Page 1 Manitowoc MLC300 Operator Manual...
Page 3 ™ The serial number of the crane and applicable attachments (i.e. luffing jib, VPC-MAX is the only method your Manitowoc dealer or the Manitowoc Crane Care Lattice Team has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator’s cab and each attachment.
Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH.
Page 5: Table Of Contents
Manitowoc Dealer........
Page 6 TABLE OF CONTENTS MLC300 OPERATOR MANUAL General..............2-23 Location .
Page 7 MLC300 OPERATOR MANUAL TABLE OF CONTENTS VPC Operation............. . . 3-67 Boom Hoist Operation .
Page 8 TABLE OF CONTENTS MLC300 OPERATOR MANUAL Gear Boxes..............4-11 Hydraulic System .
Page 9 MLC300 OPERATOR MANUAL TABLE OF CONTENTS Raise Boom Top Wire Rope Guide ..........4-89 Install Position Light and Wind Speed Indicator .
Page 10 TABLE OF CONTENTS MLC300 OPERATOR MANUAL Store Right Side Rear View Mirror ..........4-157 Store RCL Light .
Page 11 Manitowoc Dealer........
Page 12 MLC300 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 11-20-19, Control # 234-19...
Page 13: Section 1
CHANGE OF OWNERSHIP REGISTRATION • A yellow arrow (2) and dot (3) on the right top and right front sides of the carbody indicate the FRONT of the If you are the new owner of a Manitowoc crane, please carbody (see Figure 1-2).
Page 14 INTRODUCTION MLC300 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 11-20-19, Control # 234-19...
Page 15: Identification And Location Of Components
MLC300 OPERATOR MANUAL INTRODUCTION IDENTIFICATION AND LOCATION OF COMPONENTS Item Description Drum 0 (rigging winch) Drum 1 (main hoist) Lowerworks Upperworks Live Mast Boom Butt Drum 6 (luffing or auxiliary hoist) Drum 7 (tagline) Boom Straps Boom Insert (varying lengths)
Page 16 INTRODUCTION MLC300 OPERATOR MANUAL Item Description Item Description Live Mast Sheaves Turntable Bearing Self-Erect Cylinder VPC™ Tray Live Mast Straps Roller Drum 4 Counterweight Box Drum 3 VPC Trolley Drum 2 VPC Drive Mast-Assist Arms (2) VPC Roller Operator Cab...
Page 17 MLC300 OPERATOR MANUAL INTRODUCTION Item Description Cooler Assembly Engine Exhaust Aftertreatment Components DEF Tank Engine Air Cleaner Pump Drive with Pumps Crawler Pin Puller (4) Carbody Jack (4) Jack Pad (4) Figure 1-5. Left-Front View Manitowoc Published 11-20-19, Control # 234-19...
Page 18: English And Metric Conversions
INTRODUCTION MLC300 OPERATOR MANUAL ENGLISH AND METRIC CONVERSIONS Inverse Conversion DIVIDE (÷) known value by conversion factor to obtain Direct Conversion equivalent value in desired units. For example, 3,6576 m is MULTIPLY (x) known value by conversion factor to obtain converted to feet, as follows: equivalent value in desired units.
Page 19 MLC300 OPERATOR MANUAL INTRODUCTION To Convert Symbol Application Symbol Multiply By VOLUME (LIQUID)) Ounce Milliliter 29.5735 Pint Liter 0.4732 Fluid Capacities Quart Liter 0.9464 Gallon Liter 3.7854 Gallon Per Minute Pump Flow Liters Per Minute L/min 3.7854 WEIGHT Pound Unit/Component Kilogram 0.4536...
Page 20 INTRODUCTION MLC300 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 11-20-19, Control # 234-19...
Page 21: Section 2
Personnel Handling Policy ............2-24 Manitowoc...
Page 22 MLC300 OPERATOR MANUAL Pedestal/Barge Mounted Cranes ........... 2-25 Pedestal Mounted Crane .
Page 23: Continuous Innovation
If you are in Used with the safety alert symbol, indicates a hazardous doubt about any procedure, contact your Manitowoc dealer situation which, if not avoided, could result in minor or or Manitowoc Crane Care Lattice Team.
Page 24 SAFETY INFORMATION MLC300 OPERATOR MANUAL Table 2-1 Common Safety Symbols Cut or Crush Hazards Cut Hazard M100090 M100091 M100066 M100065 M100069 M100067 Fire Crush Hazards Extinguisher M100070 M100071 M100072 M100073 M100074 M100082 Explosion Fall Hazards Falling Boom (Crush) Hazards Hazard...
Page 25: Safety And Information Signs
MLC300 OPERATOR MANUAL SAFETY INFORMATION Table 2-1 Common Safety Symbols Emergency Cab Exit Table 2-2 Miscellaneous Symbols Engine Coolant Diesel Fuel Engine Coolant Engine Oil Level Hydraulic Filter Hydraulic Oil Vent M100271 M100267 M100268 M100269 M100272 M100273 Pump Drive Oil...
