Manitowoc MLC150-1 Cranes Operation Manual PDF

Model MLC150-1 Rated Capacity Limiter (RCL) Rated Capacity Indicator (RCI) Operation

Manitowoc

Published 03-08-21

F2324-1

MLC150-1 RCL/RCI Operation

© 2021 Manitowoc.

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

THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH.

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MLC150-1 RCL/RCI Operation

Contents 1.0

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

2.0

Supporting Documentation ....................................................................... 6

3.0

External Rated Capacity Indicator Light .................................................. 7

4.0

CE Requirements ....................................................................................... 7

5.0

External RCL/RCI Bypass.......................................................................... 8

6.0

Using Display Controls.............................................................................. 9

7.0

Working and Menu Screens .................................................................... 11

8.0

7.1

Working Screen................................................................................................................................ 11

7.2

Menu Screen .................................................................................................................................... 11

7.3

Configuration Screens...................................................................................................................... 13

Information/Notifications Bar.................................................................. 14 8.1

9.0

Operating Indicators ......................................................................................................................... 14

Confirmation Screen at Startup .............................................................. 15

10.0 Selecting Imperial or Metric Units .......................................................... 16 11.0 Changing Screen Brightness .................................................................. 17 12.0 Selecting Multiple Point Operation......................................................... 18 13.0 Entering Boom Butt Configuration......................................................... 19 14.0 Using Boom Butt Working Screen.......................................................... 23 15.0 Entering Boom Only Configuration ........................................................ 24 16.0 Using Boom Only Working Screen......................................................... 32 17.0 Entering Boom with Fixed Jib Configuration ........................................ 34 18.0 Using Fixed Jib Working Screen ............................................................ 40 Manitowoc

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MLC150-1 RCL/RCI Operation

19.0 Performing Boom Calibration (with or without fixed jib)...................... 42 20.0 Entering/Using Capacity Chart Information Screen.............................. 48 21.0 Sensor Status Screen .............................................................................. 50 22.0 Sensor Disable Screen ............................................................................ 51

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MLC150-1 RCL/RCI Operation

1.0

Introduction

Introduction

The RCL/RCI system is designed to aid the operator in identifying and avoiding overload conditions which can cause structural failure of the boom and jib or loss of stability (tipping).

The RCL/RCI monitors signals from the crane load sensors and angle sensors. The sensor signals are used to determine the loads suspended from the crane and the distance (radius) of each load from the centerline of rotation. The load and radius information for each lift point is compared to the selected capacity chart and a total rated capacity of the crane is calculated.

There are two parts to the RCL/RCI system: •

•

Rated Capacity Limiter (RCL) — Disables the following lifting functions when the load reaches the rated capacity: –

Hoist up

–

Boom down (or up if boom is raised above its maximum chart angle)

Rated Capacity Indicator (RCI) — Produces an audible/visual signal when the load approaches, reaches, or exceeds the rated capacity of the crane configuration.

DANGER Overload Hazard The RCL/RCI has been installed on the crane to aid the operator. If RCL/RCI is not configured correctly, it will not properly sense the load and angles and alert the operator to overload conditions.

Presence of the RCL/RCI on the crane in no way substitutes for, or lessens, the requirements that operator knowledge, experience, and judgment are required to ensure safe operation of the crane.

Before using the RCL/RCI, the operator shall read and understand the instructions in this publication.

Manitowoc

Published 03-08-21

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Supporting Documentation

2.0

MLC150-1 RCL/RCI Operation

Supporting Documentation

A Capacity Chart Manual has been supplied with your crane. The manual contains the following publications: •

Capacity Chart Information Manual: contains guides for determining total load, crawler blocking, and operating radius deducts.

•

Drum and Lagging

•

Liftcrane Capacities for various attachments (boom and jib)

•

Liftcrane Boom Butt Handling Capacities

•

Maximum Allowable Travel Specifications

•

Operating Range Diagram

•

Range Diagram (for job layout)

•

Wind Conditions

•

Wire Rope Specifications (contains parts of line and line pull information)

It is the operator’s responsibility to read and become thoroughly familiar with this information.

When entering data into the configuration screens, you need to know the number of the capacity chart in use. The capacity chart number can be obtained from the Capacity Chart Manual Table of Contents or from the right or left bottom corner of the capacity chart.

91501XXX

EXAMPLE ONLY! Do not use these chart numbers. Use the chart numbers listed in the Capacity Chart Manual supplied with your crane.

Chart descriptions and numbers in Capacity Chart Manual Table of Contents. Disregard the hyphen when entering the chart number in the Configuration Screen.

Chart numbers in lower right or left corner of Capacity Chart M104828-2 M104829

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MLC150-1 RCL/RCI Operation

3.0

External Rated Capacity Indicator Light

External Rated Capacity Indicator Light

If equipped, an external rated capacity indicator light (3, Figure 1) is mounted on top of the operator’s cab. The light is colored coded to indicate the following operating conditions: •

Flashing Red = load has exceeded the maximum capacity

•

Flashing Yellow = load is approaching the rated capacity

•

Solid Green = load is below rated capacity

1

RCL/RCI Display

2

Main Display

3

Rated Capacity Indicator Light

4

RCL/RCI Bypass Switch

Figure 1

4.0

CE Requirements

When operating between 100% and 110% rated capacity, the speed of the crane functions is limited to 15% of their maximum speed for load increasing actions (raising loads and lowering boom) and for swing and travel in both directions.

