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Manitowoc 16000WA, Operator'S Manual

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SET-UP AND INSTALLATION

16000 WIND ATTACHMENT OPERATOR’S MANUAL

4-10

Published 03-18-13, Control # 116-09

#58, 12 m (39.4 FT) MAX-ER Insert with Storable Equalizer Rails

CONFIGURED FOR USE WITH MAX-ER ATTACHMENT

Past Production only on S/N 16003016

FIGURE 4-8

1

Boom Straps and Links Stored
in Outboard Position (2 places)

1

Boom Straps and Links Stored
in Outboard Position

Removable Strap Bracket
Stored (6 places)

NOTE:

 Strap Brackets must be

removed if a luffing jib insert will
be shipped inside this insert.

Equalizer Rail in Working
Position (2 places)

3

2

3

Equalizer Rail in Working
Position (2 places)

Summary of Contents for 16000WA

Page 1: ...R e f e r e n c e O n l y Operator Manual Manitowoc 16000WA ...

Page 2: ...R e f e r e n c e O n l y ...

Page 3: ...l for the exact location of the identification plates Always furnish serial number of crane and attachment when ordering parts or discussing service problems with your Manitowoc dealer 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 qu...

Page 4: ...R e f e r e n c e O n l y The original language of this publication is English ...

Page 5: ...5 Outline Dimensions 1 7 English and Metric Conversions 1 7 Direct Conversion 1 7 Inverse Conversion 1 7 SECTION 2 Safety Information Nameplates and Decals 2 1 Safety Topics 2 1 Safety Messages 2 1 General 2 1 Safety Alert Symbol 2 1 Signal Words 2 1 Boom Disassembly Safety 2 3 General 2 3 Location 2 3 Pin Removal 2 3 Disassembly Precaution 2 3 SECTION 3 Operating Controls And Procedures Operating...

Page 6: ...sassemble Boom 4 40 Lower Boom onto Blocking 4 40 Disconnect Store Boom Wiring and Components 4 40 Store Load Lines 4 41 Disconnect Boom Butt from Boom 4 41 Install Assembly Block 4 41 Remove Boom Butt 4 42 Disconnect and Store Boom Straps 4 43 Disconnect Intermediate Suspension from Boom Straps 4 43 Remove Extended Upper Boom Point Procedure 1 4 43 Remove Extended Upper Boom Point Procedure 2 4 4...

Page 7: ...ant Product Guide 5 1 SECTION 6 Maintenance Inspection and Maintenance Checks 6 1 General Maintenance 6 1 Boom Angle Sensor Calibration 6 1 Bypass Limit Test 6 3 Automatic Boom Stop Adjustment 6 3 Maximum Boom Angle 6 3 Operation 6 3 Maintenance 6 3 Adjustment 6 5 Actuator Rod Replacement 6 5 Block Up Limit Installation and Adjustment 6 7 General 6 7 Disconnecting Block Up Limits 6 7 Removing Exte...

Page 8: ...R e f e r e n c e O n l y ...

Page 9: ...tline Dimensions 1 1 Crane Weights 1 1 Continuous Improvement 1 1 Identification and Location of Components 1 2 Wind Attachment Model Differences 1 4 58 Boom without Wind Attachment 1 4 58WA Boom with Wind Attachment 1 4 58WA Boom with Wind Attachment and Auxiliary Counterweights 1 5 58BRS Boom with Wind Attachment and Boom Raising System BRS 1 5 Outline Dimensions 1 7 English and Metric Conversio...

Page 10: ...R e f e r e n c e O n l y ...

Page 11: ...e the form MANITOWOC DEALER For questions about this manual or the 16000 crane contact your Manitowoc dealer If you do not know the contact information for your dealer locate the Manitowoc dealer nearest you as follows 1 Go to www manitowoccranes com 2 Go to Dealer Locator 3 Follow the on screen prompts to locate your Manitowoc dealer CRANE ORIENTATION The terms RIGHT LEFT FRONT REAR used in this ...

Page 12: ...13 Control 116 09 IDENTIFICATION AND LOCATION OF COMPONENTS 24 23 3 17 15 1 6 2 10 5 7 9 18 8 FIGURE 1 2 4 11 16 22 25 26 19 20 21 27 13 14 29 31 34 33 12 30 32 View A Model 16000 Two Offset Angles 28 or 35 View B Model 18000 One Offset Angle 35 Oval Cutout in Plates Circle Cutouts in Plates 28a 28b ...

Page 13: ...Guides in Insert Optional 18 Wire Rope Guide From 16000 58WA Boom 19 Extended Upper Boom Point Either from 16000 58WA Boom Rigging View A OR from 18000 55 79A Boom Rigging View B 20 Lower Point 4 Sheaves 21 Upper Point 1 Sheave 22 Load Lines 23 Hook and Weight Ball 24 Load Block 25 Boom Cap Serial Numbered 26 Transition Insert From 16000 58 Boom 27 Insert Heavy 12 m 39 4 ft From 16000 MAX ER Attac...