Page 26 SAFETY INFORMATION MLC300 OPERATOR MANUAL Item Description Operator Cab Platform with Handrails Carbody Platform (both ends and sides) Mast Platform Engine Enclosure (non-skid) Rotating Bed Handrails (both side) Folding Ladder (left side only) Rotating Bed Platform (both sides) Counterweight Tray and Boxes (non-skid)
Page 27 MLC300 OPERATOR MANUAL SAFETY INFORMATION Figure 2-1 continued Manitowoc Published 11-20-19, Control # 234-19...
Page 28: Crane Access Points
When personnel use ladders to get on or off the crane, their hands shall be free of any objects. Objects which cannot be Manitowoc has provided ladders and platforms at the carried in pockets or tool belts shall be lifted into place with a locations shown in Figure 2-1.
Page 29: Personal Fall-Protection
MLC300 OPERATOR MANUAL SAFETY INFORMATION PERSONAL FALL-PROTECTION Item Description Manitowoc has provided lifelines and anchors throughout the Lifeline crane and attachment (see Figure 2-2.) to which workers can Anchor attach their personal fall-protection equipment. WARNING Fall Hazard! To prevent falling from any height during crane assembly and disassembly, personnel shall wear fall-protection equipment.
Page 30: Operator Manual/Capacity Chart Storage
If the serial numbers of your manuals and capacity charts do not match the serial numbers of the crane or attachment, STORAGE contact your Manitowoc dealer for the proper manual or capacity charts. General Do not operate crane or attachment if proper Capacity Manitowoc provides the following manuals and other Chart is not in cab.
Page 31: Safe Operating Practices
(United States Federal Law), in ASME B30.5 American operation. Manitowoc cannot foresee all hazards that will National Standard, or in any other applicable federal, state, arise in the field; therefore, safety remains responsibility or local laws.
Page 32 SAFETY INFORMATION MLC300 OPERATOR MANUAL 4. The operator shall be thoroughly familiar with operation 10. The operator shall verify that the Capacity Chart being of the crane and its proper care. If adjustments or repairs used is the correct one for the cranes configuration are necessary or if there are known defects that impair (boom length, load line reeving, counterweight, etc.).
Page 33: Handling Load
Do not operate the crane with a snow or ice covered NOTE Capacity charts for Manitowoc cranes show the boom. The extra weight may cause overload, tipping, or total weight of freely suspended loads for various structural damage.
Page 34: Lifting/Moving Load
SAFETY INFORMATION MLC300 OPERATOR MANUAL 2. Only use slings and other rigging that are in safe All personnel are clear of the swing radius of the operating condition and have a rating equal to or greater crane’s counterweight. than the load to be lifted.
Page 35: Multiple Load Line Operation
Engage the luffing hoist pawl when operating with Manitowoc authorizes multiple load line operation for those the luffing jib at a fixed radius. applications requiring it, provided the following steps are performed: 3.
Page 36: Signals
If communication is disrupted, load indicator(s). operator shall stop all crane movements. 6. Manitowoc recommends that each load line be equipped 2. Signals to the operator must be in accordance with the with an anti two-block device. standard...
Page 37: Safety Devices
• Alternative measures are not permitted to be used for a faulty safety device. Manitowoc provides the following operational aids on its • Always tag-out any faulty safety device and place a cranes, either as standard equipment or optional equipment.
Page 38: Category 2 Operational Aids
SAFETY INFORMATION MLC300 OPERATOR MANUAL at a point that gives the signal person sufficient time Refer to the pendulum boom angle indicator on the to signal the operator and have the operator stop boom butt (visible from operator cab). the boom or jib within the minimum allowable radius.
Page 39: Assembling, Disassembling, Or Operating Crane Near Electric Power And Transmission Lines
WARNING dangerous. Electrocution Hazard! Set-Up and Operation Manitowoc cranes are not equipped with all features required to operate within OSHA 29CFR1926.1408, 1. During crane use, assume that every line is energized Table A clearances when the power lines are energized.
Page 40: Electrocution Hazard Devices
SAFETY INFORMATION MLC300 OPERATOR MANUAL source. This person should have no other duties while etc.). The insulating characteristics of these devices can the crane is working. be compromised if not kept clean, free of contamination, and undamaged. 6. Taglines should always be made of non-conductive materials.
Page 41: Refueling
Safety information in this publication is intended only as a for any evidence of damage and all damaged parts are guide to assist qualified maintenance personnel in safe repaired or replaced as authorized by Manitowoc or your maintenance. Manitowoc cannot foresee all hazards that Manitowoc dealer.
Page 42 SAFETY INFORMATION MLC300 OPERATOR MANUAL Place a warning sign at the start controls alerting 12. Avoid battery explosion: do not smoke while performing other personnel that the crane is being serviced and battery maintenance or short across battery terminals to the engine must not be started.
Page 43: Environmental Protection
33. Perform a function check to ensure proper operation at connecting bolts or pins are being removed. the completion of maintenance or repair. 28. Unless authorized in writing by Manitowoc, do not alter ENVIRONMENTAL PROTECTION the crane in any way that affects the crane’s...
