Manitowoc Cranes MLC165-1 Supplement Operator Manual PDF

Operator Manual Supplement Model MLC165-1

Published 09-27-18

F2318-1

Model MLC165-1 Operator Manual Supplement

© 2018 Manitowoc.

Due to continuing product innovation, specifications in this manual are subject to change without notice.

F2318-2

Published 09-27-18

Model MLC165-1 Operator Manual Supplement

1.0

Introduction ................................................................................................ 5

2.0

Safety........................................................................................................... 5

3.0

4.0

5.0

2.1

General............................................................................................................................................... 5

2.2

Manitowoc’s Personnel Handling Policy............................................................................................. 5

Weather Station .......................................................................................... 9 3.1

Weather Station General.................................................................................................................... 9

3.2

Weather Station Installation ............................................................................................................... 9

3.3

Weather Station Sensor Storage for Shipping ................................................................................... 9

Crane Tie-Downs ...................................................................................... 11 4.1

Tie-Down General ............................................................................................................................ 11

4.2

Tie-Down Crawler Modification ........................................................................................................ 11

4.3

Tie-Down Installation........................................................................................................................ 11

240VAC Options ....................................................................................... 13 5.1

AC Options General ......................................................................................................................... 13

5.2

AC Options Installation..................................................................................................................... 13

5.3

6.0

7.0

240VAC Load Center .......................................................................................................... 13

5.2.2

Battery Charger ................................................................................................................... 13

5.2.3

Boom Lighting ..................................................................................................................... 13

5.2.4

Rotating Bed Lighting .......................................................................................................... 13

5.2.5

Light Switches ..................................................................................................................... 15

5.2.6

5kW Generator .................................................................................................................... 15

AC Options Operation ...................................................................................................................... 17 5.3.1

Turning On AC Components ............................................................................................... 17

5.3.2

Turning Off AC Components ............................................................................................... 17

Drum 1 Personnel Handling Mode.......................................................... 18 6.1

Enabling Personnel Handling Mode ................................................................................................. 18

6.2

Disabling Personnel Handling Mode ................................................................................................ 19

Emergency Lowering System ................................................................. 21 7.1 7.2

8.0

5.2.1

Emergency Lowering System Installation ........................................................................................ 21 Emergency Lowering Procedure ...................................................................................................... 21 7.2.1

Power Unit Connection Procedure ...................................................................................... 21

7.2.2

Emergency Load Lowering Procedure ................................................................................ 21

7.2.3

Power Unit Disconnection Procedure.................................................................................. 23

Reference Publications............................................................................ 24

Manitowoc

Published 09-27-18

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Model MLC165-1 Operator Manual Supplement

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F2318-4

Published 09-27-18

Model MLC165-1 Operator Manual Supplement

1.0

Introduction

This publication supplements the Operator Manual supplied with your Model MLC165-1. It contains installation, operation, and maintenance instructions for the following optional features provided in Lift Solution 801900: •

Weather Station

•

Crane Tie-Downs

•

Lighting Package, to include: – Load Center – 5.0kW Generator – Boom Lights – Rotating Bed Lights

•

Drum 2 as a Personnel Handling Winch with Emergency Lowering

2.0 2.1

Safety General

To prevent accidents that can result in death or injury, read and understand: •

Safety Information in Section 2 of the MLC165-1 Operator Manual

•

Safe Maintenance Practices in Section 1 of the MLC165-1 Service Manual

2.2

Manitowoc’s 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 states, “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 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 must be reviewed relative to the current standard.

This new standard is consistent with the U.S. Department of Labor, Occupational Safety and Health Administration (OSHA) regulations for Construction that state, in 29CFR1926.1431(a): 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.

Use of a Manitowoc crane to handle personnel is acceptable provided: •

The crane user shall comply with the manufacturer’s specifications and limitations for lifting accessories (hooks, slings, personnel platforms, etc.).