Page 14: ...CHMENT MODEL DIFFERENCES See page 1 6 for legend 58 Boom without Wind Attachment Rigging drawing A10415 Crane serial number 16001xxx 58WA Boom with Wind Attachment Rigging drawing 81009833 Crane serial number 16007xxx BOOM TOP BOOM BUTT MAST STRAPS COUNTERWEIGHTS INTERMEDIATE SUPENSION 1 3 5 6 7 8 12 14 15 9 11 10 16 17 13 2 4 ...

Page 15: ... serial number 16007xxx Rigging drawing 81018003 Instructions F2245 at end of Section 4 in this Manual 58BRS Boom with Wind Attachment and Boom Raising System BRS Crane serial number 16008xxx Rigging drawing 81016771 Instructions F2241 in separate Operator Manual BOOM TOP BOOM BUTT MAST STRAPS COUNTERWEIGHTS INTERMEDIATE SUPENSION 18 2 4 5 6 7 12 19 20 24 13 25 25 26 27 28 9 11 10 23 21 22 17 ...

Page 16: ...Series 1 2 or 3 counterweights See Counterweight Arrangements chart 15 Series 1 2 3 or 4 counterweights See Counterweight Arrangements chart 16 Intermediate suspension Used on 58 boom crane configuration 17 Intermediate suspension 5 hole version used on Wind Attachment models 18 Strap 19 Strap 20 Load pin 21 Link 22 Link 23 Link 24 Upper FACT connector modification Holes are drilled in boom butt u...

Page 17: ...ce 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 Spring Force Newton per millimeter Nmm 0 1751 Pound Force Per Foot lb ft Newton per meter Nm 14 5939 LENGTH Inch in Adjustments Millimeter mm 25 4000 Foot ft Outline Dimensions Meter m 0 3048 Mile miles Travel Distance Kilometer km 1 6093 POWER Horsepower hp Engine Kil...

Page 18: ...UME LIQUID Ounce oz Fluid Capacities Milliliter mL 29 5735 Pint pt Liter L 0 4732 Quart qt Liter L 0 9464 Gallon gal Liter L 3 7854 Gallon Per Minute gpm Pump Flow Liters Per Minute L min 3 7854 WEIGHT Pound lb Unit Component Kilogram kg 0 4536 Ton 2 000 lb USt Load Ratings Metric Ton t 0 9072 Ton 2 000 lb USt Kilogram kg 907 1847 To Convert Symbol Application To Symbol Multiply By ...

Page 19: ...09 2 i 2 SECTION 2 SAFETY INFORMATION TABLE OF CONTENTS Nameplates and Decals 2 1 Safety Topics 2 1 Safety Messages 2 1 General 2 1 Safety Alert Symbol 2 1 Signal Words 2 1 Boom Disassembly Safety 2 3 General 2 3 Location 2 3 Pin Removal 2 3 Disassembly Precaution 2 3 ...

Page 20: ...R e f e r e n c e O n l y ...

Page 21: ... practices and maintenance procedures safety messages are used throughout this manual Each safety message contains a safety alert symbol and a signal word to identify the hazard s degree of seriousness Safety Alert Symbol Signal Words NOTE Highlights operation or maintenance procedures This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety mess...

Page 22: ...w A WRONG DANGEROUS 2 Handling Pendants are Slack 3 and there is No Blocking Under Boom Sections 4 Boom will COLLAPSE when Lower Pins are Removed View C RIGHT SAFE 1 Handling Pendants Taut and Supporting Boom 2 before Removing Bottom Pins 3 Boom Sections Lowered and Securely Blocked View B WRONG DANGEROUS 1 If Boom Point is on Ground Straps Fully Lowered onto Supports Before Removing Pins 3 Boom w...

Page 23: ...e 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 blocking individual pin connections may still be under load Pins can be ejected forcefully if t...

Page 24: ...R e f e r e n c e O n l y ...

Page 25: ...R e f e r e n c e O n l y Manitowoc Published 03 18 13 Control 116 09 3 i 3 SECTION 3 OPERATING CONTROLS AND PROCEDURES TABLE OF CONTENTS Operating Controls and Procedures 3 1 Wind Conditions 3 1 ...

Page 26: ...R e f e r e n c e O n l y ...

Page 27: ...e aware that the larger the sail area of the load the greater the wind s 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 For wind conditions specific to the extended upper boom point see the Wind Conditions Chart at end of this section or if applicable see...

Page 28: ...condition is especially dangerous when the boom is at or near the maximum angle when operating without load Wind forces on the front of the boom reduce the normal forward tipping effect of the boom The crane can tip or the boom can collapse if this condition is not avoided Forward stability is affected by wind on the rear of the boom Wind applies a force to the boom and load that adds to the crane...

Page 29: ...ntifying Boom Sections and Straps 4 8 Identifying Heavy Boom Inserts 4 8 Assemble Boom Sections 4 15 Prepare Boom Cap 4 19 Install Extended Upper Boom Point Procedure 1 4 21 Install Extended Upper Boom Point Procedure 2 4 23 Connect Boom Straps to Intermediate Suspension Strut 4 25 Connect Boom Straps 4 27 Install boom butt 4 29 Remove Assembly Block 4 33 Connect Boom Butt to Boom 4 33 Raise Adjus...

