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MLC165-1
Manitowoc MLC165-1 User Manual
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Manitowoc
Published 08-06-19, Control # 237-0
9_v2
4-113
MLC165-1 OPERATOR MANUAL
SETUP AND INSTALLATION
4
Figure
4-87
4
Item
Description
1
Jib Stop Assembly
2
Jib Stop-to-Boom Pin
3O
f
f
s
e
t
P
i
n
4
Offset Link
5
Inner Tube
6
Jib Stop Pin
7
Shackle
8
Control Cable Extension
9
Sheave
10
Shackle
11
Control Cable from Winch
12
Winch
13
Shipping Pin
14
Safety Pin for Jib Stop Pin
15
Control Cable from Jib Stop
M100935
P546
M100936
M100937
6
12
11
9
6
2
3
13
14
STORED
STORED
14
INSTALLED
DISENGAG
ED
6
ENGAGED
15
25° off
set
5° offset
15° off
set
Vie
w A
Vie
w B
Vie
w C
Vie
w D
Vie
w E
5
7
8
8
10
1
226
228
Table of Contents
Default Chapter
5
Table of Contents
5
Section 1
13
Crane/Attachment Identification
13
Manitowoc Dealer
13
Change of Ownership Registration
13
In Case of Technical or Operation Issues
13
Crane Orientation
13
Identification and Location of Components
14
Crane Weights
16
Outline Dimensions
16
English and Metric Conversions
16
Section 2
19
California Precautions
21
Continuous Innovation
21
Nameplates and Decals
21
Safety Messages
21
General
21
Safety Alert Symbol
21
Signal Words
21
Symbol Identification
21
Safety Information
21
Safety and Information Signs
23
Maintaining Signs
23
Ordering Signs
23
Crane Access Points
26
General
26
Getting on or off Crane
26
Operator Manual/Capacity Chart Storage
27
General
27
Storing Manuals
27
Safe Operating Practices
28
General
28
Read Operator Manual
28
Operator Qualifications
28
Operator Conduct
28
Handling Load
30
Size of Load
30
Attaching Load
30
Lifting/Moving Load
31
Multiple Load Line Operation
32
Signals
33
Holding Load
33
Safety Devices
34
Operational Aids
34
Category 1 Operational Aids
34
Category 2 Operational Aids
35
Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines
36
Electrocution Hazard
36
Set-Up and Operation
36
Electrocution Hazard Devices
37
Electrical Contact
37
Refueling
38
Fire Extinguishers
38
Accidents
38
Safe Maintenance
38
Maintenance Instructions
38
Safe Maintenance Practices
38
Environmental Protection
40
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
45
Definition
45
Barge Mounted Crane
46
Examples
46
Definition
46
Capacity Charts for Barge Mounted Cranes
47
Shock Loading Caused by Barge Dynamics
47
Operation on Barge
48
Barge Mount Definitions
48
Inspection of Barge Mounted Crane
48
Transporting Crane on Barge
48
Section 3
49
Cab Controls and Indicators
52
Left Console
56
Foot Pedals
59
Front Console
60
Right Console
64
Overhead Console
68
Seat Controls
71
Camera Controls
72
Bypassable Limits Identification
74
Handle-To-Drum Identification
75
Boom Angle Indicator
76
RCL/RCI Warning Light
76
Upperworks Bubble Level
76
Setup Controls
78
Remote Control
78
Carbody Controls
80
Operating Limits and Faults
81
Boom Max up Limit
81
Minimum Bail Limit
81
Block-Up Limit
81
Mast too Far Forward
81
Rated Capacity Limit
81
Main Display Information Screen
82
Engine Warning Lights and Fault Codes
83
Tier 4 Engine Faults
83
Emergency Cab Exit
84
Cab Ventilation
84
Operating in Wind
85
Crawler Blocking
85
Operating Procedures
85
Preparing the Crane for Operation
85
Startup Procedure
86
Boom Hoist (Drum 4) Operation
89
Swing Operation
90
Drum 1 and Drum 2 Full Power Operation
91
Drum 1 or Drum 2 Free Fall Operation
92
Clamshell Operation
94
Travel Operation
96
Crane Shutdown or Leaving the Crane Unattended
98
Cold Weather Operation
99
Crane Limitations
99
Wire Rope
99
Cold Weather Starting Aid
99
Cooling System
99
Batteries
99
Engine Oil, Gear Oil, and Hydraulic Oil
99
AC Electric System
101
Turning on AC Components
101
Turning off AC Components
101
Cold Weather Heater Package
103
Standard Hand Signals for Controlling Crane Operations
104
Symbols Used on Control Consoles
106
Lifting Assembly Drawing
115
Boom and Jib Assembly Drawings
115
General Safety
115
Crane Orientation
115
Assembly and Disassembly Notes
115
Assembly and Disassembly Area
116
Accessing Parts
116
Crane Weights and Shipping Data
116
Retaining Connecting Pins
116
Parts Boxes
116
Pin and Connecting Hole Cleanliness
116
Hose and Cable Cleanliness
117
Connecting/Disconnecting Hydraulic Hoses and Electric Cables
117
Self-Assembly Components
117
Load Sensing Pins
117
Self-Assembly Controls
119
Setup Mode
120