•

The requirements of the applicable national, state, and local regulations and safety codes are met.

•

A determination has been made that use of a crane to handle personnel is the least hazardous means to perform the work.

•

The crane operator shall be qualified to operate the specific type of hoisting equipment used in the personnel lift.

•

The crane operator shall remain in the crane cab at all times when personnel are off the ground.

•

The crane operator and occupants have been instructed in the recognized hazards of personnel platform lifts.

•

The crane is in proper working order.

Manitowoc

Published 09-27-18

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Model MLC165-1 Operator Manual Supplement

•

Load and boom hoist drum brakes, swing brakes, and locking devices such as pawls and dogs must be engaged when the occupied personnel platform is in a stationary position.

•

The crane must be equipped with a boom angle indicator that is visible to the crane operator.

•

The crane must be equipped with a boom hoist limiting device.

•

If the luffing jib is used for hoisting personnel, the crane must be equipped with a luffing jib angle indicator that is visible to the crane operator.

•

If the luffing jib is used for hoisting personnel, the crane must be equipped with a luffing hoist limiting device.

•

The crane is equipped with a positive acting device which prevents contact between the hook block or hook-andweight ball and the boom or jib point (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 must 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).

NOTE: Free fall of the hoist line is prohibited.

•

The crane’s Operator Manual is in the crane’s cab, readily accessible to the operator.

•

The crane’s load Capacity Chart is affixed inside the crane cab, readily accessible to the operator. The total weight of the loaded personnel platform and related rigging must not exceed 50 percent of the rated capacity for the radius and configuration of the crane. Additionally, the line pull must not exceed 50 percent.

•

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 or stabilizers must have them all extended and locked. All outriggers or stabilizers must be extended equally in accordance with the Capacity Charts and operating procedures.

•

Handling personnel from a platform suspended by wire rope from a luffing jib is acceptable, but only when it is not possible to accomplish the task using a less hazardous means. The crane user and operator shall take into account hazards that may be present when using a luffing jib.

•

Direct attachment of a personnel platform to a luffing jib is prohibited.

•

The platform meets the requirements as prescribed by applicable standards and regulations.

•

Applicable personal protection equipment is provided (such as personal fall-protection system).

•

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.

•

Personnel platforms must not be used in winds exceeding 9 m/s (20 mph) at the hoisted platform height or in

electric storms, snow, ice, sleet, or other adverse weather conditions which could affect the safety of personnel.

•

Hoisting personnel within 6 m (20 ft) of a power line that is up to 350kV or within 15 m (50 ft) of a power line that is over 350kV is PROHIBITTED, except for work covered in OSHA 29CFR1926 subpart V.

For operation outside the United States, the requirements of the applicable national, state, and local regulations and safety codes must be met. In addition to the above, this may include the following: •

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) must be provided in the hydraulic or pneumatic systems to prevent uncontrolled movement of the hoisting equipment in the case of a system failure.

Manitowoc Cranes 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 Cranes recommends that cranes be properly maintained, regularly inspected, and repaired as necessary. All safety signs must be in place and legible. We also urge Manitowoc crane owners to upgrade their cranes with rated capacity indicator/limiter systems for all lifting operations.

If you have any questions about this subject or other product safety matters relating to the operation and use of a Manitowoc crane, please contact your Manitowoc Cranes dealer or the Product Safety and Reliability Department at the following address: Manitowoc Cranes, 2401 So. 30th St., Manitowoc, WI 54220 Phone: 920-684-6621 Manitowoc

Published 09-27-18

F2318-7

Model MLC165-1 Operator Manual Supplement

Item

Description

1

Weather Station Display

2

Weather Station Sensor

3

Mounting Hardware

3a

Cap Screw (qty 2)

3b

Flat Washer (qty 4)

3c

Lock Washer (qty 2)

3d

Nut (qty 2)

4

Mounting Bracket

5

Nut Assembly

Working Position

Shipping Position

FIGURE 1 F2318-8

Published 09-27-18

Model MLC165-1 Operator Manual Supplement

3.0

Weather Station

See Figure 1.