Page 30: ...choring Wire Rope to Drum 4 49 Drum Guards 4 49 Winding Wire Rope onto Drum 4 51 Anchoring Wire Rope to Wedge Socket 4 53 Anchoring Wire Rope to Button Socket 4 53 Breaking in Wire Rope 4 53 Drum Kicker Adjustment 4 54 General 4 54 Adjustment 4 54 Pad Eye Usage for Wire Rope Reeving 4 54 General 4 54 Safety 4 54 Reeving Load Block 4 56 Load Block Identification 4 56 Wire Rope Specifications 4 56 W...

Page 31: ...fore attempting to assemble or disassemble the 58WA boom and extended upper boom point Tipping Overload Hazard Avoid tipping crane over or collapsing live mast Assemble and disassemble the boom on a firm level uniformly supporting surface Avoid Falling Off Crane and Boom It is necessary to climb onto crane and boom during assembly and disassembly steps Use sturdy owner furnished ladders or an aeri...

Page 32: ...f construction cranes Read and become thoroughly familiar with the instructions in this section and in the assembly drawings at the end of this section before attempting to assemble or disassemble the boom Contact your Manitowoc dealer for assistance if any procedure is not fully understood ASSEMBLY AND DISASSEMBLY AREA Select an assembly disassembly area that has a firm level uniformly supporting...

Page 33: ...counterweight see F2241 or F2245 at he end of this section Install the counterweight according to the instructions in Section 4 of the Operator s Manual supplied with your 16000 NOTE During setup the crane can be swung 360 with the counterweight installed either with the mast forward or in the transport position The crane must be on a firm level uniformly supporting surface ROTATING BED MODIFICATI...

Page 34: ...OR S MANUAL 4 4 Published 03 18 13 Control 116 09 FIGURE 4 3 A13170 View B 4 places 6 Firm Against Bottom Chord 2 Hooked Over Top Chord View C 4 places View A Stored View D Installed Item Description 1 40 ft 12 m Insert 2 Ladder 3 Hook 4 Keeper 5 Rubber Latch 6 Pad 1 2 3 4 5 2 2 ...

Page 35: ... top chord and pads 6 are firm against bottom chord View D Ladder must hang vertically against boom insert when in use Storing Ladders in boom butt It is recommended that two people store either ladder in the boom insert one person outside the insert to help guide the ladder into the insert and another person inside the insert to lift the ladder and latch it in position Use the following procedure...

Page 36: ...gths must be raised and lowered over the end of blocked crawlers See Capacity Charts for blocked crawler requirements and Crawler Blocking Diagram in Capacity Charts Manual for instructions Do not attempt to raise or lower the boom from or to the ground until the crawlers are blocked if required FIGURE 4 4 A10740 14a Component Identification Item Description 1 Live Mast 2 Handling Pendant Mast and...

Page 37: ...ed as desired WARNING Tipping Hazard Block ends of crawlers if required before you attempt to raise or lower boom from or to ground WARNING Falling Load Hazard Lifting lugs on a particular boom section are designed only for lifting that section only Do not attempt to lift two or more boom sections with lifting lugs only on one section Lifting lugs may break allowing boom sections to fall When lift...

Page 38: ...d for proper identification as shown in Figure 4 6 View B Identifying Heavy Boom Inserts The following 58WA boom inserts are classified as heavy 3 m 9 8 ft 6 m 19 7 ft 12 m 39 4 ft Each heavy insert has two identification plates with an H cut into them as shown in Figure 4 7 WARNING Collapsing Boom Hazard Boom can collapse if not assembled in correct sequence Follow assembly sequence in Boom Assem...

Page 39: ...R e f e r e n c e O n l y Manitowoc Published 03 18 13 Control 116 09 4 9 16000 WIND ATTACHMENT OPERATOR S MANUAL SET UP AND INSTALLATION 4 THIS PAGE BLANK ...

Page 40: ...ITH MAX ER ATTACHMENT Past Production only on S N 16003016 FIGURE 4 8 1 Boom Straps and Links Stored in Outboard Position 2 places 1 Boom Straps and Links Stored in Outboard Position Removable Strap Bracket Stored 6 places NOTE Strap Brackets must be removed if a luffing jib insert will be shipped inside this insert Equalizer Rail in Working Position 2 places 3 2 3 Equalizer Rail in Working Positi...

Page 41: ...rable Equalizer Rails CONFIGURED FOR USE WITH 16000 WIND ATTACHMENT Past Production only on S N 16003016 FIGURE 4 8 continued 1 Boom Straps and Links Stored in Inboard Position 2 places 1 Boom Straps and Links Stored in Inboard Position Removable Strap Bracket in Working Position 6 places 2 3 Equalizer Rail in Stored Position 2 places Equalizer Rail in Stored Position 2 places 3 ...

