from service.
RECOMMENDED MINIMUM
SHEAVE AND DRUM DIAMETERS
The minimum D/d ratio allowed by applicable codes and
standards covering equipment where Rotation Resistant Ropes
are typically used is 18:1.
RECOMMENDED MINIMUM DESIGN FACTOR
The minimum design factor allowed by applicable codes and
standards covering equipment where Rotation Resistant Ropes
are typically used is 5.
BRIDON AMERICAN
280 New Commerce Boulevard
Wilkes-Barre, PA 18706
Telephone: (570) 822-3349 1-800-521-5555
FAX: 1-800-233-8362
Website: http://www.bridonamerican.com
E-mail: [email protected]
Dyform is a registered trademark of Bridon American Corporation.
WARNING: Any warranties, expressed or implied, concerning the use of
this product apply only to the nominal strength of new, unused wire rope. All
equipment using this product must be properly used and maintained. Wire
rope must be properly stored, handled, used and maintained. Most
importantly, wire rope must be regularly inspected during use. Damage,
abuse or improper maintenance can cause rope failure. Consult the AISI
Wire Rope Users Manual, ASME or ANSI Standards, or Bridon American
Corporation before usage. Wire rope removal criteria are based on the use
of steel sheaves. If synthetic sheaves are used, consult the sheave
equipment manufacturer. WARNING!
12/00/1M
WEDGE SOCKET
WARNINGS AND APPLICATION
INSTRUCTIONS
Extended Wedge Socket
Assembly U.S. Patent No. 5,553,360
S-421T / US-422T
TERMINATOR
Inspection/Maintenance Safety
Always inspect socket, wedge and pin before using.
Do not use part showing cracks.
Do not use modified or substitute parts.
Repair minor nicks or gouges to socket or pin by lightly grinding
until surfaces are smooth. Do not reduce original dimension
more than 10%. Do not repair by welding.
Inspect permanent assemblies annually, or more often in severe
operating conditions.
Do not mix and match wedges or pins between models or sizes.
Always select the proper wedge and socket for the wire rope
size.
Loads may slip or fall if the Wedge Socket is not

properly installed.
A falling load can seriously injure or kill.
Read and understand these instructions before
installing the Wedge Socket.
Do not side load the Wedge Socket.
Apply first load to fully seat the Wedge and Wire
Rope in the socket. This load should be of
equal or greater weight than loads expected in
use.
Do not interchange wedges between S-421T
and US422T or between sizes.
FIGURE 1
NOTE: Existing Crosby S-421 Wedge Sockets can be retrofitted with

the New Terminator Wedge.The only existing US-422 Wedge Sockets
that can be retrofitted with terminator wedges are US4, US6 and US8.
See the Crosby Catalog for additional information.
New QUIC-CHECK Go and No-Go
features cast into wedge. The proper size
wire rope is determined when the following
criteria are met: 1. The wire rope shall pass
thru the Go hole in the wedge. 2. The wire rope shall NOT pass thru
the No-Go hole in the wedge.
Important Safety Information Read and Follow
WARNING
* TAIL
LENGTH
No-Go
RIGHT
Go
*Tail Length
Standard 6 to 8 strand wire rope

Rotation Resistant Wire Rope
A minimum of 6 rope diameters, but A minimum of 20 rope diameters,
not less than 6"
but not less than 6".
TABLE 1
5
8
1
2
1
2
7
8
7
8
118
5
8
3
4
3
4
Clip Size
3
8
3
8
*Torque Ft./lbs.
45
65
95
130
225
225
118
225
Rope Size
* The tightening torque values shown are based upon the threads being clean,
dry, and free of lubrication.
Assembly Safety
Use only with standard 6 to 8 strand wire rope of designated size.
For intermediate size rope, use next larger size socket. For
example: When using 9/16" diameter wire rope use a 5/8" size
Wedge Socket Assembly. Welding of the tail on standard wire
rope is not recommended. The tail length of the dead end should
be a minimum of 6 rope diameters but not less than 6" (See
Figure 1).
To use with Rotation Resistant wire rope (special wire rope
constructions with 8 or more outer strands) ensure that the dead
end is welded, brazed or seized before inserting the wire rope
into the wedge socket to prevent core slippage or loss of rope
lay. The tail length of the dead end should be a minimum of 20
rope diameters but not less than 6" (See Figure 1).
Properly match socket, wedge and clip (See Table 1) to wire rope
size.
Align live end of rope, with center line of pin.
(See Figure 1)
Secure dead end section of rope. (See Figure 1)
Tighten nuts on clip to recommended torque. (Table 1)
Do not attach dead end to live end or install wedge backwards.
(See Figure 2)
Use a hammer to seat Wedge and Rope as deep into socket
as possible before applying first load.
Copyright 2002 The Crosby Group, Inc.
WRONG
Rope
Backward
WRONG
Wedge
Backward
WRONG
Tail Clipped
to live Line
Figure 2
Operating Safety
Apply first load to fully seat the Wedge and Wire Rope in the
socket. This load should be of equal or greater weight than loads
expected in use.
Efficiency rating of the Wedge Socket termination is based upon
the catalog breaking strength of Wire Rope. The efficiency of a
properly assembled Wedge Socket is 80%.
During use, do not strike the dead end section with any other
elements of the rigging (Called two blocking).
SECTION 5
LUBRICATION
TABLE OF CONTENTS
Oil Can Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Approved Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Every 40 Hours or Weekly (whichever comes first) . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Every 200 Hours of Operation or Monthly (whichever comes first). . . . . . . . . . . . . . 5-5
Each Time Boom and Luffing Jib are Lowered to Ground . . . . . . . . . . . . . . . . . . . . 5-5
Every 40 Hours or Weekly (whichever comes first) . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Every 200 Hours of Operation or Monthly (whichever comes first). . . . . . . . . . . . . . 5-5
Each Time Boom and Luffing Jib are Lowered to Ground . . . . . . . . . . . . . . . . . . . . 5-5
Once Yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-i
LUBRICATION
SECTION 5
LUBRICATION
GENERAL LUBRICATION
LUBRICATION TIPS
Depending on the options the crane or attachment is

equipped with, some lubrication points given in this section
may not apply.
Keep oil and grease dispensers and containers tightly

closed and stored in a dirt and moisture-free locations.
Clean grease fittings before and after applying grease.
LUBRICATION INTERVALS
Apply grease until the bushing or bearing is purged so

dirt and water cannot enter. Wipe up excess grease.
The intervals listed in this Lubrication Guide are for average

operating conditions based on experience gained by testing
lubricants at the factory and on recommendations given by
the lubricant suppliers. Severe operating conditions
(excessively dusty or corrosive atmosphere, unusually high
or low outside temperature, extreme loadings, uncommonly
frequent or long operating cycles) may require shortening
the lubrication intervals. Follow the intervals given in this
section until adequate experience is obtained to establish
intervals which meet your operating conditions.
Bearings and bushings that are too warm, excessive play in
moving parts, binding in moving parts, excessive or
abnormal wear in gears and chains, and rust accumulation
indicate a lack of lubrication. If these conditions are found
during regular inspection, the lubrication interval for the
faulty parts should be shortened.
CAUTION
Machinery Damage!
Before lengthening lubrication intervals, check that all
parts are receiving an adequate supply of clean lubricant;
o th e r w is e, par ts w i ll b e da m a ge d fr om a l a ck o f
lu brication. C ontact your Manitow oc Cran e Care
d ist r i bu t o r f o r r ec o mm e n da t io n s o n le n gt h e n in g
lubrication intervals.
OVER-LUBRICATION
OIL CAN POINTS