3.1

Weather Station General

The weather station consists of the following components: 1 – B&G Triton2 Digital Display (2) mounted inside the operator cab.

2 – Airmar 220WX Weather Station Sensor (1) mounted on the operator cab.

The weather station can be programmed by the operator to show the desired operating information, such as: •

Wind speed

•

Barge tilt and roll

Refer to the B&G Triton2 Operator Manual at the end of this publication.

3.2

Weather Station Installation

Install the weather station components per Drawing 80110301 at the end of this publication.

3.3

Weather Station Sensor Storage for Shipping

To STORE the weather station sensor for shipping, proceed as follows (see Figure 1): 1.

Remove the mounting hardware (3) from the working position.

2.

Orient the bracket (4) in the shipping position and securely reinstall the mounting hardware (3).

3.

Unscrew the nut assembly (5) and disconnect the sensor (2) from the cable connector.

4.

Place the sensor in a protective box and store it for shipping in the operator cab.

5.

Apply heat shrink wrap to the exposed cable connector to protect it during shipping.

To DEPLOY the weather station sensor, proceed as follows (see Figure 1): 1.

Remove the heat shrink wrap from the exposed cable connector.

2.

Remove the sensor (2) from storage in the operator cab.

3.

Align key with keyway and attach the sensor (2) to the cable connector.

4.

Securely tighten the nut assembly (5).

5.

Remove the mounting hardware (3) from the shipping position.

6.

Orient the bracket (4) in the working position and securely reinstall the mounting hardware (3).

Manitowoc

Published 09-27-18

F2318-9

Model MLC165-1 Operator Manual Supplement

Item

Description

1

Crawler Assembly (qty 2)

2

Carbody

3

Barge Deck

4

Crawler Modification

5

Turnbuckle (qty 8)

6

Pin with Cotter Pins (qty 16)

FIGURE 2 F2318-10

Published 09-27-18

Model MLC165-1 Operator Manual Supplement

4.0

Crane Tie-Downs

See Figure 2.

4.1

Tie-Down General

The turnbuckles (5) are provided to secure the crane for operation on a barge deck.

Each tie-down (turnbuckle) is rated to withstand an in-line load of 26,000 lb.

4.2

Tie-Down Crawler Modification

To enable use of the turnbuckles, the crawler frames must be modified as instructed in Drawing 80111048 — Crawler Mod, Barge Tie-Down provided at the end of this publication.

The modification must be performed by a weld technician who has passed the Manitowoc Advanced Field Repair Course per Weld Instruction 00MFWI153 at the end of this publication.

All welded surfaces must be cleaned and painted with zinc-rich epoxy primer and Manitowoc gloss black paint.

4.3

Tie-Down Installation

1.

Center the crane on the barge between the mounting lugs.

2.

Apply anti-seizing lubricant to all pins, bores, and threads.

3.

Using pins (6), pin the turnbuckles (5) to the mounting lugs on the crawler (1) and the barge (3).

4.

Tighten each turnbuckle so there is minimum thread engagement of 30 mm (1-3/16 in) at both ends the turnbuckle.

Manitowoc

Published 09-27-18

F2318-11

Model MLC165-1 Operator Manual Supplement

Item

Description

1A

Light Assembly, Boom Top (qty 2)

1B

Light Assembly, Boom Section (qty varies)

2

Light Switches in Cab

3

Load Center

4

Battery Charger

5

5kW Generator

6

Light Assembly, Rotating Bed (qty 2)

7

Electric Cable from Generator

8

Receptacle

View A

View B

View C View F

View D

FIGURE 3

View E

F2318-12

Published 09-27-18

Model MLC165-1 Operator Manual Supplement

5.0

240VAC Options

See Figure 3.