Page 42: ...FOR USE WITH MAX ER ATTACHMENT Current Production FIGURE 4 9 1 Boom Straps and Links Stored in Outboard Position 2 places 1 Boom Straps and Links Stored in Outboard Position Removable Strap Bracket Stored 6 places NOTE Strap Brackets must be removed if a luffing jib insert will be shipped inside this insert Equalizer Rail in Working Position 2 places 3 2 3 Equalizer Rail in Working Position 2 plac...

Page 43: ... with Storable Equalizer Rails CONFIGURED FOR USE WITH 16000 WIND ATTACHMENT Current Production FIGURE 4 9 continued 1 Boom Straps and Links Stored in Inboard Position Removable Strap Bracket in Working Position 6 places Equalizer Rail in Stored Position 2 places Boom Straps and Links Stored in Inboard Position 2 places 1 3 Equalizer Rail in Stored Position 2 places 2 3 ...

Page 44: ...T OPERATOR S MANUAL 4 14 Published 03 18 13 Control 116 09 11 12 FIGURE 4 10 View D 7 8 View A SHIPPING View B WORKING 10 10 11 View C Remove Luffing Jib Straps Links and Pins from Boom Sections 6 9 12 1 2 3 4 4 4 5 Intermediate Suspension Strut if Equipped see page 4 17 ...

Page 45: ...ew D The bottom connecting pins are stored in tubes 9 View D on the insert 5 Block under the top end of the insert 6 Raise wire rope guide 10 View A a Remove wire lock pins 12 View A b Raise wire rope guide 10 View A from the shipping position to the working position View B c Pin struts 11 to the wire rope guide with wire lock pins 12 7 Repeat steps 3 5 for the next insert Continued on next page W...

Page 46: ...IND ATTACHMENT OPERATOR S MANUAL 4 16 Published 03 18 13 Control 116 09 18 FIGURE 4 10 continued View H 16a View E 13 17 SHIPPING 17 WORKING 17a 15 14 14a 14 and 14a STORED 16 19 20 7 19a View G RIGGING 16 18 18a 18 STORED View F SHIPPING 18a 15 18 INSTALLED ...

Page 47: ...pension strut 16 d Store pins 18 as shown in View G e Lift intermediate suspension strut 16 View H into position at the end of the insert The strut has two lifting lugs 16a f Align the connecting holes in the intermediate suspension strut with the connecting holes in strap 15 g Install pins 18 View G and retaining pins 18a Head end of pin 18a must face top end of boom h Lift intermediate suspensio...

Page 48: ...UP AND INSTALLATION 16000 WIND ATTACHMENT OPERATOR S MANUAL 4 18 Published 03 18 13 Control 116 09 View C WORKING View A SHIPPING View B LIFTING 9 8 4 5 3 3 8 5 4 View D RIGGING 7 FIGURE 4 11 2 1 2 6 7 9 Head Inward 15 6 16 16 15 16 ...

Page 49: ...ure a Attach a nylon lifting sling to the pin at the top end of links 7 View A b Lift strap 6 and links 7 into position at the butt end of insert 10 View A c Remove pins 11 View B rotate links 12 to the working position View A and install pins 11 d Pin links 13 View A to strap 6 with pin 14 Pin 14 is stored in a pocket on the vertical lacing of the insert e Lower strap 6 and links 7 to the folded ...

Page 50: ...16000 WIND ATTACHMENT OPERATOR S MANUAL 4 20 Published 03 18 13 Control 116 09 FIGURE 4 14 View A SHIPPING View B STORED View C View F WORKING View H STORED View G View E STORED 1 2 9 12 13 14 10 A B View D 12 9 15 15 17 16 13 and 14 18 20 11 19 16 17 ...

Page 51: ... pins are stored as shown in View B 7 Remove pins 13 View C and collars 14 and lower the extended upper boom point to the ground 8 Store pins 13 View H and collars 14 9 Disconnect the lifting slings 10 Unpin storage links 16 View E 11 Rotate links 15 View E rearward and pin them to straps 18 View F on the transition insert 12 Pin storage links 16 View F in the working position 13 Repin links 20 Vi...

Page 52: ...LATION 16000 WIND ATTACHMENT OPERATOR S MANUAL 4 22 Published 03 18 13 Control 116 09 FIGURE 4 15 21 21 View B View D SHIPPING 12 View E STORED 15 17 16 9 12 1 11 2 10 21 View F WORKING View A View C View G B A 21 10 10 21 20 2 9 18 19 15 16 17 ...

Page 53: ... A to the lifting lugs on extended upper boom point 10 12 Lift the extended upper boom point into position at the end of boom cap 1 View C 13 Pin links 20 View B to the desired offset holes 14 Align the bottom connecting holes in the extended upper boom point with the bottom connecting holes in the boom cap and install pins 21 View G 15 Lower the extended upper boom point to the ground and disconn...

