Manitowoc Crane MLC650 Operator Manual PDF

Description

Language : English
Pages : 360
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc Crane MLC650 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 14
VPC and VPC-MAX 16
English and Metric Conversions 16
Direct Conversion 16
Inverse Conversion 16
SECTION 2 19
Safety Information 21
Continuous Innovation 21
Nameplates and Decals 21
Safety Messages 21
General 21
Safety Alert Symbol 21
Signal Words 21
Symbol Identification 21
Safety and Information Signs 23
Maintaining Signs 23
Ordering Signs 23
Crane Access Points 26
General 26
Getting On or Off Crane 26
Personal Fall-Protection 27
Operator Manual/Capacity Chart Storage 28
General 28
Storing Manuals 28
Safe Operating Practices 29
General 29
Read Operator Manual 29
Operator Qualifications 29
Operator Conduct 29
Handling Load 31
Signals 34
Safety Devices 35
Operational Aids 35
Category 1 Operational Aids 35
Category 2 Operational Aids 36
Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines 37
Electrocution Hazard 37
Set-Up and Operation 37
Electrocution Hazard Devices 38
Electrical Contact 38
Refueling 39
Fire Extinguishers 39
Accidents 39
Safe Maintenance 39
Maintenance Instructions 39
Safe Maintenance Practices 39
Environmental Protection 41
Boom Disassembly Safety 43
General 43
Location 43
Pin Removal 43
Disassembly Precaution 43
Personnel Handling Policy 44
Pedestal/Barge Mounted Cranes 45
Pedestal Mounted Crane 46
Barge Mounted Crane 46
Capacity Charts for Barge Mounted Crane 47
Shock Loading Caused by Barge Dynamics 47
Operation on Barge 47
Barge Mount Definitions 48
Inspection of Barge-Mounted Crane 48
Transporting Crane on Barge 48
SECTION 3 49
Operating Controls And Procedures 51
Standard Hand Signals for Controlling Crane Operations 52
Symbols Used on Control Consoles 54
Symbols Used on Remote Control 57
Operating Controls 62
Left Console 66
Right Console 68
Operation of Diverting Circuits 77
Foot Pedals 78
Seat Controls 79
Climate Control Keypad 80
Other Operator Aids 81
Motion Warning Lights and Alarms 86
Service Lights 88
Remote Control Activation 90
Remote Control Operation 0
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 108
Closing Window 108
Opening Window For Ventilation 108
Operator’s Cab Emergency Exit 108
Cab Door Adjustment 108
Cab Tilt Adjustment 109
Operating in Wind 109
Crawler Blocking 110
Intermediate Suspension 110
Preparing Crane for Operation 110
Startup Procedures 111
Operating Procedures 115
VPC Operation 115
Boom Hoist Operation 116
Luffing Hoist Operation 117
Swing Operation 118
Load Drum Operation 121
Travel Operation 122
Shutdown Procedure or Leaving the Crane Unattended 124
Changing Counterweight with Boom/ Jib In Air 125
VPC 125
VPC-MAX 125
Cold Weather Operation 127
Crane Limitations 127
Wire Rope 127
Cooling System 127
Batteries 127
Engine Oil, Gear Oil, and Hydraulic Oil 127
Cold Weather Heater Package 129
Turning Heaters ON 129
Turning Heaters OFF 129
AC Operation 131
Installing APU 131
Turning ON AC Powered Components 131
Turning OFF AC Powered Components 131
Removing APU 132
SECTION 4 133
Set-Up and Installation 137
Boom and Jib Assembly Drawings 137
Liftcrane Mast Handling Capacities 137
Optional Attachments 137
General Safety 137
Crane Orientation 137
Assembling and Disassembling Notes 137
Assembly And Disassembly Area 138
Accessing Parts 138
Retaining Connecting Pins 138
Crane Weights and Shipping Data 138
Personal Fall-Protection 139
Handling Components 139
Crane Assembly Components 141
Parts Box 141
Swing Limits 144
Hydraulic Hose Identification 146
Connecting/Disconnecting Hydraulic Hoses and Electric Cables 146
Hose and Cable Cleanliness 146
Pin and Connecting Hole Cleanliness 146
Tightening Hydraulic Couplers 146
Remote Control 148
Activating the Remote Control 149
Starting Engine with Remote Control 149
Rotating Bed Jacking Cylinders Function 149
Setup Mode 149
Identification and Location of Components 150
Crane Assembly 151
Remove Cab Window Covers 151
Perform Pre-Start Checks 153
Electric System 153
Hydraulic System 153
Gear Boxes 153
Deploy Operator Cab Platform 155
Start Engine 155
Remove Rotating Bed from Trailer 159
Install Alignment Pendants 159
Deploy Rotating Bed Jacking Cylinders 159
Install Operator Cab Rear Platform 160
Install Operator Cab Ladder 161
Overview of Rotating Bed Platforms and Handrails 163
Deploy Rotating Bed Platforms 165
Install Platforms, Ladders and Handrails 167
Install Drum 3 169
Activate Auxiliary Hydraulic System 170
Connect Hand-Held Pin Puller 173
Install the Live Mast 174
Secure the Backhitch/Gantry Assemblies 177
Secure the Live Mast Hoist Drum 179
Disconnect the Live Mast Straps 179
Connect the Live Mast Hydraulic and Electrical 181
Activate Setup Mode 182
Raise Live Mast to Operating Position 182
Deploy the Self-Erect Cylinder 185
Use the Mast as a Boom 185