5.1

AC Options General

The AC Options consist of the following components: 1 - Boom Lighting in the boom top (1A) and the boom sections (1B) 2 - Light Switches in the crane cab 3 - Load Center with applicable circuit breakers 4 - Battery Charger 5 - 5kW Diesel Generator 6 - Rotating Bed Lighting

5.2

AC Options Installation

For the following installation procedures: 1.

Lower the boom onto blocking at horizontal.

2.

Lower the mast to the transport position.

3.

Stop the engine, remove the ignition key, and place a warning sign at the ignition switch to alert other personnel that the crane is being serviced and the engine must not be started. Do not remove the sign until it is safe to return the crane to service.

4.

To avoid damage to the crane’s control system, read and follow the Welding Hazard Avoidance instructions in Section 1 of your MLC165-1 Service Manual.

5.2.1 240VAC Load Center Install the load center per Drawing 80108292 at the end of this publication.

5.2.2 Battery Charger Install the battery charger per Drawing 80108626 at the end of this publication.

5.2.3 Boom Lighting 1.

2.

Modify the boom top per Drawing 80106577 at the end of this publication.

•

The modification must be performed by a weld technician who has passed the Manitowoc Advanced Field Repair Course per Weld Instruction 00MFWI153 at the end of this publication.

•

All welded surfaces must be cleaned and painted with zinc-rich epoxy primer and Manitowoc gloss black paint.

Install the boom lighting per Drawing 80106634 and Drawing 80101782 at the end of this publication.

•

The angle of the boom lights can be adjusted as shown in Drawing 80101782.

•

The insert lights can be stored as shown in Drawing 80101782.

5.2.4 Rotating Bed Lighting 1.

2.

Modify the mast per Drawing 80108291 at the end of this publication.

•

The modification must be performed by a weld technician who has passed the Manitowoc Advanced Field Repair Course per Weld Instruction 00MFWI153 at the end of this publication.

•

All welded surfaces must be cleaned and painted with zinc-rich epoxy primer and Manitowoc gloss black paint.

Install the rotating bed lighting per Drawing 80108290 at the end of this publication.

•

The angle of the rotating bed lights can be adjusted in the same manner the boom lights are adjusted.

Manitowoc

Published 09-27-18

F2318-13

Model MLC165-1 Operator Manual Supplement

Item

Description

1

Mounting Pad (qty 2 on counterweight tray)

2

Mounting Bracket with Cap Screws and Lock Washers (qty 2)

3

Pin with Safety Pins (qty 2)

4

Generator Assembly (80108293)

5

Fuel Lines (qty 2)

6

Electric Cable

7

Catwalk

8

Quick-Release Pin (qty 2)

W

Working Hole

S

Shipping Hole

Shipping

Working

FIGURE 4

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Model MLC165-1 Operator Manual Supplement

5.2.5 Light Switches Install the light switches in the operator cab per Drawing 80108321 at the end of this publication.

5.2.6 5kW Generator See Figure 4.

The diesel powered, 5kW, 120/240V, 60HZ, single-phase generator is mounted on the right-front side of the counterweight. It is used to power the light package and the emergency lowering hydraulic power unit.

Before operating the generator, read and understand the maintenance and operating instructions in the Generator Operator Manual at the end of this publication.

5.2.6.1 Generator Installation 1.

Install the generator fuel piping on the crane per Drawing 81040569 at the end of this publication.

2.

Fasten the mounting brackets (2) to the mounting pads (1) on the counterweight tray with the mounting screws and lock washers provided. Apply Loctite 243 to the threads of the mounting screws and torque them 178 Nm (130 ft-lb).

3.

Using owner supplied lifting slings from an assist crane or a fork-lift truck, lift the generator assembly (4) into position.

The unit weighs 330 kg (728 lb).

4.

Remove the pins (3) from storage.

5.