Page 54: ...ontrol 116 09 3a 6 Item Description 1 Intermediate Suspension Strut 2 Lifting Lug 2 3 Pin with Pin and Cotter Pins 2 3a Retaining Pin and Cotter Pin 2 4 Links 2 5a Strap 5b Strap 6 Alignment Hole 4 FIGURE 4 16 View E 1 4 5a View C 2 3 View A 5a 4 5b 1 5b 5b 3 1 4 View B 2 3a STORED View D 5a 4 5b 1 3 3a 6 3a 1 6 3a ...

Page 55: ... pins 3 4 Store pins 3 and 3a View B Head end of pin 3a must face top end of boom 5 Lift intermediate suspension strut 1 approximately 12 in 305 mm so there is room to rotate links 4 View B to the working position 6 Unpin links 4 View A from the shipping position and rotate them rearward to the working position View B 7 Remove retaining pins 3a View B from storage 8 Lower intermediate suspension s...

Page 56: ...4 17 Item Description 1a Strap 1b Strap 2 Link 3 Pin with Cotter Pins 4 Link 5 Pin with Collar Retaining Pin and Cotter Pins Remove Luffing Jib Straps Links and Pins from Boom Sections View B SHIPPING 4 1a 1b 1a 3 4 2 2 If equipped with intermediate suspension connect straps here FIRST see page 25 Then connect remaining straps starting here and working rearward ...

Page 57: ...the boom straps to the intermediate suspension strut first see page 25 Then connect the boom straps at the inserts starting at the transition insert and working rearward It may be difficult to connect the straps to the intermediate suspension strut if you connect the straps at the inserts firsts 1 Remove pins 3 View B rotate links 4 to the working position View A and install pins 3 at both ends of...

Page 58: ...IGURE 4 18 4 WORKING 4 SHIPPING Item Description 1 Boom Butt 2 Wire Rope Guide 3 Lifting Lug 4 Pin with Cotter Pins 5a Hoses 5b Couplers on Boom Butt 5c Couplers on Rotating Bed 6 Hinge Pin 7 Locking Pin 8 Shims View D 7 SHIPPING 1 2 1 6 Engaged 6 Disengaged 1 8 5c View C On Rotating Bed 5a View A View B On Boom Butt 5b 5a 7 WORKING 3 1 ...

Page 59: ...oard side of the boom butt and the rotating bed lug on both sides of the crane Shim tabs must face inward and rest on rotating bed lugs b Install the next thickest possible shim between the inboard side of the boom butt and the first shim on both sides of the crane c If possible install the thinnest shim between the inboard side of the boom butt and the second shim on both sides of the crane 9 Usi...

Page 60: ...R e f e r e n c e O n l y SET UP AND INSTALLATION 16000 WIND ATTACHMENT OPERATOR S MANUAL 4 30 Published 03 18 13 Control 116 09 THIS PAGE BLANK ...

Page 61: ...UAL SET UP AND INSTALLATION 4 FIGURE 4 19 Item Description 1 Coupling Assist Tool 2 Retaining Bar 3 Safety Pin 4 Motor Pilot 5 Anti Cavitation 6 High Pressure 7 Case Drain P2021 P2263a P2264a 1 4 5 View A View B View C View D From Front Views B and C are from Crane Looking Forward P2262a 5 4 3 2 4 6 6 7 6 6 6 7 ...

Page 62: ...t 4 Chain Sling 5 Assembly Block 6 Handling Pendant 7 Assist Crane Load Block 8 Nylon Sling 9 Mast Strap 10 Hooked Connector 11 Fixed Pin 12 Pin with Safety Pin 1 5 4 5 8 7 View G View B 2 3 View C 9 BLOCK HERE at both crawlers if required per Capacity Chart 6 A10740 17 A10740 19 A10740 20 14 000 lb 6 350 kg 6 Stored View A View D 2 6 Installed View F View E 11 10 12 6 6 12 store here ...

Page 63: ...0 View C Connect Boom Butt to Boom See Figure 4 20 for following procedure 1 Pin handling pendants 6 View D to lugs 2 on the boom butt 2 Boom up to lift the boom butt just clear of the ground 3 Position the 16000 so the boom butt is in line with the end of boom View C 4 Travel forward and boom down to align hooked connectors 10 View E on the boom butt with fixed pins 11 on the adjacent insert 5 Se...

Page 64: ...tric Cable From Boom 4 Electric Cable from Drum 1 on Boom 5 Electric Cable from Drum 3 on Boom 6 Pin with Collar Retaining Pin and Cotter Pins 2 7 Links 2 8 Mast Strap 2 8 6 A10740 20a ARMS DOWN before raising mast with boom connected to mast straps ARMS UP before rasing mast with boom disconnected from mast straps 1 2 3 P2281 Right Front Corner of Rotating Bed Node 6 Front of Rotating Bed 4 M4 3f...

Page 65: ...ctric cables 4 View B and 5 optional from the boom butt to the node on the front of the rotating bed 11 Remove pins 6 View A from links 7 12 Lower the mast until the holes in mast straps 8 View A are aligned with the holes in links 7 13 Install pins 6 View A 14 Fully lower the mast arms using the switch on the remote control 15 Select the proper capacity chart on the configuration screen of the RC...

