Manitowoc Crane MLC300 Operator Manual PDF

Description

Manitowoc Crane MLC300 Operator Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Crane MLC300 Operator Manual – PDF DOWNLOAD

Language : English
Pages :322
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc Crane MLC300 Operator Manual – PDF DOWNLOAD

SECTION 1 11
Introduction 13
Crane Data 13
Crane Weights 13
Outline Dimensions 13
Change of Ownership Registration 13
Manitowoc Dealer 13
Crane/Attachment Identification 13
Crane Orientation 13
Identification and Location of Components 15
English and Metric Conversions 18
Direct Conversion 18
Inverse Conversion 18
SECTION 2 21
Safety Information 23
Continuous Innovation 23
Nameplates and Decals 23
Safety Messages 23
General 23
Safety Alert Symbol 23
Signal Words 23
Symbol Identification 23
Safety and Information Signs 25
Maintaining Signs 25
Ordering Signs 25
Crane Access Points 28
General 28
Getting On or Off Crane 28
Personal Fall-Protection 29
Operator Manual/Capacity Chart Storage 30
General 30
Storing Manuals 30
Safe Operating Practices 31
General 31
Read Operator Manual 31
Operator Qualifications 31
Operator Conduct 31
Handling Load 33
Signals 36
Safety Devices 37
Operational Aids 37
Category 1 Operational Aids 37
Category 2 Operational Aids 38
Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines 39
Electrocution Hazard 39
Set-Up and Operation 39
Electrocution Hazard Devices 40
Electrical Contact 40
Refueling 41
Fire Extinguishers 41
Accidents 41
Safe Maintenance 41
Maintenance Instructions 41
Safe Maintenance Practices 41
Environmental Protection 43
Boom Disassembly Safety 45
General 45
Location 45
Pin Removal 45
Disassembly Precaution 45
Personnel Handling Policy 46
Pedestal/Barge Mounted Cranes 47
Pedestal Mounted Crane 48
Barge Mounted Crane 48
Capacity Charts for Barge Mounted Crane 49
Shock Loading Caused by Barge Dynamics 49
Operation on Barge 49
Barge Mount Definitions 50
Inspection of Barge-Mounted Crane 50
Transporting Crane on Barge 50
SECTION 3 51
Operating Controls And Procedures 53
Standard Hand Signals for Controlling Crane Operations 54
Symbols Used on Control Consoles 56
Symbols Used on Remote Control 59
Operating Controls 62
Left Console 66
Right Console 68
Seat Controls 80
Climate Control Keypad 81
Other Operator Aids 82
Motion Warning Lights and Alarms 86
Service Lights 88
Remote Control Activation 90
Remote Control Operation 92
Operating Limits Identification and Operation 98
Bypassing Limits in Luffing Jib Setup Mode 104
Resetting Luffing Jib Limits 105
Drum and Control Handle Identification 106
Right Cab Window Operation 109
Closing Window 109
Opening Window For Ventilation 109
Operator Cab Emergency Exit 109
Cab Door Adjustment 109
Cab Tilt Stop Pins Installation 109
Cab Tilt Speed Adjustment 109
Ladder Installation (Past) 111
Installing Ladder 111
Storing Ladder 111
Using Ladder (Working Position) 111
Removing Ladder 111
Ladder Installation (Current) 113
Installing Ladder 113
Storing Ladder 113
Using Ladder (Working Position) 113
Removing Ladder 113
Operating in Wind 114
Crawler Blocking 114
Intermediate Suspension 114
Preparing Crane for Operation 115
Startup Procedure 115
Operating Procedures 119
VPC Operation 119
Boom Hoist Operation 120
Luffing Hoist Operation 121
Swing Operation 122
Load Drum Operation (without free fall or with free fall disabled) 125
Load Drum Operation (with free fall enabled) 127
Free Fall Brake Pedal Hydraulic Pressure Test 129
Free Fall Brake Operational Test 129
Clamshell Operation 130
Travel Operation 132
Shutdown Procedure or Leaving the Crane Unattended 134
Changing Counterweight with Boom/ Jib In Air 135
VPC 135
VPC-MAX 135
Cold Weather Operation 137
Crane Limitations 137
Wire Rope 137
Cold Weather Starting Aid 137
Cooling System 137
Batteries 137
Engine Oil, Gear Oil, and Hydraulic Oil 137
Cold Weather Heater Package 139
Turning Heaters ON 139
Turning Heaters OFF 139
AC Operation 141
Installing APU 141
Turning ON AC Powered Components 141
Turning OFF AC Powered Components 141
Removing APU 141
SECTION 4 143
Setup and Installation 147
Lifting Assembly Drawing 147
Crane Weights and Shipping Data 147
General Safety 147
Crane Orientation 147
Boom and Jib Assembly Drawings 147
Optional Attachments 150
Accessing Parts 150
Assembly and Disassembly Notes 150
Assembly and Disassembly Area 150
Personal Fall-Protection 150
Handling Components 151
Retaining Connecting Pins 151
Crane Weights and Shipping Data 151
Parts Box 151
Assembly/Disassembly Components 152
Carbody Weights 152
Remote Control 155
Activating Remote Control 155
Starting Engine with Remote Control 155
Setup Mode 155
Pin and Connecting Hole Cleanliness 156
Hose and Cable Cleanliness 156
Hydraulic Hose Identification 156
Connecting/Disconnecting Hydraulic Hoses and Electric Cables 156