Manitowoc

Published 03-08-21

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External RCL/RCI Bypass

5.0

MLC150-1 RCL/RCI Operation

External RCL/RCI Bypass

DANGER Overload Hazard This switch bypasses the limiter (shutdown) function of the RCL/RCI. Improper use of RCL/RCI external bypass switch could result in death or serious injury.

The switch may only be used by authorized personnel during emergency operation as indicated below.

Operate in the safe direction only: raise the boom or lower the load to prevent tipping or structural damage.

Cranes meeting CE requirements are equipped with an RCL/RCI bypass switch (4, Figure 1) in a lockable box in the left-front enclosure. The bypass switch allows emergency operation of the crane functions during failure of RCL/RCI components: •

Boom angle sensor

•

Luffing jib angle sensor

•

Load sensor

When the external bypass function is activated: •

The override icon appears on the main display screen.

•

The cab alarm sounds intermittently.

•

The external RCL/RCI alarm sounds.

•

The amber overload beacon on the cab illuminates.

•

The crane functions are limited to 15% of their maximum speed for load increasing actions.

•

All relevant data is recorded in a data logger.

To activate the external bypass, press the top of the rocker switch. The external bypass is automatically turned off after 30 minutes of continued operation, engine shutdown, and/or crane shutdown.

To deactivate the external bypass, press the top of the rocker switch again. The normal RCL/RCI functions become enabled again.

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MLC150-1 RCL/RCI Operation

6.0

Using Display Controls

Using Display Controls

The RCL/RCI Display can be controlled by the display controls (Figure 2) or the jog dial controller (Figure 3) on the right console.

RCL/RCI Display

Main Display

Figure 2

1

Escape Key — Single click to back up one screen at a time. Double click to return to the Working screen from any other screen.

2

Menu Key — Press to go to the Menu screen from any other screen.

3a

Scroll Left Key — Press to move (scroll) to the left between screens and to change values.

3b

Scroll Up Key — Press to move (scroll) up between screens and to change values.

3c

Scroll Right Key — Press to move (scroll) to the right between screens and to change values.

3d

Scroll Down Key — Press to move (scroll) down between screens and to change values.

4

OK Key — Press to select a highlighted screen item or to confirm a step.

5

Alarm Key — Press to momentarily turn off the display alarm in the cab.

6

Not Used

7

Red Warning Indicator — A system warning is displayed as a blinking indicator. An operating over-limit is displayed as a steady on indicator.

8

Yellow Caution Indicator — A system caution is displayed as a blinking indicator. An approaching operating over-limit is displayed as a steady on indicator.

9

USB Port Cover — Remove to access the USB port.

NOTE: By holding down a scroll key, you can scroll faster in the desired direction when changing values.

Manitowoc

Published 03-08-21

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Using Display Controls

MLC150-1 RCL/RCI Operation

Right Console

Figure 3

1

Escape Key — Single click to back up one screen at a time. Double click to return to the Working screen from any other screen.

2

Menu Key — Press to go to the menu screen from any other screen.

3

Jog Dial — Rotate to move (scroll) between screen items and to change setting values.

4

Select Button — Press to select a highlighted screen item or to confirm a step.

5

Not Used

6

Display Selection Key — Press to toggle the jog dial function between the displays.

By depressing the jog dial and rotating it one or two clicks in either direction, you can scroll faster when changing values.

The jog dial can be toggled between controlling either the RCL/RCI Display or the Main Display by pressing the display selection key (6, Figure 3). The jog dial status icon appears in the lower left corner of the selected display.

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MLC150-1 RCL/RCI Operation

7.0

Working and Menu Screens

Working and Menu Screens

The RCL/RCI Display has two types of screens, Working and Menu.

7.1

Working Screen

The Working Screen (Figure 4) displays crane information for the active lift point. For an example, see 16.0 Using Boom Only Working Screen on page 32.

A separate Working Screen is provide for each crane configuration.

Figure 4

7.2

Menu Screen

The Menu Screen (Figure 5) allows you to select screens from four main groups.

Figure 5

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Published 03-08-21

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Working and Menu Screens

MLC150-1 RCL/RCI Operation

The menu screens are identified below.

Main Group

Screens Configuration Screen Used to set the basic crane configuration and load drum parameters.

Units Selection Screen Allows you to change the display units between imperial and metric. See 10.0 Selecting Imperial or Metric Units on page 16.

Settings

Calibration Screen Used to calibrate the load and angle sensors against measured values.

See 19.0 Performing Boom Calibration (with or without fixed jib) on page 42.

Multiple Point Screen Must be turned on when two points are used to handle the same load.

See 12.0 Selecting Multiple Point Operation on page 18.

Sensor Status Screen (Load and Angle Sensors) Displays operating information for the load and angle sensors. See 20.0 Entering/Using Capacity Chart Information Screen on page 48.

Information

Sensor Disable Screen (Load and Angle Sensors) Used to turn off faulty load or angle sensors. 22.0 Sensor Disable Screen on page 51.

Capacity Chart Information Screen Used to view crane capacities.