Oil all pins not equipped with grease fittings with engine oil
every 40 hours of operation (even if the crane is not being
operated).
WIRE ROPE LUBRICATION

New wire rope is lubricated during manufacturing, but this
lubricant is only adequate for initial storage and the early
stages of operation. To prevent the damaging effects of
corrosion and to reduce wear, the wire rope must be
lubricated at regular intervals.
Contact your wire rope manufacturer/dealer for lubrication
recommendations. The lubrication interval and the type of
lubricant used depends on the type of wire rope, the severity
of duty, and the type of corrosive elements the wire ropes is
subjected to.
The wire rope must be properly protected at all times. The
lubricant must be fluid enough to fully penetrate the strands
and rope core. Use one of the methods shown in Figure 5-1
to lubricate the wire rope. For maximum penetration, apply
lubricant where the wire rope opens up as it travels around
a sheave or winds onto a drum.
The wire rope must be clean and dry before applying
lubricant; an air jet, or wire brush are some cleaning
methods.
Oil or grease which drips onto walkways can cause

personnel to slip and be hurt.
Do not use grease to lubricate wire rope. Grease will not

penetrate rope properly and will buildup in valleys
between wires and strands. This buildup will inhibit rope
inspection and could trap moisture in ropes interior.
An extra shot of grease, if too stiff or under too much

pressure, can pop out a bearing seal.
APPROVED GREASE
Over-lubrication is not only wasteful but also harmful:
CraneLUBE E.P. #2 (MCC #471197) for all grease points.
5-1
LUBRICATION
Casing Filled with

Swab and Lubricant.
Pouring onto Slow

Moving Sheave.
WARNING
Bathing
Moving Rope Hazard!

Take every precaution to protect hands from injury
when rope is moving. Wear heavy gloves and move
rope as slowly as possible.
Brushing
Hand
Swabbing
S139
5-2
FIGURE 5-1
LUBRICATION
THIS PAGE BLANK
5-3
LUBRICATION
A1274
A08238
#44 Luffing Jib
1 or
2 and 3
2 and 3
CAUTION
Parts Damage
If luffing jib is to be operated when air temperature is
below 32F (0C), drain and refill hydraulic systems (crane
and boom) with Petro Canada Hydrex XV hydraulic oil. Be
sure that jib strut cylinders and supply lines are completely
drained before refilling.
For operation below 10F (-12C) use a thinner fluid such
as Petro Canada Premium Arctic 15.
*
9
Luffing Hoist Top Wire

Rope Guide Sheave
*
#79A Luffing Jib
5-100
5-101
Optional Remote Fitting

at Base of Boom Butt
1 or
2 and 3
2 and 3
*
P1378
P2149
4 Places
7
10
P2147
Luffing Hoist
Top Wire Rope
Guide Sheave
4
5-102
5-101
5-4
Optional Remote Fitting

at Base of Boom Butt
Jib Point Dolly
LUBRICATION
#44 LUFFING JIB LUBRICATION

Item
Description
Required Service (see NOTE)
Every 40 Hours or Weekly (whichever comes first)

1
Weight Ball Swivel
Grease.
Load Block Sheaves
Grease if equipped with fittings.
Load Block Trunnion/Swivel
Bottom Wire Rope Guide Sheave
Grease.
Every 200 Hours of Operation or Monthly (whichever comes first)

5
Block-Up Limit Switch (1 fitting inside each switch)
Grease each.
Each Time Boom and Luffing Jib are Lowered to Ground

6
Luffing Jib Wheels (2 places)
Grease each.
Luffing Jib Hinge Pins (2 places)
Grease each.
Jib Strut Hinge Pin (2 places)
Grease each.
Main Strut Hinge Pin (2 places)
Grease each.
NOTE:
See Lubrication Guide in 18000 Crane Operators

Manual for lubrication of crane and boom.
Sheaves marked with an asterisk (*) have sealed

bearings and do not require periodic lubrication.
Repack sheave bearings with grease at overhaul.
#79A LUFFING JIB LUBRICATION

Item
Description
Required Service (see NOTE)
Every 40 Hours or Weekly (whichever comes first)

1
Weight Ball Swivel
Grease.
Load Block Sheaves
Load Block Trunnion/Swivel
Bottom Wire Rope Guide Sheave
Grease.
Every 200 Hours of Operation or Monthly (whichever comes first)

5
Block-Up Limit Switch (1 fitting inside each switch)
Grease each.
Each Time Boom and Luffing Jib are Lowered to Ground

6
Jib Stop Positioner Cylinder Trunnion
Grease 1 fitting, 2 places.
Jib Hinge Pins (2 places)
Grease each (in legs of butt).
Wheel Hub Sight Glass
Check level.
Wheel Hub Fill Plug
Fill to FULL ring in sight glass with same gear oil used in
drum planetaries on crane.
Once Yearly
10
NOTE:
Jib Stop Positioner Hydraulic System

See Lubrication Guides in 18000 Crane and MAXER Operators Manuals for lubrication of crane,
MAX-ER, and boom.
See Periodic Check of Jib Stop Positioner Hydraulic Oil

Level in this section.
Sheaves marked with an asterisk (*) have sealed
bearings and do not require periodic lubrication.
Repack sheave bearings with grease at overhaul.
5-5
LUBRICATION
PERIODIC CHECK OF JIB STOP