Lower the generator assembly so that it hooks onto the mounting brackets (2).

6.

Install the pins (3).

7.

Connect the fuel lines (5) from the generator to the fuel lines under the right catwalk on the crane.

8.

Connect the electric cable (6) from the generator to the receptacle in the right enclosure on the crane (see View D, Figure 3 on page 12).

9.

Lower and pin the catwalk (7) in the working position.

5.2.6.2 Generator Removal See Figure 4.

1.

Turn off all AC components and stop the generator engine.

2.

Disconnect the generator fuel lines (5) from the fuel line couplers under the right catwalk on the crane.

3.

Disconnect the generator electric cable (6) from the receptacle in the right enclosure on the crane (see View D, Figure 3 on page 12.

4.

Secure the fuel lines and the electric cable to the generator assembly.

5.

Raise and pin the catwalk (7) in the shipping position.

6.

Use owner supplied lifting slings and an assist crane or a fork-lift truck to lift the generator assembly (4). The unit weighs 330 kg (728 lb).

7.

Remove the pins (3) and lift the generator assembly away from the crane.

8.

Reinstall the pins (3) in the holes in the generator.

Manitowoc

Published 09-27-18

F2318-15

Model MLC165-1 Operator Manual Supplement

Item

Description

1

Generator

2

Light Switches in Cab

3

Load Center

3A

50A Main Circuit Breaker

3B

15A Circuit Breaker: Boom Work Lights

3C

15A Circuit Breaker: Rotating Bed Work Light

3D

Cold Weather Heater Circuit Breakers (if equipped)

4

240VAC Receptacle

5

Electric Cable

FIGURE 5

F2318-16

Published 09-27-18

Model MLC165-1 Operator Manual Supplement

5.3

AC Options Operation

See Figure 5.

WARNING Electrocution Hazard!

Severe electric shock can cause death or serious injury.

The crane owner/user must make provisions for turning off the electrical power supply before connecting the electric cable from a shore-mounted generator.

5.3.1 Turning On AC Components 1.

Turn off the generator (1).

2.

In the load center (2), check that the main circuit breaker and each individual circuit breaker is off.

3.

In the operator cab, make sure the work light switches (2) are off.

4.

Connect the electric cable (5) from the generator to the receptacle (4) in the right enclosure.

•

If desired, power can be supplied by a shore-mounted (customer supplied) generator.

•

The electric cable (5) from the crane-mounted generator can remain connected at all times.

5.

Turn on the generator.

6.

In the load center (3), first turn on the main circuit breaker and then turn on the desired individual circuit breakers.

7.

In the operator cab, turn on work light switches (2).

5.3.2 Turning Off AC Components 1.

In the operator cab, turn off the work light switches (2).

2.

In the load center (3), turn off the individual circuit breakers and then the main circuit breaker.

3.

Turn off the generator (1).

4.

For a shore-mounted generator, unplug the electric cable from the receptacle (4).

Manitowoc

Published 09-27-18

F2318-17

Model MLC165-1 Operator Manual Supplement

6.0

Drum 1 Personnel Handling Mode

Drum 1 (whip line) is used for personnel handing. When the personnel handling mode is enabled: •

Drum 1 line speed is reduced to a maximum of 90 ft/min (approximately 10 rpm).

•

Drum 1 capacities are reduced 50 percent of the rated capacity printed on the chart or 50 percent capacity based on the maximum line pull.

•

Travel and all other load drums are disabled. The invalid configuration fault will come on if you attempt to operated another load drum.

The personnel handling mode remains in affect even if the engine is stopped and restarted.

WARNING Fall Hazard!

To prevent death or serious injury, read and comply with “Manitowoc’s Personnel Handling Policy”, on page 1-5.

The crane operator must remain seated in the operator’s cab and maintain a constant line of sight and communication with the occupants of the personnel handling platform while they are suspended midair. Use a signal person when limited visibility is unavoidable. If the use of a signal person creates a hazardous situation, then use radio communication.