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Display

Screen Brightness Used to change screen brightness to meet operator needs. See 11.0 Changing Screen Brightness on page 17.

Tool Box

Data Logger Export Screen For factory use only. Contact the Manitowoc Crane Care Lattice Team.

Published 03-08-21

MLC150-1 RCL/RCI Operation

7.3

Working and Menu Screens

Configuration Screens

The various boom and jib Configuration Screens are shown in (Figure 6).

Configuration Screens 1

Boom Butt (setup)

2

Boom

3

Fixed Jib

4

Clam/Duty Cycle

Figure 6

Manitowoc

Published 03-08-21

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Information/Notifications Bar

8.0

MLC150-1 RCL/RCI Operation

Information/Notifications Bar

An Information/Notifications Bar (Figure 7) is located along the left side of the display. It shows the following icons:

1 2

3

1

Main Group

2

Active Menu Screen

3

Operating Indicators (see 8.1)

4

Multiple Point Status

5

Jog Dial Status

When active, the corresponding icon appears in the information/ notifications bar of all screens.

4 Figure 7 5

8.1

Operating Indicators

Boom Sensor Level

Off Chart - boom angle too high

Boom Sensor Difference Tolerance

Off Chart - boom angle too low

Calibration Invalid

RCL Fault

Crane Model Invalid

RCL Override

Limit Bypass Switch

Sensor Disabled

Lift Point 1 Sensor Out of Level (lower boom point) Lift Point 2 Sensor Out of Level (upper boom point)

F2324-14

The sensor out of level indicators appears if one or both of the lift point load sensors is outside a valid range. If both sensors are within the valid range but do not match each other within a tolerance, the corresponding indicator appears but the exclamation point (!) will change to a greater than sign (>).

Published 03-08-21

MLC150-1 RCL/RCI Operation

9.0

Confirmation Screen at Startup

Confirmation Screen at Startup

Figure 8

The Confirmation Screen (Figure 8) appears in the RCL/RCI Display shortly after startup.

The crane’s computer always remembers the last configuration at shut-down.

1. If the current configuration is okay, select the green  icon and click OK. The current Working Screen appears in the display.

2. If the current configuration is not okay, select the red X icon and click OK. The Configuration Screen appears in the display. Configure the desired crane configuration.

3. The Configuration Screen appears instead of the Confirmation Screen if there is a problem with the current configuration. Complete/correct the configuration.

Manitowoc

Published 03-08-21

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Selecting Imperial or Metric Units

10.0

MLC150-1 RCL/RCI Operation

Selecting Imperial or Metric Units

1. Press the Menu Key. The Menu Screen (1, Figure 9) appears.

2 1

1

Menu Screen Icon

2

Units Icon

3

Brightness Icon

3

Figure 9

2. From the Menu Screen, scroll to the Units icon (2, Figure 9) and click OK. The Units Selection Screen (Figure 10) appears.

1

2

1

Units Icon

2

Metric Units

3

Imperial Units

3

Figure 10

3. Scroll to the desired units, metric (3) or imperial (4), and click OK. 4. The units will change in the working screen and the menu screens.

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MLC150-1 RCL/RCI Operation

11.0

Changing Screen Brightness

Changing Screen Brightness

1. Press the Menu Key. The Menu Screen (1, Figure 9) appears.

2. From the Menu Screen, scroll to the Brightness icon (3, Figure 9) and click OK. The Brightness Adjustment Screen (Figure 11) appears.

1 1

Brightness Icon

2

Brightness Level

2

Figure 11

3. Use the jog dial or the scroll keys to change the screen brightness level.

4. Press OK to accept the new value.

Manitowoc

Published 03-08-21

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Selecting Multiple Point Operation

12.0

MLC150-1 RCL/RCI Operation

Selecting Multiple Point Operation

Multiple point operation must be selected when two load points are used for handling the same load.

5. Press the Menu Key. The Menu Screen (1, Figure 12) appears.

6. From the Menu Screen, scroll to the Multiple Point icon (2, Figure 12) and click OK. The Multiple Point Selection Screen (Figure 13) appears.

1

2

1

Menu Icon

2

Multiple Point Icon

3

Multiple Point Selection Screen

4

ON Icon

5

OFF Icon

6

Multiple Point Icon

6

Figure 12

3 2

4 5

Figure 13

7. Use the jog dial or the scroll keys to scroll to the ON icon (4, Figure 13) or the OFF icon (5) and click OK. 8. Once turned on, the Multiple Point icon (6, Figure 12) appears in the information/notifications bar of all screens.

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MLC150-1 RCL/RCI Operation

13.0

Entering Boom Butt Configuration

Entering Boom Butt Configuration

1. Press the Menu Key. The Menu Screen (Figure 14) appears.

Figure 14

2. From the Menu Screen, scroll to the Configuration icon and click OK. The Configuration Screen (1, Figure 15) appears.

3. In the Configuration Screen, scroll to the Boom Butt icon and click OK. Then select the required crawler/jack configuration and click OK. The RCL Alarm Screen (Figure 16, page 20) appears.