POSITIONER HYDRAULIC OIL LEVEL
This procedure applies to the #79A Luffing Jib.
Perform the following procedure ONCE YEARLY when the
attachment is on the ground. See Figure 5-2.
NOTE:
It is normal for jib stop positioner cylinders (9) to

extend (if retracted) when engine is stopped.
5.
Stroke pump handle (4) back and forth until positioner

cylinders (9) are fully extended.
6.
Remove dipstick (3) slowly to vent pressure in tank.
7.
Wipe dipstick (3) clean and reinstall so it rests on tank

fitting for proper oil level check.
8.
Remove dipstick (3). Oil should be at top mark on

dipstick.
1.
Stop engine.
2.
Unlatch safety latches (8) with hand winch in jib top.
If necessary remove fill plug (2) and fill tank though fill
port with pre-filtered Arctic 15 hydraulic oil (MCC
#A03745).
3.
Loosen lock nut (10) and slowly turn valve screw (11)
counterclockwise to transfer oil from accumulator (5) to
hydraulic tank (1).
If oi l le vel i s m ore th an 1- 2 cu ps of o il l ow,

thoroughly inspect system for oil leaks. Repair as
required.
Positioner cylinders (9) will fully retract (jib stops lower)

when this step is performed.
4.
5-6
Once cylinders are retracted, turn valve screw (11) fully

clockwise and tighten lock nut (10).
9.
Move pump handle (4) back and forth until oil level is at
low mark on dipstick. Gauge reading must be 2,450 2,500 psi (169 - 172 bar).
10. Apply hydraulic thread sealant to threads and securely

reinstall dipstick (3) and fill plug (2).
LUBRICATION
11
10
3
4
1
5
5-103
Right Side of Boom Top
P2150
Item
1
2
3
4
5
6
7
8
9
10
11
Both sides of Boom Top
P2149
Description
Hydraulic Tank
Fill Plug
Dipstick
Pump Handle
Accumulator
Pressure Gauge
Jib Stop
Safety Latch
Positioner Cylinder
Lock Nut
Valve Screw
FIGURE 5-2
5-7
SECTION 6
MAINTENANCE
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removing Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Boom Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
#44 Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
#79A Luffing Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Preliminary Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Max Up 1 Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Max Up 2 Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Max Down Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Final Adjustment Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Jib Stop Adjustment (Current Production). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Pre-Erection Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Jib Maximum Up 1 and 2 Limit Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Jib Maximum Down Limit Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Actuator Rod Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Automatic Boom Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maximum Operating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Boom and Mast Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Actuator Rod Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Adjustment (without luffing jib) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Adjustment (with luffing jib) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Physical Boom Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Boom and Luffing Jib Angle Indicator Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Block-Up Limit Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Block-Up Limit Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Disconnecting Block-Up Limit Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Removing Upper Boom Point or Jib Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Storing Electric Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6
6-i
MAINTENANCE
SECTION 6
MAINTENANCE
GENERAL MAINTENANCE
This section contains maintenance and adjustment
instructions for the limit devices used with the luffing jib
attachment.
WARNING
Falling Attachment Hazard!
Do not operate crane unless luffing jib stops are properly
adjusted and operational.
Operating luffing jib above MAX UP limit or below MIN
limit is neither intended nor approved. Jib can be pulled
over backwards or collapse.
For maintenance and inspection of the following

components, see the Service Manual supplied with your
crane:
Straps
Wire Rope
Load Block and Weight Ball
Removing Luffing Jib
Boom and Jib
Perform the following steps to bypass the luffing jib stops and
block-up limits when the luffing jib is removed. If you fail to
perform these steps, the operating limit alert will come on
and you will not be able to boom down or hoist loads.
JIB STOP ADJUSTMENT (PAST

PRODUCTION)
General
The luffing jib attachment is equipped with three limit
switches (Figure 6-1) which automatically stop the luffing
hoist and apply its brake when the luffing jib is raised or
lowered to the following angles:
NOTE:
Luffing jib angles given in this section can vary plus

or minus 1.

Unplug electric cords from receptacles R1- R4 on boom

node controller (1).
2.
Coil electric cords and fasten to boom top adapter frame

for storage.
3.
Connect terminating plugs T1 - T4 to receptacles R1- R4

on boom node controller (1).
Boom Stop Adjustment

For operation with luffing jib installed, the boom stop must be
set at:

#44 Luffing Jib

85 for #44 Luffing Jib on 140 - 180 ft (42,7 - 54,9 m) of

#55-79A Boom.
87 for #44 Luffing Jib on 200 - 300 ft (61,0 - 91,4 m) of

#55-79A Boom.

below 50).
1.
Luffing Jib Max Down (minimum angle) 70 boom to

luffing jib angle. This limit cannot be bypassed.
The operating limit alert (yellow light and buzzer in operators

cab) comes on when the jib reaches any of the limits. The
operating limit alert also comes on any time the luffing jib is
lowered below horizontal.
#79A Luffing Jib
85 for #79A Luffing Jib on 140-180 ft (42,7 - 54,9 m) of

#55 or #55A Boom.
87 for #79A Luffing Jib on 200-340 ft (61,0 - 103,6 m) of

#55 or #55A Boom.
For operation with luffing jib removed, the boom stop must be
set at 83.
6
6-1
MAINTENANCE
Lead Wire Seal and

Roll Pin (Typical)
R2
R3
R1
3a
3b
S1
4b
S2
S3
6-100
4a
Receptacle
S1-1 (White)
S1-2 (Black)
S2-1 (Green)
S2-2 (Black)
S2-3 (White)
S3-1 (White)
S3-2 (Black)
LIMIT SWITCH WIRING

Terminal
System Operation
S1-22
24 Volts DC
S1-21
MAX UP 1
S2-21
MAX UP 2
Not Used
S2-22
24 Volts DC
S3-22
24 Volts DC
S3-21
MAX DOWN
5a
2
8
5b
Boom Top
Adapter Frame
6 in
Hole A
2
Hole B
Left Side of Boom

Typical for #44 Luffing Jib
and #79A Luffing Jib
T3
T2
Jib Butt
T1
6-101
Item
1
2
3a
3b
4a
4b
5a
5b
6
7
8
6-2
Description
Boom Node Controller
Actuator
Limit Switch - MAX UP 1
Cam - MAX UP 1
Cam - MAX UP 2
Limit Switch - MAX DOWN
Cam - MAX DOWN
Alignment Pin
Spacer (each limit switch)
Mounting Bracket
Item Description
Receptacles
R1
MAX DOWN
R2
MAX UP 1 (maximum working)
R3
MAX UP 2 (maximum)
R4
To Luffing Jib Cable Reel
Terminating Plugs
T1
MAX DOWN
T2
MAX UP 1 (maximum working)
T3
MAX UP 2 (maximum)
T4
To Luffing Jib Cable Reel
R1
R2 R3
R4
6-102
T4
FIGURE 6-1
MAINTENANCE
Maintenance
Max Up 2 Limit Adjustment
At least once weekly, check that the limit switches stop the
luffing jib at the specified angles; if not, replace any defective
parts and/or adjust jib stop limit switches.