Page 66: ...on 1 Intermediate Suspension Strut 1a Top Strut 1b Bottom Strut 2a Support 2 Past Production 2b Blocking 2 Current Production 4 in x 4 in x 30 in 102 mm x 102 mm x 762 mm 3 Pin with Cotter Pin 2 4 Latch 2 5 Hitch Pin with Hair Pin Cotter 2 6 Beam View F View D 12 9 16 in 319 mm 3 1b View B 5 1b 1a 1b 4 5 4 View A View C 3 1a View E 2 To Crane 6 6 2b OR 2a ...

Page 67: ...ns 3 6 Slowly boom up to raise top strut 1a to the required operating length View G Make sure the top strut does not hang up on the boom strap brackets as the strut is raised 7 Install pins 3 to connect the top strut to the bottom strut at the required length 8 Unpin latch 4 View A on both ends of beam 6 NOTE The boom may start to rise off the blocking before the bottom strut shaft engages the lug...

Page 68: ...ll 9 Link 10 Button Socket 11 Chain 9 ft 2 7 m 2 11a Shackle 3 11b Pin 3 12 Block Up Limit Weight 13 Load Block 14 Block Up Limit Switch 2 15 Link 16 Wireless Load Cell 17 Link 18 Block Up Limit Weight with Lift Plate 19 Link 20 Link 21 Hook and Weight Ball 22 Aircraft Warning Light 23 Wind Speed Indicator 21 11 18 Dead End Load Line 11 12 Multiple Part Load Line Single Part Load Line 20 16 19 10 ...

Page 69: ... to proper receptacles on the boom node controller 8 To protect electrical components a Attach protective caps to the ends of all unused cables unused receptacles and unused terminator plugs b If equipped attach terminator plugs to unused receptacles Perform Pre Raising Checks Perform the following pre raising checks and correct any defects before raising the boom o Crane on firm level surface o C...

Page 70: ... is resting on supports 2a View F or blocking 2b d Close latches 4 and install pins 5 View B for storage e Boom up or down as needed to loosen pins 3 View C f Remove pins 3 g Slowly boom down to fully lower top strut 1a to Position A View G h Install pins 3 to connect the top strut to the bottom strut i Slowly boom up to raise the intermediate suspension strut approximately 12 in 305 mm j Remove a...

Page 71: ...Disconnect the boom butt See Figure 4 20 for following procedure a Unpin handling pendants 6 View A from the mast and pin them to the lugs on the boom butt View D b Boom up until handling pendants 6 View G are just taut c Remove pins 12 View F and store them in the pockets on the insert d Slowly boom down to lower the boom onto blocking at least 6 in 152 mm high View C e Boom down until hooked con...

Page 72: ...o lifting lug 3 View A on wire rope guide 2 b Support the wire rope guide so pins 4 are loose and remove the pins c Lower the wire rope guide from the operating position to the shipping position d Install pins 4 e Disconnect the lifting sling 2 Disconnect the hydraulic hoses between the boom butt and the rotating bed see Figure 4 19 a Thoroughly clean each coupler and connect sealing covers to cou...

Page 73: ...all them View A 8 Lower intermediate suspension strut 1 until the lifting slings are slack 9 Disconnect the lifting slings 10 Disconnect the remaining boom straps NOTE There are two procedures for removing the extended upper boom point Procedure 1 The boom cap and extended upper boom point are shipped assembled Procedure 2 The boom cap and extended upper boom point are shipped separately Remove Ex...

Page 74: ...ition insert 16 Place the boom cap on a trailer for shipping or on blocking for storage 17 Disconnect the lifting slings 18 Reverse the Prepare Boom Cap steps on page 4 19 to store the wire rope guide and to store the mast straps and links Disassemble Boom Sections Reverse the assembly steps on page 4 15 to disassemble the boom If the transition insert will be shipped with the wind attachment stra...

Page 75: ...R e f e r e n c e O n l y Manitowoc Published 03 18 13 Control 116 09 4 45 16000 WIND ATTACHMENT OPERATOR S MANUAL SET UP AND INSTALLATION 4 THIS PAGE BLANK ...

Page 76: ...E identifies 16000 parts that stay with the existing crane YELLOW identifies 16000 MAX ER parts that can ship with the wind attachment or stay with the existing MAX ER Ship loose parts in the job box supplied with the Wind Attachment See the decal inside the job box for identification of parts 14 16 15 17 18 19 5 12 m 39 4 ft MAX ER Insert with Storable Equalizer Rails see Figure 4 8 1 2 3 4 6 13 ...

Page 77: ...Cell without Electric Cable 10 Wireless Load Cell 11 Aircraft Warning Light without Mounting Hardware 12 Wind Speed Indicator with Mounting Hardware Yellow 16000 MAX ER Parts Red Stay with Wind Attachment 13 Counterweight Box 2 14 Mast Straps and Links store in boom cap 15 3 m and 6 m Inserts 1 each 16 3m and 6 m Straps stored on inserts 17 Intermediate Suspension 18 Boom Cap 19 Extended Upper Boo...