1

2

Manitowoc

1

Configuration Screen

2

Crane on Both Crawlers

2

Crane on One Crawler and Two Jacks

2

Crane on Four Jacks

Published 03-08-21

3

4

Figure 15

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Entering Boom Butt Configuration

MLC150-1 RCL/RCI Operation

Figure 16

4. To enable the RCL alarm, scroll to the green  icon and click OK. To disable the RCL alarm, scroll to the red X icon and click OK. NOTE: The RCI alarm function cannot be disabled if the crane has been programmed for CE Requirements.

After the icon is selected, the RCL Limiter Screen (Figure 17) appears.

Figure 17

5. To enable the RCL limiter, scroll to the green  icon and click OK. To disable the RCL limiter, scroll to the red X icon and click OK. NOTE: The RCL limiter function cannot be disabled if the crane has been programmed for CE Requirements.

After the icon is selected, the Deduct Weight Screen (Figure 18) appears.

Figure 18

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MLC150-1 RCL/RCI Operation

Entering Boom Butt Configuration

6. Using the jog dial or the scroll keys, enter the required deduct weight, if listed in the applicable capacity chart, and click OK. The Drum Screen (Figure 19) appears.

Figure 19

7. Scroll to the Drum 1 and click OK. The Line Pull Screen (Figure 20) appears.

Figure 20

8. Using the jog dial or the scroll keys, enter the line pull for the wire rope being used — see the Wire Rope Specifications chart — and click OK. The Parts of Line Screen (Figure 21) appears.

Figure 21

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Published 03-08-21

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Entering Boom Butt Configuration

MLC150-1 RCL/RCI Operation

9. Using the jog dial or the scroll keys, enter two parts of line and click OK. The Block Weight Screen (Figure 22) appears.

Figure 22

10. Using the jog dial or the scroll keys, scroll to the required block weight and click OK. The Boom Butt Configuration Confirm Screen (Figure 23) appears.

Figure 23

11. If the configuration is correct, scroll to the green  icon and click OK. The Boom Butt Working Screen (Figure 24, page 23) appears.

If the configuration is not correct, select the red X icon. The boom butt configuration starts over.

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MLC150-1 RCL/RCI Operation

14.0

Using Boom Butt Working Screen

Using Boom Butt Working Screen

The Live Mast Working Screen (Figure 24) displays crane information for the live mast.

1 2

3 10

4

5

13

9

6

11

7 8

12

Item 1

Figure 24

Description Boom Butt Length RCL Alarm Enabled

2 RCL Alarm Disabled

RCL Limiter Enabled 3 RCL Limiter Disabled 4

Liftcrane Boom Butt Capacities Chart Number

5

Deducts

6

Drum ID

7

Line Pull

8

Parts of Line

9

Swing Angle

10

Radius (from centerline of rotation to centerline sheave)

11

Boom Butt Angle

12

Capacity at the Current Radius Rated Capacity Triangle - Shows the total rated capacity of the crane. The size of the triangle increases as the load increases. The color of the triangle indicates capacity: 1 Green = load is below the rated capacity.

2 Yellow = load is approaching the rated capacity.

3 Red = load has exceeded the maximum capacity.

13 1

2

3

M103164

Manitowoc

Published 03-08-21

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Entering Boom Only Configuration

15.0

MLC150-1 RCL/RCI Operation

Entering Boom Only Configuration

1. Press the Menu Key. The Menu Screen (Figure 25) appears.

Figure 25

2. From the Menu Screen, scroll to the Configuration icon and click OK. The Configuration Screen (Figure 6, page 13) appears.

3. In the Configuration Screen (Figure 6, page 13), scroll to the Boom icon and click OK. The Counterweight Screen (Figure 26) appears.

Figure 26

4. Using the jog dial or the scroll keys, change the counterweight (match to counterweight installed on crane) and click OK. The Boom Length Selection Screen (Figure 27) appears.

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MLC150-1 RCL/RCI Operation

Entering Boom Only Configuration

Figure 27

5. Using the jog dial or the scroll keys, increase or decrease the boom length (match boom length installed on crane) and click OK. The Barge Selection Screen (Figure 28) appears, but only if barge capacity charts are provided in the RCL/RCI. This symbol and the corresponding list appears, if 0°, 1°, 2°, or 3°, is selected.

0°, 1°, 2° or 3°

OFF

Figure 28

6. Using the jog dial or the scroll keys, select the desired barge list (OFF, 0°, 1°, 2°, or 3°) and click OK. The RCL Alarm Screen (Figure 29) appears.

Figure 29

7. To enable the RCL alarm, scroll to the green  icon and click OK. To disable the RCL alarm, scroll to the red X icon and click OK. After the icon is selected, the RCL Limiter Screen (Figure 30, page 26) appears.

NOTE: The RCI alarm function cannot be disabled if the crane has been programmed for CE Requirements.

Manitowoc

Published 03-08-21

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Entering Boom Only Configuration

MLC150-1 RCL/RCI Operation

Figure 30

8. To enable the RCL limiter, scroll to the green  icon and click OK. To disable the RCL limiter, scroll to the red X icon and click OK. After the icon is selected, the Lower Boom Point Enable Screen (Figure 31) appears.

NOTE: The RCI limiter function cannot be bypassed if the crane has been programmed for CE Requirements.

Figure 31

9. To enable the Lower Boom Point, scroll to the ON (I) icon and click OK. To disable the Lower Boom Point, scroll to the OFF (O) icon and click OK. The Capacity Chart Screen (Figure 32) appears.