1.
Loosen screws in limit switch (4a).
2.
Rotate actuator (2) so roller on limit switch (4a) is

between cams (4b and 5b).
3.
Slide limit switch (4a) toward actuator (2) until roller just
touches actuator and hold. Switch must not click open.
4.
Securely tighten screws in limit switch.
5.
After boom and jib are raised, check operation of MAX

UP 2 limit following instructions under Operational
Checks.
Adjustment
The jib stop limit switches must be installed, adjusted, and
sealed at initial assembly of the attachment. Limit switch
adjustments must be checked and readjusted if required
each time the attachment is reassembled and when parts are
replaced. Seals must be removed to allow readjustment.
See Figure 6-1 for following procedures.
Preliminary Adjustment
Max Down Limit Adjustment
1.
Lower attachment to ground.
2.
Remove screws connecting actuator (2) to jib butt.
1.
2.
Rotate actuator (2) counterclockwise until Hole B in

actuator lines up with hole in boom top.
3.
Insert alignment pin (6) through Hole B in actuator and

into hole in boom top. Make sure shoulder of pin rests
squarely against actuator to ensure proper alignment for
adjustment.
4.
Slide limit switch (5a) against cam (5b) until limit switch
just clicks open and hold.
5.
6.
Remove alignment pin (6).
7.
Check MAX DOWN limit setting as follows:
NOTE:
Check jib butt side-to-side position on pivot pin

when attaching actuator. Ensure switches remain
on cam surface when jib butt shifts side to side.
Install shims at actuator attachment point or jib butt,
if necessary.
Max Up 1 Limit Adjustment

1.
2.
Rotate actuator (2) clockwise until Hole A in actuator

lines up with hole in boom top.
3.
Insert alignment pin (6) through Hole A in actuator and

into hole in boom top. Make sure shoulder of pin rests
squarely against actuator to ensure proper alignment for
adjustment.
4.
Slide limit switch (3a) against cam (3b) until limit switch
just clicks open and hold.
5.
6.
Remove alignment pin (6).
7.
Check MAX UP 1 limit setting as follows:

a.
b.
c.
d.
8.
Rotate actuator (2) counterclockwise and then

clockwise so MAX UP 1 limit switch roller contacts
cam (3b).
Limit switch must click open when Hole A in actuator
lines up with hole in boom top (step 3).
With LUFFING JIB mode selected, pull luffing jib
handle back. Luffing hoist must not turn and
LUFFING JIB MAX UP 1 operating limit should
come on.
Readjust limit switch if necessary to ensure proper
operation.
After boom and jib are raised, check operation of MAX

UP 1 limit. See instructions under Operational Checks.
a.
Rotate actuator (2) clockwise away from limit switch

and then counterclockwise so MAX DOWN limit
switch roller contacts cam (5b).
b.
Limit switch must click open when Hole B in actuator

lines up with hole in boom top (step 3).
c.
With LUFFING JIB mode selected, push luffing jib

handle forward. Luffing hoist must not turn and
LUFFING JIB MAX DOWN operating limit should
come on.
d.
Readjust limit switch if necessary to ensure proper

operation.
Final Adjustment Steps

1.
Securely fasten actuator (2) to jib butt with screws and

lock washers provided.
2.
Once limit switches are properly adjusted, drill and seal

limit switch spacers (7, Figure 6-1) to mounting bracket
(8) with roll pins and lead wire seals.
3.
Make sure boom and luffing jib angle indicators are

properly adjusted before raising boom and luffing jib.
See instructions in this section.
6-3
MAINTENANCE
Operational Checks
NOTE:
Make the following operational checks after the boom and jib
are raised.
1.
Raise boom and luffing jib until boom is at 80.
2.
Monitor BOOM TO LUFFING JIB ANGLE on digital

display while performing remaining steps.
3.
SLOWLY raise luffing jib.
4.
Luffing hoist must stop and be inoperable when boom to

luffing jib angle is 168 (maximum working angle).
5.
Operating limit alert should come on indicating

LUFFING JIB MAX UP 1 limit has been reached.
Stop raising luffing jib immediately if limit switch

fails to stop luffing hoist. Lower boom and jib to
ground and readjust MAX UP 1 limit switch.
Luffing jib angles given in this section can vary plus

or minus 1.


below 50).
Luffing Jib Max Down (minimum angle) 70 boom to

luffing jib angle. This limit cannot be bypassed.
6.
Turn limit bypass key clockwise to bypass MAX UP 1

limit.
7.
SLOWLY raise luffing jib past MAX UP LIMIT 1.
8.
Luffing hoist must stop and be inoperable when boom to

luffing jib angle is 169.2 (maximum angle).
Maintenance
9.
Operating limit alert should come on indicating

LUFFING JIB MAX UP 2 limit has been reached.
At least once weekly and each time the attachment is

erected, check that the luffing jib stops at the specified
angles.
Stop raising luffing jib immediately if limit switch

ground and readjust MAX UP 2 limit switch.
Pre-Erection Checks
10. SLOWLY lower luffing jib.

11. Luffing hoist must stop and be inoperable when boom to
Stop lowering luffing jib immediately if limit switch

ground and readjust MAX DOWN limit switch.
JIB STOP ADJUSTMENT (CURRENT

PRODUCTION)
A minimum limit switch is provided as a backup to stop

the jib if the programmed minimum limit fails.
To insure proper operation of the luffing jib stops:
The jib stop cables must be connected to receptacles (7

and 8, Figure 6-11, View A).
The luffing jib angles must be properly calibrated. See

Rated Capacity Indicator/Limiter Operation Guide for
instructions.
The jib stop limit switches must be mounted properly.
Jib Maximum Up 1 and 2 Limit Checks

Perform the following steps with the boom and luffing jib on
the ground:
WARNING
1.