Tightening Hydraulic Couplers 157
Pre-Start Checks 157
Electric System 157
Engine 157
Gear Boxes 157
Hydraulic System 157
Swing Limits 159
Crane Assembly 161
Start Engine 161
Raise Operator Cab 161
Remove Carbody-Rotating Bed Module from Trailer 161
Deploy Operator Cab 163
Deploy Cab Rear Platform 163
Move Cab Tilt Stop Pins to Working Position 163
Remove Window Covers 165
Raise RCL Light to Working Position 165
Deploy Right Side Rear View Mirror 165
Move Rotating Bed Left-Front Platform to Working Position 167
Move Rotating Bed Left-Front Ladder to Working Position 167
Install Rotating Bed Handrails 169
Deploy Rotating Bed Left-Rear Platform 169
Deploy Valve Cover Platforms 169
Deploy Exhaust Shield 169
Using Rotating Bed Left-Rear Ladder 171
Remove Live Mast Package from Trailer 173
Install Live Mast Package 177
Install Drum 2 181
Install Drum 3 181
Camera Connections 185
Activate Setup Mode 186
Raise Live Mast 186
Live Mast Operating Precautions 187
Lubricate Crawler-to-Carbody Machined Surfaces 189
Install First Crawler 191
Install Second Crawler 193
Install Crawler Ladders 193
Install Carbody Front and Rear Platforms 194
Deploy Carbody Side Platforms 194
Prepare VPC Trolley 197
Install VPC Trolley 199
VPC Trolley Limit Switch Checks 205
Remove Counterweight Tray from Trailer 205
Remove Counterweight Boxes from Trailer 206
Prepare Counterweight Tray 206
Install Counterweight Tray 209
Install Counterweight Boxes 211
Block Crawlers 213
Boom and Jib Rigging — General 213
Assist Crane Requirements 213
Assembly Drawings 213
Identifying Boom and Jib Components 213
Handling Components 215
Boom #500 Assembly 217
Connect Boom Butt to Crane 217
Assemble Boom Inserts 219
Install Intermediate Wire Rope Guide 223
Install Drop-Down Suspension 225
Install Boom Top 227
Raise Boom Top Wire Rope Guide 229
Install Position Light and Wind Speed Indicator 229
Connect Boom Top Electric Cables 229
Connect Boom Straps 231
Install/Remove Lower Boom Point 233
Remove/Install Lower Boom Point Sheaves 233
Install Upper Boom Point 235
Connect Terminator/Shorting Plugs at Boom Top 235
Close Boom 237
Connect Mast Straps to Boom Straps 239
Deactivate Setup Mode 239
Connect Hydraulic Hoses from Crane to Boom Butt 241
Connect Electric Cables from Boom Butt to Crane 241
Install Boom Top Camera and Connect Electric Cables 243
Install the Boom Load Lines 245
Install Boom Block-Up Limit Components 245
Prepare Intermediate Suspension Pendants 247
Raise Boom 248
Pre-Raising Checks 248
Boom Raising Procedure 248
Shipping Crane Components 249
Lower Boom 250
Boom Disassembly 251
Remove Block-Up Limit Components 251
Store the Load Lines 251
Disconnect Boom Butt Electric Cables 251
Disconnect Boom Butt Hydraulic Hoses 251
Activate Setup Mode 253
Disconnect Mast Straps from Boom Straps 253
Open Boom 255
Disassemble Boom Sections 255
Disconnect Boom Butt from Crane 257
Crane Disassembly 259
Remove Counterweight Boxes 259
Remove Counterweight Tray 261
Remove VPC Trolley 263
Prepare VPC Trolley for Shipping 267
Store Carbody Side Platforms 269
Remove Carbody Front and Rear Platforms 269
Prepare Crawlers for Removal 269
Remove First Crawler 271
Remove Second Crawler 273
Lower Live Mast to Transport Position 275
Remove Drum 2 277
Remove Drum 3 277
Install/Store Rotating Bed Platforms 277
Remove Live Mast Package 278
Install Live Mast Package on Trailer 285
Store Rotating Bed Left-Rear Platform and Handrails 289
Remove Rotating Bed Handrails 289
Remove Rotating Bed Left-Rear Ladder 289
Move Rotating Bed Left-Front Ladder to Working Position 291
Move Rotating Bed Left-Front Platform to Working Position 291
Store Right Side Rear View Mirror 293
Store RCL Light 293
Move Cab Tilt Stop Pins to Shipping Position 293
Store Cab Rear Platform 293
Secure Operator Cab 293
Install Window Covers 293
Store Operator Cab 293
Install Carbody-Rotating Bed Module on Trailer 295
Store Remote Control 295
Final Checks 295
Wire Rope Installation 297
Wire Rope Specifications 297
Wire Rope Storage 297
Seizing and Cutting Wire Rope 297
Anchoring Wire Rope to Drum 298
Winding Wire Rope onto Drum 298
Anchoring Wire Rope to Wedge Socket 301
Anchoring Wire Rope to Button Socket 301
Pad Eye Usage for Wire Rope Reeving 303
Breaking in Wire Rope 303
Rigging Winch Operation 304
Selecting Rigging Winch Mode 304
Operating Rigging Winch 305
Load Line Reeving 307
Guide Sheaves and Drums 307
Dead End Locations 307
Load Block Identification 307
Duplex Hook 307
Wire Rope Specifications 307
Load Block Reeving 307
Load Block Tieback 309
General 309
Specifications 309
SECTION 5 311
Lubrication 313
Lubrication 313
Lube and Coolant Product Guide 313
SECTION 6 315
Maintenance Checklist 317
Inspection and Maintenance Checklist 317
Fiberglass Maintenance 317

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