Page 44 SAFETY INFORMATION MLC300 OPERATOR MANUAL View A WRONG – DANGEROUS! and there is No Blocking If Boom is Off Ground Under Boom Sections... and Supported by Straps... Boom will COLLAPSE when Lower Pins are Removed! View B WRONG – DANGEROUS! Handling Pendants are Slack...
Page 45: Boom Disassembly Safety
MLC300 OPERATOR MANUAL SAFETY INFORMATION BOOM DISASSEMBLY SAFETY blocking, individual pin connections may still be under load. Pins can be ejected forcefully if the boom has any pressure NOTE The term “boom” used in the following instructions on it or if the boom is not supported properly.
Page 46: Personnel Handling Policy
50 percent of the rated capacity conditions. for the radius and configuration of the crane. Use of a Manitowoc crane to handle personnel is acceptable • The crane is uniformly level within one percent of level provided: grade and located on a firm footing.
Page 47: Pedestal/Barge Mounted Cranes
Manitowoc recommends that cranes be properly maintained, regularly inspected, and repaired as necessary. All safety WARNING signs must be in place and legible. We also urge Manitowoc The crane owner/user shall verify that the method used to crane owners to upgrade their cranes with rated capacity fasten or restrain the crane to the foundation, the barge, indicator/limiter systems for all lifting operations.
Page 48: Pedestal Mounted Crane
M a n i t o w o c d e a l e r f o r t h e NOTE Manitowoc does not permit traveling on a barge recommended bolt pattern and for the type and deck with load.
Page 49: Capacity Charts For Barge Mounted Crane
If the crane’s boom or structure is shock loaded during operation, or there is any indication of shock loading, all Manitowoc provides two types of Capacity Charts for a crane structural components of the crane must be inspected to mounted on a barge or other supporting structure under detect cracks and other damage.
Page 50: Barge Mount Definitions
1. Machine List, as defined by Manitowoc, is the crane’s required. Correct each defect found before placing the crane out-of-level condition — from side-to-side — as into service.
Page 51: Section 3
Load Drum Operation (with free fall enabled) ........3-75 Manitowoc...
Page 52 MLC300 OPERATOR MANUAL Free Fall Brake Pedal Hydraulic Pressure Test ........3-77 Free Fall Brake Operational Test .
Page 53 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 11-20-19, Control # 234-19...
Page 54: Standard Hand Signals For Controlling Crane Operations
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5-2014. Table 3-1. Standard Hand Signals for Controlling Crane Operations M100118 M100119 M100120 M100121 M100122 M100123 M100124 M100125...
Page 55 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-1. Standard Hand Signals for Controlling Crane Operations Item Description HOIST—With forearm vertical, forefinger pointing up, move hand in small horizontal circles. LOWER—With arm extended downward, forefinger pointing down, move hand in small horizontal circles.
Page 56: Symbols Used On Control Consoles
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL SYMBOLS USED ON CONTROL CONSOLES The following symbols are used on the control consoles to identify the operating controls and their operation. Table 3-2. Symbol Identification — Control Consoles C y l i n d e r s , M a s t A s s i s t A r m s ,...
Page 57 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-2. Symbol Identification — Control Consoles Engine Run Light, Dome M100159 M103338 Engine Start Light, Consoles M100160 M100165 Engine Stop Light, Position M100161 M100291 Light, Work (and camera) M100142 M100166 Heater Lighter...
Page 58 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Table 3-2. Symbol Identification — Control Consoles Park Off Travel Forward—Left Crawler M100192 Park On Travel Forward—Right Crawler M100172 M100193 Speed, Fast Travel Reverse—Left Crawler M100183 M100194 Speed, Slow Travel Reverse—Right Crawler M100184...
Page 59: Symbols Used On Remote Control
MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SYMBOLS USED ON REMOTE CONTROL The following symbols are used on the remote control to identify the operating controls and their operation. Table 3-3. Symbol Identification — Remote Control Alert Energize M100141 M100154...
Page 60 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Table 3-3. Symbol Identification — Remote Control Jack, Carbody Right Front and Right Rear M102446 M100170 Jack, Carbody Right Rear M102447 M100171 Jack, Carbody Right Rear and Left Rear Pin (Disengage) M102448 M100177...
Page 61 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-3. Symbol Identification — Remote Control Pins, Live Mast Hinge Winch, Rigging M102450 M101687 Pins, VPC Trolley Front Winch, Rigging (Pay Out/Haul In) M102433 M101687b Trolley, Rotating Bed Mounted (In/ Pins, VPC Trolley Rear...
Page 62: Operating Controls
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL OPERATING CONTROLS Figure 3-1. Cab Controls and Indicators 3-10 Published 11-20-19, Control # 234-19...
Page 63 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-4. Cab Controls and Indicators Item Name Description Louvers Vents to circulate air in the operator cab. Travel Foot Pedals page 3-26 for more information. Free Fall Brake Pedals page 3-27 for more information.