Do not operate crane unless luffing jib stops are properly
adjusted and operational.
Operating luffing jib above MAXIMUM UP 2 limit or below
MAXIMUM DOWN limit is neither intended nor approved.
Jib can be pulled over backwards or collapse.
Perform remaining steps with engine running and

appropriate Luffing Jib Capacity Chart selected.
2.
Depress limit switch (1) actuator rod to activated

Dimension D1 and hold. Listen for limit switch to click
open (LED OFF).
3.
Turn limit bypass key clockwise and hold.
General
The luffing jib attachment is equipped with three limits which
automatically stop the luffing hoist and apply its brake when
the luffing jib is raised or lowered to the following angles.
6-4
Check Dimension D1, View A. If necessary, adjust

position of limit switch housing to obtain deactivated
dimension.
Item
D1
D2
MAINTENANCE
Description
Edge of Actuator Rod to
Edge of Jib Stop Tube
Edge of Actuator Rod to
Center of Pin
Deactivated
Activated
1.44 in (36,7 mm)
1.22 in (30,9 mm)
1.75 in (44,5 mm)
1.79 in (45,4 mm)
D1
2a
1b
2
2b
1
D2
1a
5
1
3
6-103
Item
1
1a
1b
2
2a
2b
3
4
5
See
Figure 6-11
A2
Left Side of Boom

and Luffing Jib
A1
Description
Actuator Rod
Actuator Rod Bracket
Limit Switch - MAX DOWN
Actuator Rod
Actuator Rod Bracket
Luffing Jib Butt
Jib Stop (Mechanical)
Boom Top
Item
A1
A2
Description
Max Up 1 Angle = 168
Max Down Angle = 70
FIGURE 6-2
6-5
MAINTENANCE
4.
Pull luffing jib handle back.
7.
Luffing hoist must not turn in up direction and JIB

MAXIMUM UP 2 fault should come on.
Turn limit bypass key clockwise to bypass MAXIMUM

UP 1 limit.
8.
SLOWLY raise luffing jib past MAXIMUM UP LIMIT 1.
9.
Luffing hoist must stop and be inoperable in up direction

when boom to luffing jib angle is 170.
Jib Maximum Down Limit Checks

Perform the following steps with the boom and luffing jib on
the ground:
1.
Check Dimension D2, View B. If necessary, adjust

position of limit switch housing to obtain deactivated
dimension.
Perform remaining steps with engine running and
appropriate Luffing Jib Capacity Chart selected.
2.
Depress limit switch (2) actuator rod to activated

Dimension D2 and hold. Listen for limit switch to click
open (LED OFF).
3.
Turn limit bypass key clockwise and hold.
4.
Push luffing jib handle forward.
10. Fault alarm should come on indicating JIB MAXIMUM

UP 2 limit has been reached.
I f m a x im u m s t o p s d o n o t o p e r a t e p r o p e r l y,
troubleshoot system.
11. SLOWLY lower luffing jib.
12. Luffing hoist must stop and be inoperable when boom to
Turn limit bypass key clockwise to bypass minimum
angle and lower jib. Luffing hoist must stop and be
inoperable in down direction when boom to luffing jib
angle is approximately 67.
I f m i n i m u m s t o p s d o n o t o p e r a t e p r o p e r l y,
troubleshoot system.
Luffing hoist must not turn in down direction and JIB

MAXIMUM DOWN fault should come on.
Actuator Rod Replacement

Operational Checks
Make the following operational checks after the boom and jib
are raised.
1.
Remove damaged actuator rod (1).
2.
Slide spring washers (3 and 5) and spring (4) over new

actuator rod while sliding actuator rod into bracket
assembly.
3.
Position actuator rod (1) so tapered end just touches

limit switch (6) roller (View A). Actuator rod must not
depress limit switch roller.
1.
Travel crane onto a firm level surface or level crane by

blocking under crawlers.
2.
Raise boom and luffing jib until boom is at 80.
3.
Monitor BOOM TO LUFFING JIB ANGLE on main

display information screen while performing remaining
steps.
4.
Drill 1/4 in (6,35 mm) hole through spring washer (3) and
actuator rod (1).
4.
SLOWLY raise luffing jib.
5.
Install dowel pin (2).
5.
Luffing hoist must stop and be inoperable in up direction

when boom to luffing jib angle is 168.
6.
Check limit switch roller to insure there is over-travel as

shown in View B.
6.
Fault alarm should come on indicating JIB MAXIMUM

UP 1 limit has been reached.
6-6
MAINTENANCE
6-104
View B
Switch Activated
Circuit Opened
Roller
Over-Travel
LED
ON
LED
OFF
8
7
JIB MAXIMUM DOWN Limit Switch Shown

JIB MAXIMUM UP 2 Limit Switch Opposite
Item
1
2
3
4
5
6
7
8
Description
Actuator Rod
Dowel Pin
Spring Washer
Spring
Spring Washer
Limit Switch
Cover
Bracket Assembly
View A
Switch Deactivated
Circuit Closed
Receptacle
1 (green)
2 (black)
3 (white)
Limit Switch Wiring

Switch Terminals
22
B
14
A
21
13
Operation
Jib Max Up or
Jib Max Down
LED
24 VDC Supply
FIGURE 6-3
6
6-7
MAINTENANCE
Limit Switch Wiring

Receptacle
1 (green)
2 (black)
3 (white)
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Switch
Terminal
22
A
21
Operation
Max Angle
LED (Ground Bus)
24V DC System Bus
Description
Lower Boom Point
Load Block
Platform
Spring Washer
Spring
Dowel Pin
Actuator Rod
Jam Nut
Adjusting Rod
Store Extra Adjusting Rod Here
Coupling
Cover
Limit Switch
Boom Butt
Roller Over-Travel
A831
3-1/2 in (89 mm) Boom Only

3 in (76 mm) with Luffing Jib
4
LED
ON
18000MOM601
12
13
DIMENSION
A
Center of Freely
Suspended Load Block
or Single-Part Line
3
Front Edge of Rotating
Bed Adapter Frame at
Center of Crane
14
11
View A
SWITCH
CLOSED
10
15
LED
OFF
View B
SWITCH
OPENED
FIGURE 6-4
6-8
MAINTENANCE
AUTOMATIC BOOM STOP ADJUSTMENT
Boom and Mast Stability
See Figure 6-4 for the following procedure.
To maintain boom stability when operating at high boom

angles, adhere to the minimum load requirements specified
in the capacity chart for the boom and luffing jib combination
in use.
Maximum Operating Angle