Crane Assembly
125
Remove Crane from Trailer
125
Remove Cab Window Covers
126
Deploy Operator Cab
126
Install RCL/RCI Indicator Light
127
Install Rotating Bed Mirror
127
Raise Handrails
129
Perform Pre-Start Checks
131
Start Engine
131
Prepare Mast for Raising
133
Raise Mast to Vertical
133
Mast Working Angles
135
Install Crawlers - Preliminary Steps
136
Install First Crawler
137
Finish Installing Crawlers
141
Install Upperworks Platform Sections
143
Install Carbody Counterweight (Series 2)
145
Assemble Crane Counterweight
147
Install Crane Counterweight
151
Install Counterweight Work Lights
153
Remove Boom Butt from Trailer
154
Raise Boom Butt Wire Rope Guide
154
Raise Boom Stops
154
Attached Boom Butt to Crane
157
Assemble Boom to Boom Butt
158
Connect Mast Straps to Boom Straps
160
Connect Electric Cables from Crane to Boom Butt
161
Connect Boom Butt Hydraulic Hoses
163
Complete Boom and Jib Assembly
163
Raise Boom
165
Pre-Raising Checks
165
Boom Raising Procedure
165
Section 4
115
Shipping Crane Components
167
Crane Disassembly
167
Prepare Crane
167
Lower Boom
167
Remove Block-Up Limit Components
169
Store the Load Lines
169
Remove Boom Work Lights
169
Disconnect Boom Wiring
169
Disconnect Boom Butt Electric Cables
169
Disconnect Boom Butt Hydraulic Hoses
169
Disconnect Mast Straps from Boom Straps
171
Disconnect Boom Butt from Boom
173
Disassemble Boom from Boom Butt
173
Remove Boom Butt
175
Lower Boom Stops
177
Lower Boom Butt Wire Rope Guide
177
Lift Boom Butt Onto Trailer
177
Store Counterweight Work Lights
177
Remove Crane Counterweight
179
Disassemble Crane Counterweight
183
Remove Carbody Counterweight (Series 2)
185
Remove Upperworks Platforms
187
Remove Crawlers - Preliminary Steps
189
Remove First Crawlers
191
Remove Second Crawler
193
Store Upperworks Platform Sections
193
Lower Mast to Transport Position
195
Lower Handrails
195
Remove or Store Rotating Bed Mirror
195
Store RCL/RCI Indicator Light
195
Stop Engine
195
Install Window Covers
195
Store Operator Cab
195
Install Crane from Trailer
197
Boom Ladders
199
Installing the Ladders
199
Storing the Ladders
199
Boom and Jib Rigging
200
Assist Crane Requirements
200
Blocked Crawlers
200
Boom Handling with Mast
200
Assembly Drawings
200
Identifying Boom and Jib Components
200
Handling Components
202
Boom #74A Assembly
205
Assemble Boom Inserts
205
Install Intermediate Suspension Strut
207
Install Boom Top
209
Raise Wire Rope Guide
209
Remove or Install Lower Boom Point Sheave Clusters
213
Install the Upper Boom Point
214
Install Pile Driver Adapter for Fixed Leads
215
Install the Wind Speed and Position Light Components
216
Connect Boom Wiring
216
Install the Boom Load Lines
216
Install the Boom Block-Up Limit Components
216
Boom #74A Disassembly
217
Install Tagline Assembly
217
Remove Intermediate Suspension Strut
219
Jib #134 Assembly
221
Connect Jib Butt to Boom Top
222
Install Jib Inserts and Jib Top
222
Install Jib Pendants
223
Connect Backstay Pendants to Boom
225
Install the Jib Stop
226
Install the Wind Speed and Position Light Components
228
Connect the Jib Wiring
228
Install the Jib Load Lines
229
Install the Jib Block-Up Limit Components
229
Jib #134 Disassembly
230
Lower Boom and Jib
230
Store Jib Stop
230
Lower Jib Strut
230
Remove Backstay Pendants
230
Wire Rope Installation
231
Wire Rope Specifications
231
Wire Rope Storage
231
Seizing and Cutting Wire Rope
231
Remove Jib Pendants
231
Disassemble the Jib
231
Anchoring Wire Rope to a Drum
232
Winding Wire Rope Onto a Drum
232
Breaking in Wire Rope
233
Anchoring Wire Rope to Wedge Socket
235
Anchoring Wire Rope to Button Socket
235
Pad Eye Usage for Wire Rope Reeving
237
General
237
Safety
237
Rigging Winch Operation
238
Selecting Rigging Winch Mode
238
Operating Rigging Winch
239
Load Line Reeving
240
Guide Sheaves and Drums
240
Dead End Locations
240
Load Block Identification
240
Load Block Reeving
240
Load Block Tieback
244
General
244
Specifications
244
Shackle
244
Sling Length
244
Sling Capacity
244
Section 5
245
Lubrication
245
Lube and Coolant Product Guide
247
Section 6
251
Inspection and Maintenance Checklist
251
Fiberglass Maintenance
251
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Manitowoc MLC165-1 Specifications
General
Brand
Manitowoc
Model
MLC165-1
Category
Construction Equipment
Language
English
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