Page 64 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Outside Air Control Handle Pull out to close the vents and push to open the vents. Left Console page 3-14 for more information. Houses the main components for the operator cab heating and cooling HVAC Housing system (fan, heating and cooling coils, valves).
Page 65 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES page 3-30 for more information. Boom Angle Indicator GPS/GSM Antenna Contact your Manitowoc dealer for CraneSTAR information. Manitowoc 3-13 Published 11-20-19, Control # 234-19...
Page 66: Left Console
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Left Console Table 3-5. Left Console Item Name Description Maximum current draw is 10A. For fuse location, see Section 3 of the Service 12VDC Power Source Manual. Seat Riser Control Item Description Engage switch in this location to raise or lower the rear riser.
Page 67 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-5. Left Console • Move the handle FORWARD to DECREASE the engine speed. • Move the handle BACK to INCREASE the engine speed. Hand Throttle Engine speed must be fast enough to provide sufficient power for the work being done.
Page 68: Right Console
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Right Console Table 3-6. Right Console 3-16 Published 11-20-19, Control # 234-19...
Page 69 Not Used Displays operating conditions, faults, and diagnostic information. See the Main Display MLC300 Main Display Operation Manual at the end of this section for detailed information. Manitowoc 3-17 Published 11-20-19, Control # 234-19...
Page 70 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Table 3-6. Right Console • Press and hold the TOP of the rocker to tilt the front of the cab UP to a maximum of 21° above horizontal. • Release the rocker CENTER to LOCK the cab in the desired position.
Page 71 The regeneration/inhibit switch is a three-position rocker switch. The top position is momentary. The center and bottom positions are maintained. For more information on this switch, see Section 7 of the MLC300 Service Manual. Active Position The active center position is for normal engine operation. The position does not require operator assistance under normal conditions.
Page 72 The switch will remain depressed. The amber LED in the rocker will glow. To re-enable active regeneration, manually return the switch to the active position. Do not use the Inhibit switch unless specifically instructed by a Manitowoc or Cummins technical advisor. Engine Regeneration/Inhibit...
Page 73 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-6. Right Console Travel Operation on page 3-80. The following directions of travel are with the front of the rotating bed and the front of carbody facing the same direction. The swing and travel alarm beeps to warn personnel when the crane is traveled.
Page 74 Dome Lights The setup mode must be on (live mast configuration selected) to operate the mast assist arms. See Section 4 of the MLC300 Operator Manual for instructions. • Press and hold the TOP of the rocker to EXTEND the mast arm cylinders.
Page 75 • RELEASE to TURN OFF the horn. Before swinging or traveling, sound the horn to alert nearby personnel. Used in conjunction with the Crane Control System (CCS). See the MLC300 Jogdial Main Display Operation Manual and the RCL/RCI Operation Manual for more information.
Page 76 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Table 3-6. Right Console Each load drum has a spring-applied, hydraulically-released, disc-type drum brake on the motor end of the drum. Additionally, if the front or rear drum has free fall, a spring-applied, hydraulically- released disc-type brake is provided on the left end of the drum.
Page 77 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-25 Published 11-20-19, Control # 234-19...
Page 78 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Foot Pedals Table 3-7. Foot Pedals Item Name Description • Press DOWN on the foot throttle to INCREASE engine speed above the hand throttle setting. Engine Foot Throttle • RELEASE the foot throttle to DECREASE engine speed to idle or to the hand throttle setting.
Page 79 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-7. Foot Pedals The crane can be equipped with 1 or 2 optional free fall brake pedals. The left pedal is for the front hoist (Drum 2) and the right pedal is for the rear hoist (Drum Each free fall equipped drum has a spring-applied, hydraulically-released brake that is controlled by the corresponding free fall brake pedal.
Page 80: Seat Controls
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Seat Controls Table 3-8. Seat Controls Item Name Description Seat Riser on Left Console page 3-14 for operating instructions. • Push the lever to the LEFT to UNLOCK the seat. Fore-Aft Control • Use body weight to slide the seat to the desired position.
Page 81: Climate Control Keypad
MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Climate Control Keypad Table 3-9. Climate Control Keypad Item Name Description Temperature Set Switches Adjusts the desired cab temperature UP or DOWN. Turns the fan on and opens the fresh air door to bring in air from outside the Windshield Defrost cab.
Page 82: Other Operator Aids
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Other Operator Aids • Amber Beacon ON = Crane’s rated capacity is approaching the maximum level. Boom Angle Indicator • Red Beacon ON = Crane’s rated capacity has been The boom angle indicator...
Page 83 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES The circular level (Figure 3-4) indicates crane levelness from front-to-rear and from side-to-side using four concentric rings (2). • The crane is level when the bubble (1) is centered in the 0° ring of the glass.
Page 84: Crane Cameras
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Crane Cameras Table 3-10. Crane Camera Locations Item Name Camera Points at DRUM 6 Camera Points at VPC-MAX Camera Points at DRUM 4 Camera Points at DRUM 2/3 Camera Points at VPC-MAX Camera Points at DRUM 5...