A limit switch (Figure 6-4) automatically stops the boom hoist
and applies its brake when the boom is raised to the
following angle:
83 for #55-79 Boom without Luffing Jib.
83 for #55-79A Boom without Luffing Jib.
83 for #55 or #55A Boom without Luffing Jib.
85 for #44 or #79A Luffing Jib on 140 - 180 ft (42,7 54,9 m) of #55-79A, #55, or #55A.
87 for #44 or #79A Luffing Jib on 200 - 340 ft (61,0 103,6 m) of #55-79A, #55, or #55A Boom.
WARNING
Do not operate crane unless automatic boom stop is
properly adjusted and operational. Do not adjust MAX
operating angle higher than specified. Boom could be
pulled over backwards or collapse.
Boom will settle back against boom stops, boom hoist

reeving between boom and mast will go slack, and load
block will swing in toward boom if minimum load is not
used.
Table 6-1
DIMENSION A for MAX Boom Angle
Boom Length
DIMENSION A
at 83
#55 or #55A Boom,
#55-79 Boom, or
#55-79A Boom
ft
(m)
ft in
(m)
120
36,6
18 5
5,60
140
42,7
20 10
6,34
160
48,8
23 4
7,09
180
54,9
25 8
7,83
200
61,0
28 1
8,57
220
67,1
30 7
9,32
Operation
240
73,2
33 0
10,06
See Figure 6-4 for following instructions.
260
79,2
35 6
10,81
When the boom is below the MAX angle, the limit switch is
closed and its LED (light-emitting diode) is on (View A). The
boom hoist can be operated as long as the switch is closed.
280
85,3
37 11
11,55
300
91,4
40 4
12,29
When the boom is raised to its MAX angle, the actuator rod
opens the limit switch and the LED goes off (View B). Boom
hoist operation stops automatically because the open limit
switch turns off power to the boom hoist electric circuit. The
boom hoist pump shifts to neutral and the brake applies to
stop boom movement.
320
97,5
42 10
13,04
340
103,6
45 2
13,78
360
109,7
47 8
14,52
380
115,8
50 1
15,27
400
121,9
52 6
16,01
Maintenance
420
128,0
55 0
16,75
At least once weekly, check that the automatic boom stop

stops the boom at the specified MAX angle. If not, replace
any defective parts and/or adjust the boom stop.
NOTE 1:
Dimension A is measured from front of rotating

bed to centerline of load block suspended freely
from lower boom point.
NOTE 2:
If a single part line is used over lower boom

point, add 14 in (0,35 m) to dimensions in table
and measure to centerline of freely suspended
single-part line.
6
6-9
MAINTENANCE
Actuator Rod Replacement
5.
If boom stops automatically at Dimension A, further

adjustment is not needed.
See Figure 6-4, View A for following procedure.

1.
Remove defective actuator rod.
2.
Slide spring washers and spring over new actuator rod

while sliding new actuator rod into bracket assembly.
3.
Position actuator rod so that tapered end just touches

limit switch roller. Actuator rod should not be pressing
limit switch roller down.
4.
Stop booming up when boom reaches Dimension A.
If boom stops automatically before reaching Dimension

A, perform step 6.
If boom reaches Dimension A before it automatically
stops, perform step 7.
6.
Drill 0.25 in (6,35 mm) hole through spring washer and

actuator rod.
If boom stops before reaching Dimension A (See

Figure 6-4):
a.
Loosen jam nut at adjusting rod coupling (View A).
5.
Install dowel pin.
b.
Turn adjusting rod all the way into coupling.
6.
Adjust actuator rod as needed for correct MAX angle.
c.
Boom up slowly until boom reaches Dimension A.
d.
Turn adjusting rod out against boom butt until

actuator rod clicks limit switch open and LED on
limit switch goes out.
e.
Tighten jam nut.
Adjustment (without luffing jib)

Unless otherwise specified, see Figure 6-4 for following
procedure.
The automatic boom stop was set at the factory and should
not require periodic adjustment. However, adjustment is
necessary when:
Parts are replaced.
Luffing jib is installed.
Luffing jib is removed.
1.

2.
Make sure 3-1/2 in (89 mm) long adjusting rod is

installed.
3.
See Table 6-1 to determine Dimension A for boom

length in use.
4.
Boom up slowly. Carefully monitor distance between

front edge of rotating bed adapter frame and center of
load block (Dimension A) while booming up.
6-10
7.
If boom reaches Dimension A before it stops (See

Figure 6-4):
a.
b.

c.
Tighten jam nut.
8.
Check that actuator rod over-travels limit switch as

shown in Figure 6-4, View B.
9.
Boom down and then back up. Boom must stop at

specified Dimension A. If boom fails to stop, repeat
steps 4 - 8.
MAINTENANCE
Adjustment (with luffing jib)
7.
Unless otherwise specified, see Figure 6-5 for following

procedure.
1.

2.
Make sure 3 in (76 mm) long adjusting rod is installed.
3.
See to Table A in to determine required jib angle for

boom length in use.
4.
Use an accurate digital protractor-level held against

underside of right-bottom boom chord to measure
Protractor Angle (Table B) during remaining steps.
5.
Boom up slowly. Carefully monitor angle on protractorlevel while booming up.
6.
Stop booming up when boom reaches specified

Protractor Angle.
8.
If boom stops automatically at specified Protractor

Angle, further adjustment is not needed.
If boom stops automatically before reaching specified
Protractor Angle, perform step 7.
If boom reaches specified Protractor Angle before it
automatically stops, perform step 8.
9.
If boom stops before reaching specified Protractor Angle

(See Figure 6-1):
a.
b.
Turn adjusting rod all the way into coupling.
c.
Boom up slowly until boom reaches specified

Protractor Angle.
d.

e.
Tighten jam nut.
If boom reaches specified Protractor Angle before it

stops (See Figure 6-4):
a.
b.

c.
Tighten jam nut.
Check that actuator rod over-travels limit switch as

shown in Figure 6-1, View B.
10. Boom down and then back up. Boom must stop at
specified Protractor Angle. If boom fails to stop, repeat
steps 4 - 9.
Table A
Boom Length
ft
(m)
Boom
Angle
140 - 180
42,7 - 54,9
85
200 - 340
61,0 - 103,6
87
Table B
Boom
Angle
Protractor
Angle
85
72.7
87
74.7
Digital
Protractor-Level
Against Bottom Chord
on Right Side of Crane
6-110
6-109
FIGURE 6-5
6-11
MAINTENANCE
PHYSICAL BOOM STOP
Assist in preventing the boom rigging from pulling the

boom back when traveling or setting loads with the
boom at any angle above 77.
Assist in moving the boom forward when lowering the

boom from any angle above 77.
Provide a physical stop at 89 .
WARNING
Physical boom stops must be installed and pinned in
working position for all crane operations.
Physical boom stops do not automatically stop boom at
maximum operating angle. Automatic boom stop must be
installed and properly adjusted.
General
The physical boom stops (Figure 6-6):
6-12
Assist in stopping the boom smoothly at any angle

above 77.
Operation
See Figure 6-6 for following instructions.
1.
When boom is raised to 77, springs in boom stop tubes

begin to compress.
2.
As boom is raised higher, spring compression increases

to exert greater force against boom.
3.
If for any reason boom is raised to 89, boom stop

springs fully compress to provide a physical stop.
MAINTENANCE
A1258
Physical
Boom Stops
77
Start of Spring Cushioning
89
Physical Stop
Boom
Butt
6-106
FIGURE 6-6
6
6-13
MAINTENANCE
BOOM AND LUFFING JIB ANGLE