Main Display Screen

Once Personnel Handling is enabled, the personnel handling prompt will flash on all screens.

Function Selection Screen

Drum 1 Function Screen

6.1

FIGURE 6

Enabling Personnel Handling Mode

1.

Position the crane on a firm, level, uniformly supporting surface in the desired work area.

2.

Read and become thoroughly familiar with “Manitowoc’s Personnel Handling Policy”, on page 1-5. Read and comply with your local, state, or national regulations for handling personnel from a mobile crane.

3.

Land the loads from Drums 2 and 3 and disconnect the loads from the hooks.

4.

Raise the hooks from Drums 2 and 3 to the desired position and park the drums so they do not interfere with operation of Drum 1.

5.

Disable Drum 1 free fall. Free fall cannot be enabled when the personnel handling mode is enabled.

F2318-18

Published 09-27-18

Model MLC165-1 Operator Manual Supplement

6.

At the Main Display Screen, press the Scroll Up key or Scroll Down key until the Function Icon becomes highlighted with a blue border.

7.

Press the Enter key

8.

At the Function Selection Screen, press the Scroll Up key crane functions until Drum 1 becomes highlighted in yellow.

9.

Press the Enter key

. The Function Selection screen appears.

12. Press the Scroll Up key

or Scroll Down key

to cycle through highlighted

. The Drum 1 Function screen appears.

10. Press the Scroll Up key or Scroll Down key field becomes highlighted with a blue border.

11. Press the Enter key

to cycle through the screen icons

to cycle through the screen fields until the personnel handling

. The field becomes highlighted with a red border. or Scroll Down key

to enable

the Drum 1 personnel handling mode.

13. Drum 1 can now be used to raise and lower the personnel platform.

NOTE: The personnel handling prompt will flash on all screens when the personnel handling mode is enabled.

14. Attach the load line from Drum 1 to the personnel platform with the socket and wedge provided. Comply with the manufacturer’s specifications and limitations for all lifting accessories: socket and wedge, shackles, hooks, slings, personnel platform, etc.

15. Prior to lifting personnel, test the crane for proper operation, as follows: •

Slowly lift the personnel platform 1,83-2,44 m (6-8 ft) off the foundation.

•

Slowly move the control handle to off. The hoisting function must stop and the personnel platform must not lower.

•

Lower the personnel platform 0,91-1,22 m (3-4 ft).

•

Slowly move the control handle to off. The lower function must stop and the personnel platform must not lower.

16. Make sure the wind is within the allowable limit for handling personnel.

17. Perform all operations — raising and lowering the personnel platform, booming up and down, and swinging in either direction — slowly and smoothly.

18. If the personnel platform will be suspended at a given elevation for any length of time during operation, turn on the Drum 1 park switch to prevent inadvertent operation of the drum.

6.2

Disabling Personnel Handling Mode

1.

Land the personnel platform and disconnect it from the hook of Drum 1.

2.

Repeat step 6 through step 12 above to disable

3.

Raise the Drum 1 hook to the desired position so it does not interfere with operation of the other drums.

4.

PARK Drum 1.

Manitowoc

the Drum 1 personnel handling mode.

Published 09-27-18

F2318-19

Model MLC165-1 Operator Manual Supplement

View C

View E

View D

Item

View B

View A

See Figure 8 on page 22 View F

Description

1

Hydraulic Power Unit

1A

Power Switch

1B

Drum Handle

1C

Brake Handle

1D

Pawl Handle

2

Electric Cable from Generator

3

Brake Hose

4

Tank Hose

5

M-Lower Hose

6

Suction Hose

7

Pawl Out Hose

8O

Pawl In Hose (operation)

8S

Pawl In Hose (startup)

9

M-Fill Hose

10

M-Raise Hose

11

Shut-Off Valves (qty 2)

M = Motor

FIGURE 7 F2318-20

Published 09-27-18

Model MLC165-1 Operator Manual Supplement

7.0

Emergency Lowering System

7.1

Emergency Lowering System Installation

For the following installation procedure: 1.