Page 85: Crane Camera Monitor
MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Crane Camera Monitor Table 3-11. Camera Monitor Operating Controls M103341 NOTE For detailed information about the camera monitors, refer to the camera manual that is supplied with the crane. Item Name Description To change the label (“DRUM 3” in this case), refer to the vendor Camera label manual.
Page 86: Motion Warning Lights And Alarms
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL MOTION WARNING LIGHTS AND ALARMS Table 3-12. Motion Warning Lights and Alarms 3-34 Published 11-20-19, Control # 234-19...
Page 87 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-12. Motion Warning Lights and Alarms Item Name Description Swing and Travel Alarm, Front Dual-tone, interrupted alarms that sound when the swing or either travel control handle is moved in either direction from off.
Page 88: Service Lights
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL SERVICE LIGHTS Table 3-13. Service Light Components Drum Description Service Work Light (2) On-Off Switch Load Center Receptacle (4) 3-36 Published 11-20-19, Control # 234-19...
Page 89 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-13. Service Light Components Item Name Description This crane is equipped with two portable service lights (1) stored in the lockable storage compartment on the left side of the operator cab. Each light has an...
Page 90: Remote Control Activation
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL REMOTE CONTROL ACTIVATION Table 3-14. Remote Control Components Item Description Remote Control Electric Cable: 20 m (66 ft) Transceiver Receptacle (2) Battery Charger External Engine Switch DC Load Center 3-38 Published 11-20-19, Control # 234-19...
Page 91 3-38) is turned COUNTERCLOCKWISE to the STOP position or the remote control is turned off in the Remote Control Selection Screen in the Main Display (see MLC300 Main Display Operation Manual). The remote control will also turn off (go to sleep) after 10 minutes of non-use. If this happens, press the remote control...
Page 92: Remote Control Operation
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL REMOTE CONTROL OPERATION Table 3-15. Identification and Operation of Remote Controls NOTE See Section 4 in this manual for Assembly and Disassembly procedures using the remote control. 3-40 Published 11-20-19, Control # 234-19...
Page 93 The remote control can be operated without an electric cable (wireless) if job site conditions allow transmission of a wireless signal. If you are unable to get a wireless signal, the electric cable (A) supplied by Manitowoc can be connected between the remote control receptacle (4) and the transceiver receptacle (B). Receptacle Not Used Rotate CLOCKWISE to INCREASE engine speed (high).
Page 94 If the signal is lost, troubleshoot the system (dead battery or connection, faulty electric cable, faulty electric cable connection). Glows RED to indicate that an operating limit has been exceeded. See MLC300 Fault Light Main Display Operation Manual.
Page 95 Each remote control has a unique identification number (A) on the side of the unit. This number must be entered in the Main Display when turning on the remote control in the Remote Control Selection Screen. See MLC300 Main Display Operation Manual for instructions.
Page 96 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Table 3-15. Identification and Operation of Remote Controls • Select and confirm item 15. • Move the control handle I in either direction to energize the function. Live Mast Assist Arms • Move the control handle II FORWARD to EXTEND the mast assist arms and cylinders or move the control handle II REARWARD to RETRACT the mast assist arms and cylinders.
Page 97 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-15. Identification and Operation of Remote Controls • Select and confirm item 25. Trolley Travel • Move the control handle I in either direction to energize the function. (beam mounted trolley) • Move the control handle II FORWARD to travel the trolley OUT or move the control handle II REARWARD to travel the trolley IN.
Page 98: Operating Limits Identification And Operation
3-52. Cranes meeting European requirements (CE) are equipped with an RCI/RCL External Override Switch located outside the operator cab. See MLC300 Rated Capacity Indicator/Limiter Operation Manual. CE = Cranes that comply with 2010 European requirements. Only if boom or luffing jib is below allowable angle given in capacity chart (while raising or lowering boom and luffing jib from or to ground level).
Page 99 Do not hoist the load above the minimum block clearance given in the Reeving Diagrams (see Section 4 of the MLC300 Operator Manual). Do not use the limit bypass switch to lower the boom or the luffing jib after the block-up limit is contacted, or two-blocking could occur.
Page 100 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Operating Limit Icon Function Diverted This limit prevents Drums 1 and 3 from being operated at the same time. Drum 3 must be parked to operate Drum 1. Drum 1 must be parked to operate Drum 3.
Page 101 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Operating Limit Icon Luffing Jib Maximum Up 1 (maximum working angle) This programmed limit stops the luffing jib when the boom-to-luffing jib angle is 169°. • The luffing jib can be lowered after this limit is reached.
Page 102 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Operating Limit Icon Mast Assist Arms Up With the Setup Mode OFF (any boom or jib configuration selected in RCL/RCI), this limit stops the boom hoist if you attempt to raise the boom when the mast assist arms are up.
Page 103 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Operating Limit Icon Transducer Fault In the setup mode, this limit stops operation if there is a transducer fault. Troubleshoot the hydraulic system using the screens in the Main Display to determine the faulty transducer. Take corrective action to correct the fault.