INDICATOR CALIBRATION
The angle indicator potentiometers are located inside the
node controllers mounted on the boom top and on the luffing
jib top. The boom and luffing jib angles are calibrated
automatically by the cranes programmable controller as part
of the load indicator calibration procedure (See Rated
Capacity Indicator/Limiter Operation manual for
instructions).
Potentiometer
Mounted Inside
P1518
WARNING
Two-Blocking Hazard!
Block-up limit control is a protective device designed only
to assist operator in preventing a two-blocking condition;
any other use is neither intended nor approved.
Block-up limit control may not prevent two-blocking when
load is hoisted at maximum single line speed. Operator
must determine fastest line speed that allows block-up
limit control to function properly and, thereafter, not
exceed that line speed.
The block-up limit system consists of the following
components (See to Figure 6-8):
1.
a.
Lower boom point.
b.
Upper boom point.
c.
Lower luffing jib point.
d.
Upper luffing jib point.
e.
Fixed jib point.
2.
Weight freely suspended by chain from each limit switch

actuating lever (weight encircles load line as shown in
Figure 6-10).
3.
Lift block fastened to load line or lift plates fastened to

load block (See Figure 6-10).
Typical Node Controller Installation on

Boom or Luffing Jib Top
FIGURE 6-7
Normally closed limit switch assembly fastened at any or

all of the following locations:
BLOCK-UP LIMIT INSTALLATION AND

ADJUSTMENT
For detailed drawings of limit switch locations, see Boom

Wiring and Limits Drawing in Section 4 of this manual.
General
Block-Up Limit Control Operation
A block-up limit control (also called anti two-block device) is

a two-blocking prevention device which automatically stops
the load drum from hoisting and the boom from lowering
when a load is hoisted a predetermined distance.
See Figure 6-8 through Figure 6-10 for following description.
DEFINITION: Two-blocking is the unsafe condition in

which the load block or the weight ball contacts the sheave
assembly from which either is suspended.
Two-blocking can result in failure of sheaves and wire
rope, possibly causing load to fall.
During normal operation, the weight overcomes spring force

and rotates the actuating lever away from the limit switch
lever. This action allows the limit switch to close the load
drum up and boom/luffing jib down electric circuits. The load
can be hoisted and the boom/luffing jib can be lowered.
When the weight is lifted by the lift block or lift plates, spring
force rotates the actuating lever against limit switch lever.
This action causes the corresponding limit switch to open the
load drum up and boom/luffing jib down electric circuits.
The load drum and boom hoist pumps stroke to off. At the
same time, the load drum and boom/luffing jib parking brakes
apply to stop the load drum from hoisting and the boom/
luffing jib from lowering.
6-14
MAINTENANCE
18000MOM603
7
8
6
2
1
9
Strain Relief on Cable Must

be Connected to Hook
in Boom and Jib Point
13
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
Lift Block
Weight - 1-Part
Weight - Multiple Part
8 Ft (2,4 m), 1 or 2 each
Upper Boom or Jib Point
Limit Switch Assembly
Lower Boom Point
Boom Node
Load Cell Receiver
Electrical Cable From Cable Reel
Lift Plates
Load Block
Chain - 12 ft (3,7 m)
10
3
11
Block-Up Limit at #55-79A Boom Point Shown

Block-Up Limit at #79 Boom Point, at #55 Boom
Point and at Luffing Jib Points is Similar
12
FIGURE 6-8
6
6-15
MAINTENANCE
A1131
Item
1
2
3
4
5
Description
Electrical Cable
Cable Reel
Fixed Jib Butt
Brackets
Cable
Typical
Boom Butt or
Luffing Jib Butt
FIGURE 6-9
Dead-End Load Line

or Slowest Live Line
A837
3
2
Item
1
2
3
4
5
6
Lower or Upper Boom Point

(multiple part)
Two Chains Prevent

Weight from Turning
Description
Weight
Shackle
Chain
Connecting Pin
Lift Plate
Lift Block
See Load Block Reeving in Section 4

for Suggested Location of Weight
3
1
2
1
3 ft (0,9 m) to Top
of Weight Ball
Upper Boom Point (1-part)

Upper Jib Point (1-part)
Lower Jib Point (1-part)
6-16
1-Part Reeving
FIGURE 6-10
6-114
MAINTENANCE
View A
WNE14
WN18
View B
Node 8 on
Boom Butt
WNE08
1
Node 7 on
Adapter Frame
7
6
7
Item Description
1
Sealing Cap (3 each)
2
Terminating Plug
3
Electric Cable WNE14
4
Electric Cable WBM150 from Cable Reel
5
Boom Node Controller *
6
Sealing Cap (14 each)
7
Terminating Plug (5 each)
8
Wind Speed
9
Digital Output
10
Block Level Switch 1
11
Block Level Switch 1
12
Electric Cable from Boom Cable Reel
13
Block-Up Limit (Lower Point Boom or Jib)
14
Block-Up Limit (Upper Point Boom or Jib)
15
Electric Cable Out to Jib
16
Luffing Jib Max Angle Limit
17
Luffing Jib Max Angle Limit
18
Luffing Jib Min Angle Limit
* An identical controller (less luffing jib angle
receptacles) is mounted on luffing jib point.
6
7
17
16
8
18
6
5
10
11
13
14
1
12
15
6
7
2
View C
6
7
Disconnecting Block-Up Limit Control

Terminating plug (2, Views A and B) is provided so the blockup limit control can be disconnected for the following
reasons:
Crane setup and rigging.
Maintenance.
FIGURE 6-11
If electric cable (3) is terminated, all of the block-up limits (on

boom and jib), the RCL, the block level sensor, and the wind
speed indicator will be inactive.
1.
Unscrew sealing cap (1, View A) from terminating plug

(2).
2.
Disconnect electric cable (3, View B) from cable (4).
3.
Connect sealing cap (1, View A) to electric cable (4).
6-17
MAINTENANCE
4.
Connect terminating plug (2, View B) to electric cable

(2).
Store excess electric cable for the fixed jib by winding it

around the brackets on the fixed jib.
Failing to perform this step will prevent load drums from

hoisting and boom from lowering. Operating limits alert
will come on.
Maintenance
CAUTION
Reverse above steps to reconnect the block-up limits, the

RCL, the block level sensor, and the wind speed indicator.
Removing Upper Boom Point or Jib Point