Lower the boom onto blocking at horizontal.

2.

Stop the engine, remove the ignition key, and place a warning sign at the ignition switch to alert other personnel that the crane is being serviced and the engine must not be started. Do not remove the sign until it is safe to return the crane to service.

3.

To avoid damage to the crane’s control system, read and follow the Welding Hazard Avoidance instructions in Section 1 of your MLC165-1 Service Manual.

4.

Modify the rotating bed per Drawing 80110835 at the end of this publication.

5.

•

The modification must be performed by a weld technician who has passed the Manitowoc Advanced Field Repair Course per Weld Instruction 00MFWI153 at the end of this publication.

•

All welded surfaces must be cleaned and painted with zinc-rich epoxy primer and Manitowoc gloss black paint.

Install the hydraulic piping per Drawing 80110834 at the end of this publication.

7.2

Emergency Lowering Procedure

See Figure 7 for the following procedure.

7.2.1 Power Unit Connection Procedure 1.

Clear the area around the disabled crane and from beneath the load.

2.

Park all crane functions and stop the engine.

3.

Lift the hydraulic power unit (1) into position on the left side of the crane.

4.

•

Use a fork-lift truck or an owner furnished hoist with lifting slings attached to the lifting rings on the power unit.

•

The unit weighs 605 kg (1,334 lb).

Attach the hydraulic hoses — M-fill (9), M-lower (5), suction (6), tank (4), brake (3), and pawl out (7) — from the hydraulic power unit to their appropriate quick disconnects on the crane (View C, D, and E).

•

Thoroughly clean all couplers and nipples before connecting the hoses.

5.

Temporarily connect the pawl in hose to the quick-disconnect at location (8S, View E). This step is for startup only.

6.

Leave the M-raise hose (10) disconnected (the M-fill hose is connected in its place).

7.

Close the shut-off valves (11, View C) at the front drum (levers perpendicular to hoses). If this is not done, the emergency lowering function will not work properly.

8.

If running, stop the generator (crane-mounted or shore-mounted).

9.

Connect the electric cable (2, View A) from the generator to the receptacle on the hydraulic power unit (1).

10. Check the hydraulic fluid level in the crane’s hydraulic tank and add fluid if low.

7.2.2 Emergency Load Lowering Procedure 1.

Verify the M-raise hose (10, View C, Figure 7) is disconnected and the M-fill hose (9, View C) is connected.

2.

Move the pawl handle (1D, Figure 8) to the motor start/pawl in position.

3.

Start the generator.

4.

Turn on the hydraulic power unit (1) using the power switch (1A, View A, Figure 7).

Continued on next page.

Manitowoc

Published 09-27-18

F2318-21

Model MLC165-1 Operator Manual Supplement

NEUTRAL

NOTE: Both handles (1B and 1C) are spring returned to neutral when released.

Handle (1D) is maintained in the position it is moved to.

FIGURE 8

5.

Move the pawl handle (D1, Figure 8) to the neutral position.

6.

Disconnect the pawl in hose from location (8S, View E, Figure 7 on page 20) and connect it to the quick-disconnect at location (8O, View D).

WARNING Falling Load Hazard!

Do not pull back the brake release handle (1C) while performing the following step 7. The load will lower.

7.

Push forward and hold the drum handle (1B, Figure 8) for 10 minutes. This step must be performed to ensure there is no air in the drum motor before lowering the load.

8.

After 10 minutes, release the drum handle (1B) to neutral.

9.

Disconnect the M-fill hose (9, View C, Figure 7 on page 20) from the quick-disconnect on the motor and connect the M-raise hose (10, View C) to the quick-disconnect.