Page 104: Bypassing Limits In Luffing Jib Setup Mode
Display (Figure 3-5). The limits will remain bypassed for 10 seconds after the See the MLC300 Main Display Operation Manual for control handle(s) is returned to off. detailed instructions. Turn the luffing jib setup mode OFF (4) for normal Turn the luffing jib setup mode ON (2).
Page 105: Resetting Luffing Jib Limits
MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES RESETTING LUFFING JIB LIMITS When either prompt appears: 1. Release the control handle to off. This procedure applies only to cranes meeting CE requirements. See Figure 3-6. 2. Press either select button (3) to reset the limit.
Page 106: Drum And Control Handle Identification
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL DRUM AND CONTROL HANDLE IDENTIFICATION Drum Description Main Hoist Auxiliary Front Hoist (optional) Auxiliary Rear Hoist (optional) Boom Hoist (standard) OR Mast Hoist (VPC-MAX) Boom Hoist (VPC-MAX) Luffing or Auxiliary Hoist Tagline Winch (optional)
Page 107 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES HANDLE A HANDLE C HANDLE D HANDLE B Configuration Controls Drum Controls Drum Controls Drum Controls Drum With Live Mast (without fixed mast) Live Mast Handling (crane assembly) or 2 or 3 6 or 5...
Page 108 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL View A View B Item Description Window Latch Handle Figure 3-8. Right-Side Cab Window SHIPPING Position WORKING Position Item Description WORKING Position Two Places Cab Support Safety Pin (2) Stop Pin (2) Figure 3-9. Cab Tilt Stop Pin...
Page 109: Right Cab Window Operation
MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES RIGHT CAB WINDOW OPERATION Figure 3-8 for the following procedure. Item Description Flow Control Valve Closing Window Set Screw Adjusting Knob Rotate the window latch handle DOWN to the position shown in View A.
Page 110 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL View D — ROTATING BED WORKING View A — STORED View B— ROTATING BED WORKING View E — STANDALONE Item Description Left-Rear Platform View C — STANDALONE Top Ladder Bottom Ladder Ladder Hook (2)
Page 111: Ladder Installation (Past)
Otherwise, the ladder will be damaged. The ladder has been provided only for accessing and servicing the Manitowoc MLC300 crane. Any other use is Removing Ladder neither intended nor approved. 1. Lower the bottom ladder (3) to the standalone position Figure 3-11 for following procedures.
Page 112 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL View D ROTATING BED WORKING View A — STORED View C STANDALONE View B ROTATING BED WORKING and STANDALONE Item Description Left-Rear Platform Top Ladder Bottom Ladder Ladder Hook (2) Pin with Hair-Pin Cotter (2)
Page 113: Ladder Installation (Current)
Manitowoc MLC300 crane and VPC-MAX attachment is installed. The ladder can be connected attachment. Any other use is neither intended nor to the rear of the VPC-MAX beam. See MLC300 approved. VPC-MAX Operator Manual for instructions. 1. Lower the bottom ladder (3) to the working/standalone Figure 3-12 for following procedures.
Page 114: Operating In Wind
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL OPERATING IN WIND CRAWLER BLOCKING Wind adversely affects lifting capacity and stability. The result could be loss of control over the load and crane, even DANGER if the load is within the crane’s capacity.
Page 115: Preparing Crane For Operation
The crane must be rigged and operated according to the sure the roller paths are clean and free of all debris. instructions given in the capacity charts, in Section 4 of the MLC300 Operator Manual, and in Section 4 of the • Adjust the operator’s seat. See Seat Riser Control on MLC300 Luffing Jib Manual.
Page 116 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL CAUTION Pump Damage Do not start the engine until the hydraulic tank shutoff valve is open. Otherwise, the pumps could cavitate and be damaged. 2. Make sure the battery disconnect switch is in the...
Page 117 • For a Cummins engine only, the WAIT NOTE For fault identification, see the MLC300 Main Display TO START icon will appear in the Main Operation Manual. Display indicating that the pre-heater is warming the engine’s air intake.
Page 118 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL YELLOW = Indicates reduced drum speed. The shorter the bar, the slower the drum speed. Speed can be so slow that it appears the drums are not turning. GREEN = Up to Full Drum Speed...
Page 119: Operating Procedures
MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES OPERATING PROCEDURES of the crane, operations increasing load moment — hoisting up, booming down, or luffing down — will be limited. VPC Operation Drum speed and VPC movement can be monitored in the...
Page 120: Boom Hoist Operation
The physical boom stop angle. For detailed instructions, see the Automatic cushions boom raising between approximately 75° Boom Stop Adjustment topic in Section 4 of the MLC300 and the maximum boom angle. The boom stop also Service Manual.
Page 121: Luffing Hoist Operation
Use extreme care when operating the luffing hoist and the angle. For detailed instructions, see the Automatic boom hoist at the same time. The maximum or minimum Boom Stop Adjustment topic in Section 4 of MLC300 operating radius will be reached quickly when operating Service Manual.