Failing to perform following steps will prevent load
drums from hoisting and boom (or luffing jib) from
lowering. Also operating limits alert will come on.
Remove terminating plugs and reconnect electric cables to
proper receptacles when corresponding attachment is
reinstalled.
Prevent Damage
To prevent two-blocking from occurring, do not operate
crane un til ca use for im prop er op erat ion and all
hazardous conditions have been found and corrected.
Inspect and test the block-up limit controls weekly or every
40 hours of operation, as follows:
1.
See Figure 6-9 for following procedures.
Lower the boom onto blocking at ground level and

carefully inspect the following items:
a.
Inspect each limit switch lever and actuating lever

(Figure 6-10) for freedom of movement. Apply onehalf shot of grease to the fitting on the actuating
lever. Wipe away any excess grease.
b.
Inspect each weight (Figure 6-9) for freedom of

movement on the load line.
c.
Inspect each weight, each chain, each shackle and

each connecting pin (Figure 6-9) for excessive or
abnormal wear. Make sure cotter pins for shackles
are installed and spread.
If Upper Boom Point, Upper Luffing Jib Point, or Fixed

Jib is Removed:
1.
Disconnect cable from receptacle (14, View C).
2.
Unscrew sealing cap (6, View C) from terminating plug

(7) and attach to receptacle (14).
3.
Connect sealing cap to end of cable and store on upper

boom point or upper jib point.
If Luffing Jib Is Removed:

1.
Unscrew sealing cap (1, View C) from terminating plug

(2).
d.
Inspect the entire length of electric cables for

damage.
2.
Disconnect cable from receptacle (15, View C).
e.
3.
Connect terminating plug (2, View C) to receptacle (15).
4.
Connect sealing cap to end of cable and coil cable onto

cable reel (luffing jib butt).
Check that the electric cables are clear of all moving

parts on the boom and jib and that the cables are
securely fastened to the boom and jib with clips or
nylon straps.
f.
Check that all cables and terminating plugs

(Figure 6-9) are securely fastened.
5.
Remove sealing caps (7, View C) from terminating plugs

(6) and connect terminating plugs to jib stop receptacles
(16, 17, and 18).
Storing Electric Cable
2.
Test the block-up limit controls for proper operation

using either of the following methods:
a.
BOOM LOWERED: Manually lift each weight

one at a time while the engine is running. The
load drum should not operate in the hoist direction
and the boom/luffing hoist should not operate in the
lower direction.
b.
BOOM RAISED: Slowly hoist each load block and

weight ball one at a time against the weight.
When the chain goes slack, the corresponding load
drum should stop hoisting and the boom/luffing hoist
should not operate in the lower direction.

The electric cables for the boom and jib are long enough to
accommodate the maximum length of each attachment.
Store excess electric cable for the boom and luffing jib by
winding it onto the reel on mounted on the respective butt.
The reel is equipped with a locking pin. Disengage the
locking pin to allow the reel to be wound. Engage the locking
pin to lock the reel in position. The electric cable from the
crane to the reel must be disconnected before the reel can
be wound.
6-18
MAINTENANCE
1.
Adjust spring tension so there is enough force to lift

weight of chain and rotate actuating lever when weight is
lifted.
2.
Loosen setscrew in limit switch lever so lever is free to

rotate.
3.
Manually lift weight to allow actuating lever to rotate

upward.
4.
Hold lever at Dimension A.
Adjustment
5.
Hold roller on limit switch lever against actuating lever

while performing step 6
6.
Turn limit switch shaft CLOCKWISE only enough to

click limit switch open and hold. Then securely tighten
setscrew in limit switch lever.
7.
Test limit switch for proper operation (see Maintenance

topic); repeat adjustment steps until limit switch
operates properly.
CAUTION
Avoid Sheave Damage
Use extreme care when testing block-up limit controls
when boom is raised. If block-up limit control fails to stop
load, immediately stop load by moving drum control
handle to off or by applying drum working brake;
otherwise, two-blocking may occur.
Lower boom onto blocking at ground level and adjust each

limit switch as follows:
6-115
Item
1
2
3
4
5
6
Limit Switch for

Lower Boom Point
(has 2 springs)
Description
From Boom or Jib Node
Elbow with Cord Gripper
Setscrew
Spring
Enclosure
Spring Tension Adjusting
Screw
Item
7
8
9
10
11
12
Description
Grease Fitting
Actuating Lever
Roller
Limit Switch Lever
Shaft
Cover
1
Limit Switch for
Upper Boom Point and Jib Point
2
12
11
10
9
3
4
Left Hand Shown

Right Hand Opposite
Dimension A
1.04 in (26 mm)
FIGURE 6-12
6-19
ALPHABETICAL INDEX

Accessing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Approved Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Automatic Boom Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Blocked Crawlers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Block-Up Limit Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Boom and Luffing Jib Angle Indicator Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Counterweight Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Crane data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Crane Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crane Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Handling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Identifying Jib Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Jib Stop Adjustment (Current Production). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Luffing Jib Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Luffing Jib Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Luffing Jib Rigging Guide #44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Oil Can Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Operating Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Physical Boom Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Index-i
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Removable Lacings #44 Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Rigging Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Rigging Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Safe Maintenance Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Safety and Information Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Shipping Crane Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Standard Hand Signals for Controlling Crane Operations . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wind Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Index-ii

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OPERATORS MANUAL

This manual has been prepared for and is considered part of -

This Manual is divided into the following sections:

To prevent death or serious injury:

Avoid unsafe operation and maintenance.

Do not operate or work on crane or attachments without first reading and

Store Operator Information Manual and Service Manual in operators

National Crane Corporation

18000 LUFFING JIB OPERATORS MANUAL

See end of this manual for Alphabetical Index

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup And Installation

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

Preparing Crane, Boom, and Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

Published 06-20-08, Control # 033-07

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

For the exact location of the identification labels on your

EC Declaration (if applicable).

The terms RIGHT, LEFT, FRONT, REAR used in this manual

Operators cab is at front of upperworks.

Crawler motors are at rear of lowerworks.

Crawler pin handles on carbody are at front of

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

IDENTIFICATION AND LOCATION OF COMPONENTS

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

FIGURE 1-2 continued

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

A1=100 ft (30,48 m) Mast = 118 ft, 11 in (36,25 m)

Outline Dimensions Continued on Next Page

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

Published 06-20-08, Control # 033-07

18000 LUFFING JIB OPERATORS MANUAL

Published 06-20-08, Control # 033-07

ENGLISH AND METRIC CONVERSIONS

DIVIDE ( / ) known value by conversion factor to obtain

MULTIPLY ( x ) known value by conversion factor to obtain

Pound Force Per Inch

Newton per millimeter

Pound Force Per Foot

Newton per meter

Hydraulic & Air

Oil, Air, Etc.

Miles Per Hour