Figure 32

10. The correct capacity chart should appear based on the counterweight entered earlier. If the correct capacity chart appears, click OK. The Deduct Weight Screen (Figure 33) appears.

If the correct capacity chart does not appear, use the jog dial or the scroll keys to enter the correct capacity chart and click OK. The Deduct Weight Screen (Figure 33) appears.

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MLC150-1 RCL/RCI Operation

Entering Boom Only Configuration

Figure 33

11. Using the jog dial or the scroll keys, enter the required deduct weight, if listed in the applicable capacity chart, and click OK. The Drum Screen (Figure 34) appears.

Figure 34

12. Scroll to the desired drum icon for Single Drum or Two Drums — as appropriate for how the lower point is rigged — and click OK. 13. The Hook Type Screen (Figure 35) appears. Select either single hook or dual hook and click OK.

SINGLE HOOK

DUAL HOOK Figure 35

14. The Drum Assignment Screen (Figure 36, page 28) appears.

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Entering Boom Only Configuration

MLC150-1 RCL/RCI Operation

SINGLE HOOK

DUAL HOOK Figure 36

15. Scroll to the drum number that will be used with the highlighted boom point and click OK. •

If “Dual Hooks” was selected, perform this step for both drums.

•

If “Two Drums” was selected, perform this step for both drums.

16. The Line Pull Screen (Figure 37) appears.

Figure 37

17. Using the jog dial or the scroll keys, enter the line pull for the wire rope on the selected drum — see the Wire Rope Specifications chart — and click OK. •

If “Dual Hooks” was selected, perform this step for both drums.

•

If “Two Drums” was selected, perform this step for both drums.

18. The Parts of Line Screen (Figure 38) appears.

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MLC150-1 RCL/RCI Operation

Entering Boom Only Configuration

Figure 38

19. Using the jog dial or the scroll keys, enter the required parts of line for how the boom point is reeved and click OK. •

If “Dual Hooks” was selected, perform this step for both drums.

20. The Block Weight Screen (Figure 40) appears.

Figure 39

21. Using the jog dial or the scroll keys, enter the required block weight and click OK. •

If “Dual Hooks” was selected, perform this step for both blocks.

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Entering Boom Only Configuration

MLC150-1 RCL/RCI Operation

22. The Boom Configuration Screen (Figure 40) appears.

Figure 40

23. If the configuration is correct, scroll to the green  icon and click OK. The next boom point screen highlights and appears (Figure 41).

If the configuration is not correct, select the red X icon. The boom point configuration starts over.

Figure 41

24. Repeat steps 9 through 23 until all boom points have been configured. After all boom points have been configured, the Boom Working Screen (Figure 42, page 32) appears.

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MLC150-1 RCL/RCI Operation

Entering Boom Only Configuration

THIS PAGE INTENTIONALLY LEFT BLANK

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Using Boom Only Working Screen

16.0

MLC150-1 RCL/RCI Operation

Using Boom Only Working Screen

The Boom Working Screen (Figure 42) displays crane status information for the active lift point.

Single Drum

1

14

23 21

4

22 16 6

13

17

8 18

11 24

15

3

2 20

5

14

23

15

3

2

Two Drums

1

20

21

4

22

5

16

7

6

13 9

8 11

17

24

18

12 10

19

19

Clam/Duty Cycle

1

If “dual hooks” was selected, the displayed drum data depends on which drum is being operated.

23

14 3

15

2

20

21

4

22

5

16 6

13

17

8 18

11 24

19 Figure 42

Item 1

Description Boom Length RCL Alarm Enabled

2 RCL Alarm Disabled

RCL Limiter Enabled 3 RCL Limiter Disabled

4

Capacity Chart Number (for load point currently in use) To view the current capacities, go to the capacity chart information screen (see 20.0 Entering/Using Capacity Chart Information Screen on page 48).

5

Capacity Chart Deduct

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MLC150-1 RCL/RCI Operation

Using Boom Only Working Screen

6

First Drum Assigned to Lift Point

7

Second Drum Assigned to Lift Point (two drum lift only)

8

First Drum Line Pull Weight

9

Second Drum Line Pull Weight (two drum lift only)

10

Total Parts of Line

11

First Drum Parts of Line

12

Second Drum Parts of Line (two drum lift only)

13

Swing Angle

14

Active Lift Point Radius (from centerline of rotation to the centerline of load)

15

Active Lift Point (highlighted in orange)

16

Tare Weight - For the active lift point.

NOTE: Tare is a load value that is subtracted from the displayed load so that the operator can easily view load differences. For example, the weight of the hook block can be entered as a tare. The displayed load then would only show the weight suspended from the hook block. However, tare is just a visual aid and does not affect the rated capacity calculation of the RCL/RCI.

17

Hook Load Weight - Shows the suspended load.

18

Boom Angle

19

Capacity Chart Maximum Weight - The capacity chart’s maximum allowable load at a specified radius for the current load point and capacity chart in use. This capacity is always the least of the capacity chart or the line pull limit.

Rated Capacity Triangle - Shows the total rated capacity of the crane. The size of the triangle increases as the load increases. The color of the triangle indicates capacity: 1 Green = load is below the rated capacity.