Page 122: Swing Operation
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL 9. As the luffing jib nears the desired angle, slowly move 2. Select the correct capacity chart and crane configuration the luffing jib control handle toward off to decrease using the RCL/RCI Display. For detailed instructions, speed.
Page 123 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-71 Published 11-20-19, Control # 234-19...
Page 124 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Use this Handle for TANDEM Drums when Both Drums are Unparked T Appears if TANDEM Drums are Configured and Both Drums are Unparked Figure 3-21. Load Drum Control Handles Item Description Lower Boom Point Sheaves...
Page 125: Load Drum Operation (Without Free Fall Or With Free Fall Disabled)
MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Load Drum Operation (without free fall or with NOTE In the TANDEM drum configuration: free fall disabled) • With both tandem drums unparked, the left handle on the right console (Figure 3-21) controls both...
Page 126 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Drum 2 Drum 3 Locking Pin Selector Handle (Drum 2) Selector Handle (Drum 3) Figure 3-23. Free Fall Selector Valves Menu Free Fall Screen Selection Screen Free Fall Icon Identification Free Fall Mode...
Page 127: Load Drum Operation (With Free Fall Enabled)
MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Load Drum Operation (with free fall enabled) d. For the desired drum, remove the locking pin (1, Figure 3-23), rotate the selector handle (2 or 3) OUT The location of the load drum control handles varies to the “I”...
Page 128 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL b. Leave the free fall brake pedal latched down. Pull the drum control handle BACK from OFF to RAISE the load. The drum brake will release. WARNING d. As the load nears the desired position, slowly move...
Page 129: Free Fall Brake Pedal Hydraulic Pressure Test
T h e b r a k e c o u l d s l i p a l l o w i n g t h e l o a d t o l o w e r uncontrolled. Free Fall Brake Operational Test A free fall operational test must be performed weekly as instructed in Section 2 of your MLC300 Service Manual. Drum 2 or 3 Free Fall Brake Pressure Drum 2 Icon Drum 3 Icon...
Page 130: Clamshell Operation
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Clamshell Operation DUMPING BUCKET 1. Push the closing line handle forward to dump bucket at For clamshell operation, the crane must be equipped with the desired speed. Drums 2 and 3: 2. Release the closing line handle to off as soon as bucket Drum 2 is the closing line is empty and fully open.
Page 131 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-79 Published 11-20-19, Control # 234-19...
Page 132: Travel Operation
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL Travel Operation CAUTION Boom Damage WARNING Abrupt travel operation could result in shock loading the boom and rigging. To avoid this, perform all travel Tipping Hazard functions—starting, turning, stopping—slowly and The travel surface must be firm and uniformly supporting.
Page 133 MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 4. For travel on grade, the VPC Lockout Key Switch NOTE The following directions of travel are with the front of (page 3-20) must be in the LOCK position (not the rotating bed and the front of carbody facing the same direction.
Page 134: Shutdown Procedure Or Leaving The Crane Unattended
OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL SHUTDOWN PROCEDURE OR LEAVING 11. To make a GRADUAL LEFT TURN (Figure 3-29), move both crawler handles to front from the neutral position. THE CRANE UNATTENDED Move the right crawler control handle farther to the front than the left crawler handle.
Page 135: Changing Counterweight With Boom/Jib In Air
MLC300 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CHANGING COUNTERWEIGHT WITH BOOM/ The suspended load under the boom and jib points must be as small as permitted by the capacity chart. JIB IN AIR 2. Make sure the current boom length, luffing jib length (if equipped) and radius are valid for both the current series capacity chart and the desired series capacity chart.
Page 136 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-84 Published 11-20-19, Control # 234-19...
Page 137: Cold Weather Operation
The static load-carrying limitations of the steels used in off, leaving rope without lubrication. Manitowoc cranes are not affected by cold weather. Manitowoc’s capacity charts are acceptable for use in cold Consult your wire rope supplier for recommended cold– weather.
Page 138 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL View D View C View E View B View A Figure 3-31. Cold Weather Heaters 3-86 Published 11-20-19, Control # 234-19...
Page 139: Cold Weather Heater Package
(1) on the crane and to the receptacle on the Package is available. The package contains the following generator (APU). 240VAC heaters: 5. Start the generator (APU) engine. The Manitowoc Figure 3-31 supplied APU can be started from inside the operator cab.
Page 140 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL View D View E View A View B View C Item Description Item Description Electric Cable (DC, WAC1) Locking Pin with Hair-Pin Cotter (2) Electric Cable (DC, WAD1) Hook (2) Power Supply Cable (AC, WAA1)
Page 141: Ac Operation
11. Connect the electric cable (9, View C) to the receptacle 60 HZ AC generator and a DC charging system is available on the APU and to the receptacle on the rotating bed from Manitowoc to power the following operations when the (View E). crane engine is off: 12.
Page 142 OPERATING CONTROLS AND PROCEDURES MLC300 OPERATOR MANUAL b. Start the crane engine and run the air conditioner in d. Disconnect all hoses and cables. the cab using the crane engine for at least two 2. Remove the APU from the crane (reverse Installing APU minutes.
Page 143 Camera Connections ............4-41 Manitowoc...