Page 78: ... 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 27 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 ...

Page 79: ... 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 Wire Rope Type Seizings Required Preformed 1 Non preformed 3 View A Rope Diameter 1 in 26 mm and Larger View B Rope Diameter Smaller than 1 in 26 mm WARNING Moving Machinery Hazard Guards must be secured to drums during crane operation Whe...

Page 80: ...R e f e r e n c e O n l y SET UP AND INSTALLATION 16000 WIND ATTACHMENT OPERATOR S MANUAL 4 50 Published 03 18 13 Control 116 09 THIS PAGE BLANK ...

Page 81: ...ts 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 30 3 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 Da...

Page 82: ...to Live End Dead End Terminator Wedge Right Method C WRONG Rope Backward WRONG Dead End Clipped to Live End WRONG Wedge Backward ALL ARE DANGEROUS AND PROHIBITED TL Tail Length 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 T Rope Clip Nut Torque Wire Rope Clip Size i...

Page 83: ... the wire rope s diameter as the strands compact around the core 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 rope s life from release of the load WARNING Falling Load Haza...

Page 84: ...g washers 3 4 Loosen lock nuts 4 and adjust set screws 5 to move kickers 1 into drum 5 Repeat steps 1 3 only enough to improve spooling Moving drum kickers in too far can cause premature wire rope wear 6 Securely tighten set screws 5 and lock nuts 4 7 Reinstall drum guards PAD EYE USAGE FOR WIRE ROPE REEVING See Figure 4 34 for following procedure General Some rotation resistant wire rope supplied...

Page 85: ...inch or Fork Lift Truck B D F E G C A Wire Rope Wire Rope with Button Pad Eye Connector OR No 1 5 Pad Eye Item Inch mm Approximate Capacity 1220 lb 553 kg A 5 8 16 00 B 1 4 6 35 C 1 25 40 D 7 16 11 18 E 1 1 8 28 70 F 1 16 4 06 G 1 5 16 33 27 No 1 Pad Eye Item Inch mm Approximate Capacity 1220 lb 553 kg A 3 8 9 65 B 1 4 6 35 C 7 8 22 40 D 13 32 10 40 E 7 8 22 40 F 1 8 3 30 G 1 1 32 25 40 No 2 Pad E...

Page 86: ...ptional shackle can be attached as shown in Figure 4 35 Guide Sheaves and Drums See Figure 4 36 for identification of the load drums and guide sheaves 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 Load Block Reeving See Fig...

Page 87: ...uide on boom cap 5 Lower Point 6 Upper Point 7 Load Block Dead End Socket Block Up Limit Weight 2 1 3 WARNING Avoid Death or Serious Injury 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 8 Part 5 Sheave Block 6...

Page 88: ...R e f e r e n c e O n l y C B A E D F D E F Upper Point 1 Part Upper Point 2 Part Lower Point FIGURE 4 37 ...

Page 89: ... 4 7 m 6 ft 1 in 1 9 m 22 ft 2 in 6 8 m 4 Sheave 200 USt 181 t Block Lower Point with 35 Offset Parts of Line A Minimum B C Minimum Comments 4 20 ft 11 in 6 4 m 4 ft 2 in 1 3 m 25 ft 7 in 7 8 m 3 Sheave 110 USt 100 t Block 4 17 ft 11 in 5 5 m 6 ft 1 in 1 9 m 24 ft 9 in 7 5 m 4 Sheave 200 USt 181 t Block 6 15 ft 1 in 4 6 m 6 ft 1 in 1 9 m 21 ft 11 in 6 7 m 4 Sheave 200 USt 181 t Block 8 15 ft 1 in ...

Page 90: ...R e f e r e n c e O n l y SET UP AND INSTALLATION 16000 WIND ATTACHMENT OPERATOR S MANUAL 4 60 Published 03 18 13 Control 116 09 ...

Page 91: ...R e f e r e n c e O n l y Manitowoc Published 03 18 13 Control 116 09 5 i 5 SECTION 5 LUBRICATION TABLE OF CONTENTS Lubrication 5 1 Lube and Coolant Product Guide 5 1 ...

Page 92: ...R e f e r e n c e O n l y ...

Page 93: ...ublished 03 18 13 Control 116 09 5 1 16000 WIND ATTACHMENT OPERATOR S MANUAL LUBRICATION 5 SECTION 5 LUBRICATION LUBRICATION See F2109 at the end of this section LUBE AND COOLANT PRODUCT GUIDE See the publication at the end of this section ...

Page 94: ...R e f e r e n c e O n l y ...

Page 95: ...aintenance 6 1 Boom Angle Sensor Calibration 6 1 Bypass Limit Test 6 3 Automatic Boom Stop Adjustment 6 3 Maximum Boom Angle 6 3 Operation 6 3 Maintenance 6 3 Adjustment 6 5 Actuator Rod Replacement 6 5 Block Up Limit Installation and Adjustment 6 7 General 6 7 Disconnecting Block Up Limits 6 7 Removing Extended Upper Boom Point 6 8 Maintenance 6 8 Adjustment 6 9 ...