2 Yellow = load is approaching the rated capacity.

3 Red = load has exceeded the maximum capacity.

20 1

2

3

M103164

21

Current Wind Speed measured at highest point. For allowable operating limits, see the Wind Conditions chart in the Capacity Chart Manual supplied with your crane.

22

Top Wind Gust since crane was started. The top wind gust can be reset by scrolling to the box and clicking OK.

23

Selected barge list symbol: 0°, 1°, 2°, or 3°. No symbol appears if barge list is off.

24

Counterweight

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Entering Boom with Fixed Jib Configuration

17.0

MLC150-1 RCL/RCI Operation

Entering Boom with Fixed Jib Configuration

1. Press the Menu Key. The Menu Screen (Figure 43) appears.

Figure 43

2. From the Menu Screen, scroll to the Configuration icon and click OK. The Configuration Screen (Figure 6, page 13) appears.

3. In the Configuration Screen (Figure 6, page 13), scroll to the desired Fixed Jib icon and click OK. The Counterweight Selection Screen (Figure 44) appears.

Figure 44

4. Using the jog dial or the scroll keys, change the counterweight (match to counterweight installed on crane) and click OK. The Boom Length Selection Screen (Figure 45) appears.

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MLC150-1 RCL/RCI Operation

Entering Boom with Fixed Jib Configuration

Figure 45

5. Increase or decrease the boom length (match to boom length installed on crane) and click OK. The Fixed Jib Length Selection Screen (Figure 46) appears.

Figure 46

6. Increase or decrease the fixed jib length (match to jib length installed on crane) and click OK. The Fixed Jib Offset Screen (Figure 47) appears.

Figure 47

7. Scroll to the required offset (match to offset installed on crane) and click OK. The RCL Alarm Screen (Figure 48, page 36) appears.

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Entering Boom with Fixed Jib Configuration

MLC150-1 RCL/RCI Operation

Figure 48

8. To enable the RCL alarm, scroll to the green  icon and click OK. To disable the RCL alarm, scroll to the red X icon and click OK. After the icon is selected, the RCL Limiter Screen (Figure 49) appears.

NOTE: The RCI alarm function cannot be disabled if the crane has been programmed for CE Requirements.

Figure 49

9. To enable the RCL limiter, scroll to the green  icon and click OK. To disable the RCL limiter, scroll to the red X icon and click OK. After the icon is selected, the Lower Boom Point Enable Screen (Figure 50) appears.

NOTE: The RCI limiter function cannot be bypassed if the crane has been programmed for CE Requirements.

Figure 50

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MLC150-1 RCL/RCI Operation

Entering Boom with Fixed Jib Configuration

10. To enable the Lower Boom Point, scroll to the ON (I) icon (Figure 50) and click OK. If the lower boom point is turned on, proceed to configure the lower boom point in the normal manner. Perform steps 9 through 23 starting on page page 26.

To disable the Lower Boom Point, scroll to the OFF (O) icon and click OK. 11. Once the lower boom point is configured or turned off, the Fixed Jib Point Enable Screen (Figure 51) appears.

Figure 51

12. To enable the Fixed Jib Point, scroll to the ON (I) icon and click OK. To disable the Fixed Jib Point, scroll to the OFF (O) icon and click OK.The Deduct Weight Screen (Figure 52) appears.

Figure 52

13. Scroll to the required deduct weight, if listed in the applicable capacity chart, and click OK. The Drum Assignment Screen (Figure 53) appears.

Figure 53

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Entering Boom with Fixed Jib Configuration

MLC150-1 RCL/RCI Operation

14. Scroll to the drum number that will be used with the fixed jib point and click OK. The Line Pull Screen (Figure 54) appears.

Figure 54

15. Using the jog dial or the scroll keys, enter the line pull for the wire rope on the selected drum — see the Wire Rope Specifications chart — and click OK. The Parts of Line Screen (Figure 55) appears.

Figure 55

16. Using the jog dial or the scroll keys, enter the required parts of line for how the fixed jib point is reeved and click OK. The Block Weight Screen (Figure 56) appears.

Figure 56

17. Using the jog dial or the scroll keys, enter the required block weight and click OK. The Fixed Jib Configuration Confirm Screen (Figure 57) appears.

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MLC150-1 RCL/RCI Operation

Entering Boom with Fixed Jib Configuration

Figure 57

18. If the configuration is correct, scroll to the green  icon and click OK. If the configuration is not correct, select the red X icon. The fixed jib point configuration starts over.

Manitowoc

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Using Fixed Jib Working Screen

18.0

MLC150-1 RCL/RCI Operation

Using Fixed Jib Working Screen

The Fixed Jib Working Screen (Figure 58) displays crane status information for the active lift point.

1

15 3

2

14

5

4

16

6

13 7 8

17

12

18

9 10 11

19

20 21 Figure 58

Item

Description

1

Boom Length

2

Fixed Jib Length

3

Fixed Jib Offset Angle RCL Limiter Enabled

4 RCL Limiter Disabled

RCL Alarm Enabled 5 RCL Alarm Disabled

6

Capacity Chart Number (for fixed jib point) To view the current capacities, go to the capacity chart information screen (see 20.0 Entering/Using Capacity Chart Information Screen on page 48).