10. Before attempting to lower the load, make sure personnel are clear of the landing area.

11. Push the pawl handle (1D, Figure 8) forward to disengage the pawl. Visually confirm that the pawl is fully disengaged. If the pawl fails to disengage, contact Manitowoc Crane Care for corrective action.

The pawl can be re-engaged at any time by pushing the handle forward. If the pawl is re-engaged while the drum is moving, it will not be possible to disengage it again without using the crane’s power plant and controls.

12. To begin lowering the load, push the drum handle (1B, Figure 8) forward to build pressure in the system. Then pull back the brake handle (1C). The drum brake will release and the load will start lowering.

Both handles (1B and 1C) need to be engaged to lower the load. The load will stop if either handle (1B or 1C) is released to neutral. Releasing the brake release handle (1C) to neutral while the drum is turning will cause premature brake wear.

13. To properly stop the load, move the drum handle to neutral, followed quickly by moving the brake release handle to neutral. The goal is to engage the drum brake as soon as the drum stops turning.

14. If at any time the load begins to run away, immediately release both handles (1B and 1C) to neutral stop the load.

15. Monitor the oil temperature gauge on the hydraulic tank during the lowering procedure. If the oil temperature rises above 180°F (82°C), release both handles to neutral to stop lowering the load. Wait a few minutes to allow the oil temperature to return to a safe level before continuing to lower the load.

16. Once the load is landed, move all handles to neutral.

F2318-22

Published 09-27-18

Model MLC165-1 Operator Manual Supplement

7.2.3 Power Unit Disconnection Procedure 1.

Turn off the hydraulic power unit.

2.

Turn off the generator.

3.

Unplug the electric cable from the power unit.

4.

Disconnect the hoses from the hydraulic power unit at the quick-disconnects on the crane.

5.

Thoroughly clean the hydraulic couplers, the nipples, and the dust caps.

6.

Attach the dust caps to the hydraulic couplers and nipples.

7.

Coil the hoses around the hose hooks on the hydraulic power unit.

8.

Store the hydraulic power unit for future use.

9.

Open both shut-off valves (11, View C, Figure 7 on page 20) at the front drum. The levers must be in line with the hoses. If this is not done, the normal function of the front drum will not work.

Manitowoc

Published 09-27-18

F2318-23

Model MLC165-1 Operator Manual Supplement

8.0

Reference Publications

The following reference material is provided at the end of this publication:

Publication

Description

Weather Station Drawing 80110301

ESI Weather Station Airmar 220WX Owner’s Guide and Installation Instructions B&G Triton2 Display Quick Guide B&G Triton2 Operator Manual

Crane Tie-Down Drawing 80111046

Crawler Barge Tie-Down

Drawing 80111048

Barge Tie-Down Crawler Modification

Lighting Package Drawing 80106634

Light Assembly, Generic #74 Boom

Drawing 80106577

Boom Top Lights Modification

Drawing 80101782

Light Assembly, Generic 150W LED

Drawing 80108686

Light Assembly, Generic 150W Additional (wide spot and medium flood)

Drawing 80108289

ESI 240VAC Options

Drawing 80108290

Light Assembly, Rotating Bed

Drawing 80108291

Live Mast Light Modification

Drawing 80108292

ESI Load Center

Drawing 80108834

5kW Generator Installation Assembly

Drawing 80108293

5kW Generator Assembly

Drawing 80108321

ESI Cab Light Switches

Drawing 80108626

ESI Battery Charger

Drawing 81040569

Generator Fuel Piping

981-0183 (Issue 11)

Onan HDKBB and HDKBC Operator Manual

981-0273 (Issue 18)

Onan HDKBB and HDKBC Parts Manual

Drum 2 Personnel Handling Drawing 80110834

Hydraulic Emergency Lowering Assembly

Drawing 80110835

Emergency Lowering Modification

Welding 00MFWI153

F2318-24

Welding Instruction

Published 09-27-18