Page 96: ...R e f e r e n c e O n l y ...

Page 97: ...ollows 1 Locate three black wires from the circuit board in the boom node controller 2 Cut the wires from the faulty boom angle sensor at the connections on the black wires 3 Remove and discard the faulty boom angle sensor It is attached with three screws and silicone sealant 4 Thoroughly clean all silicone sealant from the sensor mounting surface in the boom node controller 5 Apply a ring of sili...

Page 98: ... a Boom Up Limit that Can be Bypassed 84 For Cranes with a Boom Up Limit that Cannot be Bypassed To determine if the boom up limit on your crane can be bypassed or not perform the Bypass Limit Test given below FIGURE 6 2 1 5 Horizontal Item Description 1 Boom Butt 2 Adjusting Rod 5 Limit Switch Centerline of Boom Right Side of Crane Angle A 2 ...

Page 99: ...um angle boom butt 1 pushes adjusting rod 2 in and actuator rod 11 View A opens limit switch 5 The LED then goes OFF 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 Maintenance At least once weekly check that the automatic boom stop stops the b...

Page 100: ... Coupling 5 Limit Switch 6 Cover 7 Spring Washer 8 Spring 9 Spring Washer 10 Dowel Pin 1 4 in 6 35 mm Diameter 11 Actuator Rod 12 Digital Level see Figure 6 4 Roller Over Travel LED ON 7 8 9 10 11 Luffing Jib LED OFF 5 5 6 11 2 4 3 Limit Switch Wiring Receptacle Switch Terminals Function 1 green 22 B 14 Max Angle 2 black A 13 LED 3 white 21 12 VDC Supply 1 VIEW B SWITCH CLOSED FIGURE 6 3 Actuating...

Page 101: ...ches the specified angle d Turn adjusting rod 2 out against boom butt 1 until limit switch 5 clicks open and the LED is OFF View A e Tighten jam nut 3 7 If the boom reaches the specified angle before it stops a Loosen jam nut 3 View B b Turn adjusting rod 2 out against boom butt 1 until limit switch 5 clicks open and the LED is OFF View A c Tighten jam nut 3 8 Check that actuator rod 11 over trave...

Page 102: ... Item Description 1 Boom Cap 10 Button Socket 18 Weight with Lift Plate 2 Extended Upper Boom Point 11 Chain 9 ft 2 7 m 2 19 Link 3 Lower Point 11a Shackle 3 20 Link 4 Upper Point 11b Pin 3 21 Hook and Weight Ball 5 Boom Node Controller in boom cap 12 Block Up Limit Weight 22 Aircraft Warning Light 5a Terminating Plug 13 Load Block 23 Wind Speed Indicator 6 Wireless Transceiver in boom cap 14 Bloc...

Page 103: ...load line as shown 4 Lift block on load block or lift plate on load line 5 Cable reel 26 in boom butt which allows the cable to be lengthened or shortened to meet varying boom lengths Disconnecting Block Up Limits See Figure 6 5 for following procedure Failing to perform following steps will prevent load drums from hoisting and boom from lowering Also a fault alarm will come on 1 To provide proper...

Page 104: ...e load line c Inspect each weight each chain each shackle and each connecting pin Figure 6 5 for excessive or abnormal wear Make sure the cotter pins for the shackles are installed and spread d Inspect the entire length of electric cables for damage e Check that electric cables are clear of all moving parts on the boom and extended upper boom point and that the cables are securely fastened with cl...

Page 105: ...r 4 against actuating lever 6 while performing step 6 6 Turn limit switch shaft 3 in the required direction see below only enough to click the limit switch open and hold Then securely tighten setscrew 11 in the limit switch lever COUNTERCLOCKWISE for lower point CLOCKWISE for upper point 7 Test the limit switch for proper operation see Maintenance topic repeat the adjustment steps until the limit ...

Page 106: ...R e f e r e n c e O n l y ...

Page 107: ...ent Identification 1 1 Disassemble Boom 4 40 Drum Kicker Adjustment 4 54 English and Metric Conversions 1 7 General Maintenance 6 1 General Safety 4 1 General 4 1 Identification and Location of Components 1 2 Identifying Parts for Shipping 4 44 Inspection and Maintenance Checks 6 1 Introduction 1 1 Lube and Coolant Product Guide 5 1 Lubrication 5 1 Lubrication 5 1 Maintenance 6 1 Manitowoc Dealer ...

Page 108: ...R e f e r e n c e O n l y 16000 WIND ATTACHMENT OPERATOR S MANUAL Index 2 Published 03 18 13 Control 116 09 Wind Attachment Model Differences 1 4 Wind Conditions 3 1 Wire Rope Installation 4 48 ...

Page 109: ...R e f e r e n c e O n l y ...

Page 110: ...R e f e r e n c e O n l y ...

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