7

Capacity Chart Deduct

8

Drum Assigned to Lift Point

9

Drum Line Pull Weight

10

Total Parts of Line

11

Counterweight

12

Swing Angle

13

Top Wind Gust since crane was started. The top wind gust can be reset by scrolling to the box and clicking OK.

14

Current Wind Speed measured at the fixed jib point. For allowable operating limits, see the Wind Conditions chart in the Capacity Chart Manual supplied with your crane.

15

Active Lift Point Radius (from centerline of rotation to the centerline of load)

16

Active Lift Point (highlighted in orange)

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MLC150-1 RCL/RCI Operation

Using Fixed Jib Working Screen

17

Tare Weight - For the active lift point.

NOTE: Tare is a load value that is subtracted from the displayed load so that the operator can easily view load differences. For example, the weight of the hook block can be entered as a tare. The displayed load then would only show the weight suspended from the hook block. However, tare is just a visual aid and does not affect the rated capacity calculation of the RCL/RCI.

18

Hook Load Weight - Shows the suspended load.

19

Boom Angle Rated Capacity Triangle - Shows the total rated capacity of the crane. The size of the triangle increases as the load increases. The color of the triangle indicates capacity: 1 Green = load is below the rated capacity.

2 Yellow = load is approaching the rated capacity.

3 Red = load has exceeded the maximum capacity.

20 1

2

3

M103164

21

Capacity Chart Maximum Weight - The capacity chart’s maximum allowable load at a specified radius for the current lift point and capacity chart in use. This capacity is always the least of the capacity chart or the line pull limit.

Manitowoc

Published 03-08-21

F2324-41

Performing Boom Calibration (with or without fixed jib)

19.0 jib)

MLC150-1 RCL/RCI Operation

Performing Boom Calibration (with or without fixed

The Boom Calibration Screens are used to calibrate (match) actual measured values (radius and load) to the angle and load sensor data (current). If the sensors are not calibrated correctly, the boom angle and load may not be interpreted correctly by the crane’s control system.

The boom/crane must be configured before you perform the boom calibration.

The sensors must be calibrated at the following intervals: •

When the boom angle sensor is replaced

•

When any displayed angle is not within +0° to -1°

•

When any displayed load is not within 0 to 10%

1. Press the Menu Key. The Menu Screen (Figure 59) appears.

2. Scroll to the Calibration icon and click OK.

Figure 59

3. The Passcode Screen (Figure 60) appears.

Figure 60

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MLC150-1 RCL/RCI Operation

Performing Boom Calibration (with or without fixed jib)

4. Using the jog dial or the scroll keys, enter the passcode, 2401 one digit at a time and click OK on the green  icon. The Calibration Screen (Figure 61) appears.

Upper Boom Point or Fixed Jib

Sensor OK

Signal from sensor is out of range and has failed high

Signal from sensor is out of range and has failed low Boom Butt Angle Sensor

Figure 61 Slope data — shows the slope calibration constant for the sensor being calibrated. This number (as well as intercept data) should be recorded after a calibration. If the system loses calibration, this constant (as well as intercept data) can be manually restored. Do not alter the slope data value unless restoring a lost calibration.

Intercept data — shows the intercept calibration constant for the sensor being calibrated. This number (as well as slope data) should be recorded after a calibration. If the system loses calibration, this constant (as well as slope data) can be manually restored. Do not alter the intercept data value unless restoring a lost calibration. mA

Sensor Output Voltage Figure 61

5. If the boom angle sensor (1, Figure 62) is being replaced or adjusted, it must be properly oriented as follows.

1

Boom Angle Sensor

2

Cap Screw, Flat Washers, Lock Washer, Nut (4 places)

3

Electric Cable

4

Boom Butt (right inboard side) Figure 62

a. Install the boom angle sensor as shown in Figure 62. Tighten the mounting hardware just enough that you can still rotate the boom angle sensor in the mounting slots. b. In the Calibration Screen (Figure 61), scroll to the Slope Selection Box (1, Figure 63, page 44.

Manitowoc

Published 03-08-21

F2324-43

Performing Boom Calibration (with or without fixed jib)

MLC150-1 RCL/RCI Operation

1

Figure 63

–

Click OK. The Slope Change Box (2, Figure 64) appears.

2

Figure 64

c. The slope should read 14222. If necessary use the jog dial or the scroll keys to enter 14222 and click OK. d. Perform one the following steps: –

For boom butt only: lower the boom butt so the stand is lightly contacting level ground (where the ground is in the same plane as the crawlers).

–

For fully rigged boom (Figure 65): lower the boom until the angle of the boom butt top chords is +6.8° and the angle of the boom butt bottom chords is -6.8°. Use a smart level for this step.

+6.8°

-6.8° Figure 65

e. Rotate the boom angle sensor (1, Figure 62, page 43) until the displayed angle in the Calibration Screen (Figure 66) reads one of the following: F2324-44

Published 03-08-21

MLC150-1 RCL/RCI Operation

– –

Performing Boom Calibration (with or without fixed jib)

For boom butt only, -6.9°.

For fully rigged boom, 0.0°.

-6.9° for Boom Butt Only OR 0.0° for Fully Rigged Boom

Figure 66

f.

Securely tighten the boom angle sensor mounting hardware.

NOTE: The remaining steps require a fully rigged boom 6. From the capacity chart in use, raise the boom to the shortest radius with a boom angle less than 58°.