Aligning Rotating Bed to Carbody 187
Attaching Rotating Bed to Adapter Frame 189
Removing Carbody Cavity Platform 189
Deploying Carbody Jacking Cylinders 191
Storing Rotating Bed Jacking Cylinders 192
Installing Hydraulic Connections 193
Deploying Operator Cab (Working Position) 196
Installing Crawlers 197
Storing Carbody Jacking Cylinders 203
Installing Carbody Cavity Platform 204
Installing Crawler Drive Shafts 207
Installing Carbody Platforms 208
Installing Carbody Ladders and Handrails 209
Installing Front Platforms, Ladders, and Handrails from Rotating Bed and Cab 211
Installing Counterweight Tray 213
Installation of the Hydraulic Hoses 217
Align the Counterweight Tray to the Pinions 217
Remove Counterweight Boxes from Trailer 219
Assemble Boom and Jib 219
Install Counterweight Boxes 219
Boom And Jib Rigging—General 224
Assist Crane Requirements 224
Blocked Crawlers 225
Boom Handling with Mast 225
Assembly Drawings 225
Identifying Boom and Jib Components 225
Handling Boom and Jib Sections 227
Boom Ladders 229
General 229
Removing Ladders from Insert 229
Installing Ladders on Boom Inserts 229
Storing Ladders in Insert 229
Boom Assembly 231
Assemble Boom Inserts and Top 231
Raise Boom Top Wire Rope Guide 241
Install/Remove Lower Boom Point 243
Install Position Light and Wind Speed Indicator 245
Connect Boom Straps 247
Install Upper Boom Point 249
Connect Terminator/Shorting Plugs at Boom Top 249
Prepare 4M Insert 253
Raise Wire Rope 253
Connect 4M Insert to Boom Butt 255
Lower Carbody Platform 255
Connect Boom Butt to Crane 257
Lower Boom Butt and 4M Insert 259
Raise Carbody Platform 259
Connect Hydraulic Hoses from Crane to Boom Butt 261
Connect Electric Cables from Boom Butt to Crane 261
Connect 4M to Boom 263
Connect Mast Straps to Boom Straps 265
Deactivating Setup Mode 265
Connect Camera and Electric Cables 267
Install the Boom Load Lines 269
Install the Boom Block-Up Limit Components 269
Prepare Intermediate Suspension Pendants 271
Raise Boom 272
Pre-Raising Checks 272
Boom Raising Procedure 272
Shipping Crane Components 273
Crane Disassembly 274
Preparing Crane 274
Lowering Boom 274
Removing Block-Up Limit Components 274
Storing the Load Lines 274
Removing Boom Top Cameras 274
Disconnecting Boom Butt Electric Cables 274
Disconnecting Boom Butt Hydraulic Hoses 274
Activating Setup Mode 277
Disconnecting Mast Straps from Boom Straps 277
Lowering Carbody Platform 277
Disconnecting Boom from 4M Insert 279
Deploying Self-Erect Cylinder 279
Removing Boom Butt and 4M 280
Separating 4M Insert from Boom Butt 283
Lowering the Wire Rope Guide 283
Loading Boom Butt 284
Raising Carbody Platform 284
Disassembling Boom 285
Removing Counterweight Boxes 286
Preparing Counterweight Tray for Removal 288
Disconnecting Counterweight Tray Hydraulics and Electrical Wiring 289
Removing Counterweight Tray 291
Removing Carbody Platforms 293
Removing Carbody Cavity Platforms 293
Disconnecting and Storing Drive Shafts 295
Deploying Carbody Jacking Cylinders 297
Removing First Crawler 299
Removing First Crawler (continued) 300
Removing Second Crawler 303
Deploying Rotating Bed Jacking Cylinders 305
Storing Carbody Jacking Cylinders 307
Installing Carbody Cavity Platforms 307
Disconnecting Carbody from Rotating Bed 309
Disconnecting Hydraulic Hoses 310
Removing Carbody and Adapter Frame from Rotating Bed 311
Storing Self-Erect Cylinder 313
Securing Live Mast, Gantry, and Backhitch 315
Removing Drum 3 317
Disconnecting Live Mast Hydraulics and Electrical Connectors 319
Removing Live Mast 319
Removing Rotating Bed Handrails and Rear Platform 323
Removing Front Platform and Ladders From Rotating Bed and Cab 324
Storing Rotating Bed Platforms 326
Moving Operator Cab (Shipping Position) 328
Removing Operator Cab Ladder 329
Removing Operator Cab Rear Platform 330
Storing Operator Cab Front Platform 331
Securing Operator Cab 332
Extending Rotating Bed Jacking Cylinders 333
Lowering Rotating Bed Jacking Cylinders 335
Installing Cab Window Covers (If Equipped) 336
Wire Rope Installation 337
Wire Rope Specifications 337
Wire Rope Storage 337
Seizing and Cutting Wire Rope 337
Anchoring Wire Rope to Drum 338
Winding Rope onto Drum 338
Anchoring Wire Rope to Wedge Socket 341
Anchoring Wire Rope to Button Socket 341
Pad Eye Usage for Wire Rope Reeving 343
Breaking in Wire Rope 343
Rigging Winch Operation 344
Selecting Rigging Winch Mode 344
Operating Rigging Winch 345
Load Line Reeving 347
Guide Sheaves and Drums 347
Load Block Identification 347
Duplex Hook 347
Wire Rope Specifications 348
Load Block Reeving 348
Dead End Locations 348
SECTION 5 349
Lubrication 351
Lubrication 351
Lube and Coolant Product Guide 351
SECTION 6 353
Maintenance Checklist 355
Inspection and Maintenance Checklist 355
Fiberglass Maintenance 355

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