7. Scroll to the Angle Selection Box in the Calibration Screen (Figure 67). .

OR

Configured with Jib without Hook over Boom Point

Configured with Boom Only

Figure 67

8. Click OK. The following screen appears.

VIEW A

VIEW B

Figure 68

9. Using the jog dial or the scroll keys, enter the boom angle (from step 6) in the Boom Angle Box (View A, Figure 68).

Manitowoc

Published 03-08-21

F2324-45

Performing Boom Calibration (with or without fixed jib)

MLC150-1 RCL/RCI Operation

10. Scroll to the check mark (View B, Figure 68) and click OK to confirm the angle. The Block Weight Selection Screen (Figure 69, page 46) appears.

This Icon will be Highlighted

OR

Configured with Jib without Hook over Boom Point

Configured with Boom Only

Figure 69

11. With the boom/load block at the same radius and angle from step 6, raise the load block or the hook-andweight ball as close to the block-up limit switch as possible without tripping it.

12. Scroll to the Block Weight Selection Box (Figure 69) and click OK. The following screen appears.

Figure 70

13. Using the jog dial or the scroll keys, enter the total load hanging from the boom point in the Block Weight Selection Box (Figure 70).

The operator must calculate the total load. Remember, the total load includes the combined weight of everything hanging below the boom point, as instructed in the capacity chart for the crane’s current configuration.

14. Scroll to the check mark (Figure 70) and click OK to confirm the load. The following screen appears.

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MLC150-1 RCL/RCI Operation

Performing Boom Calibration (with or without fixed jib)

This Icon will be Highlighted

Figure 71

15. From the capacity chart in use, raise the boom to the shortest radius.

16. Raise the load block or the hook-and-weight ball as close to the block-up limit switch as possible without tripping it.

17. Repeat steps 13 and 14.

18. This completes the calibration procedure.

Manitowoc

Published 03-08-21

F2324-47

Entering/Using Capacity Chart Information Screen

20.0

MLC150-1 RCL/RCI Operation

Entering/Using Capacity Chart Information Screen

The Capacity Chart Information screen (Figure 72) allows you to view crane capacities.

To access the Capacity Chart Information screen, select the Load Chart Display icon of the Menu Screen.

in the Information Screen

Without Luffing Jib 1

2

3

4

5

7

If “dual hooks” was selected.

6

With Luffing Jib OR

3

4

5

8

6

Figure 72

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MLC150-1 RCL/RCI Operation

Item

Entering/Using Capacity Chart Information Screen

Description

1

Information Bar (see page 14)

2

Crane Configuration Data (from how crane was originally configured)

3

Radius

4

Angle (boom or jib)

6

Capacity (see NOTE) Where no capacity is shown (0), operation is not intended or approved.

Up/Down Icons for scrolling through the crane capacities.

7

Operating Indicators (see page 14)

8

Boom Angle Selection Box: Changing the boom angle (from Liftcrane Luffing Jib Capacities Chart) allows you to scroll through additional crane capacities (5).

5

NOTE: Capacities match the published capacities provided with the crane and correspond to the Capacity Chart selected during crane configuration.

Manitowoc

Published 03-08-21

F2324-49

Sensor Status Screen

21.0

MLC150-1 RCL/RCI Operation

Sensor Status Screen

The Sensor Status Screen contains the information identified in Figure 73.

Scroll to the Sensor Status icon in the Menu Screen and click OK. The Sensor Status Screen appears.

4

5

1

Boom Butt Angle Sensor

2

Load Sensor (gantry A)

3

Load Sensor (gantry B)

4

Sensor Status

5

Sensor Output Voltage

6

Angle Sensor Angle Reading OR Load Sensor Load Reading

6

1

Sensor OK

2 3 Signal from sensor is out of range and has failed high

Signal from sensor is out of range and has failed low

Figure 73

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MLC150-1 RCL/RCI Operation

22.0

Sensor Disable Screen

Sensor Disable Screen

The boom has two angle sensors, one in the boom top and one in the boom butt.

The boom also has two load sensors: one in the link on the left side of the boom top and one in the link on the right side of the boom top.

The Sensor Disable Screen (Figure 74) allows you to turn off a faulty angle sensor or load sensor so the current operation can be completed. Take corrective action as soon as possible.

1

Load Sensor (gantry A)

2

Load Sensor (gantry B)

3

Passcode

4

Sensor Status

5

Sensor Output Voltage

6

Load Sensor Load Reading

7

ON-OFF Selector Box

3

Sensor OK

Signal from sensor is out of range and has failed high 1

7

2

7 4

5

Signal from sensor is out of range and has failed low

6

Figure 74

1. Scroll to the Sensor Status icon in the Menu Screen and click OK. The Sensor Status Screen appears.

2. Using the jog dial or the scroll keys, enter the passcode 2401 one digit at a time and click the green  icon.

3. Scroll to the desired ON-OFF selector box. Highlight either I for ON or O for OFF and click OK. 4. Repeat the process for each sensor you want to be turn off.

Manitowoc

Published 03-08-21

F2324-51

Sensor Disable Screen

MLC150-1 RCL/RCI Operation

THIS PAGE INTENTIONALLY LEFT BLANK

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Published 03-08-21