Page 144 MLC300 OPERATOR MANUAL Activate Setup Mode ............4-42 Raise Live Mast To Operating Position .
Page 145 MLC300 OPERATOR MANUAL Remove Block-Up Limit Components ..........4-113 Store the Load Lines .
Page 146 MLC300 OPERATOR MANUAL Load Block Identification............4-171 Duplex Hook .
Page 147: Boom And Jib Assembly Drawings
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION SECTION 40 SETUP AND INSTALLATION BOOM AND JIB ASSEMBLY DRAWINGS The Boom and Jib Rigging drawings that apply to your crane are located at the end of this section. WARNING Avoid Falling Off Crane and Boom!
Page 148: Assembly And Disassembly Notes
Maintain communication between operator and access those areas of the crane, live mast, and boom that assemblers to avoid accidents. cannot be reached from the ground or from Manitowoc- • Do not raise or lower the live mast until all personnel provided steps, ladders, catwalks and platforms.
Page 149: Personal Fall-Protection
See the Crane Weights topic in Section 1 of this manual for and disassembly, personnel shall wear fall-protection the weights of individual crane components. equipment. See the MLC300 Product Guide in Section 1 of this manual • Anchors and lifelines are designed to handle only one for outline and shipping dimensions.
Page 150: Parts Box
• To install the counterweight tray and counterweight boxes. See Install Counterweight Tray on page 4-71 Manitowoc provides a parts box that can be lifted with a Install Counterweight Boxes on page 4-73. forklift. The MLC300 is equipped with the following self-erect...
Page 151 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Item Description Live Mast Mast Strap (2) Self-Erect Cylinder Figure 4-6 on page 4-7 Lifting Link (see Figure 4-6 on page 4-7 Shackle: 25 t (28 USt) (see ) (6 past, 2 current) Figure 4-5 on page 4-6...
Page 152 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL PAST AND CURRENT PRODUCTION Item Description Endless Synthetic Rope Sling Working Load Limit: 18 144 kg (40,000 lb) Straight 14 515 kg (32,000 lb) Chocker 36 287 kg (80,000 lb) Basket Four Supplied by Manitowoc...
Page 153 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION PAST AND CURRENT PRODUCTION Description Item Shackle: 25 t (28 USt) Six Supplied by Manitowoc, Past Production Two, Supplied by Manitowoc, Current Production Item 225,0 8.86 57,0 2.25 313,0 12.34 106,0 4.19 73,0 2.88 51,0 2.00...
Page 154: Remote Control
SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Operator Cab Storage Compartment Remote Control Electric Cable: 20 m (66 ft) Transceiver Front of Rotating Bed DC Load Center External Engine Switch Figure 4-7 REMOTE CONTROL The remote control can be operated without the electric...
Page 155: Activating Remote Control
MLC300 Main Display Operation Manual). • Activate the remote control in the Mode Selection Group of the Main Display. See the MLC300 Main Display The remote control will “go to sleep” after 10 minutes of non- Operation Manual for instructions.
Page 156: Pin And Connecting Hole Cleanliness
SETUP AND INSTALLATION MLC300 OPERATOR MANUAL PIN AND CONNECTING HOLE CLEANLINESS To prevent dirt from damaging closely machined surfaces of pins and connecting holes: • Thoroughly clean all pins and connecting holes. • Apply a light coat of grease to all pins and connecting holes.
Page 157: Pre-Start Checks
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION 4. Check for leaks after the crane has been operated and the hydraulic oil is at operating temperature. Retighten the couplers if necessary. 5. All plugs, regardless of location, must be fully screwed together into their corresponding caps until there is metal to metal contact during crane assembly.
Page 158 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description CAN D Terminator Dust Cap Left-Front Side of Rotating Bed CAN Terminator 14S Right Side of Rotating Bed at VPC Trolley Bulkhead Figure 4-10 4-12 Published 11-20-19, Control # 234-19...
Page 159: Swing Limits
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION SWING LIMITS Refer to Table 4-2 for the swing limits during crane assembly and disassembly. In all cases given below, Drums 2 and 3 can be either installed or removed and the counterweight tray is removed.
Page 160 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL WARNING Falling Load Hazard! These lugs are for factory use only. Do not attempt to lift the rotating bed and carbody with them. The lugs could break allowing the rotating bed and carbody to fall.
Page 161: Crane Assembly
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION CRANE ASSEMBLY CAUTION Start Engine Avoid Structural Damage 1. Perform the pre-start checks given on page 4-11. Do not extend the carbody jacks when they are stored. 2. Remove remote control from storage Serious structural damage will occur to the carbody and compartment on the left side of the operator cab (see jacks.
Page 162 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A SHIPPING Item Description Item Description Operator Cab Operating Lugs Hitch Pin with Hair-Pin Cotter Cab Rear Platform Support Arm Quick-Release Pin (2) Pin with Hair-Pin Cotter Handrail View C Turnbuckle Safety Pin (3)
Page 163: Deploy Cab Rear Platform
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Deploy Operator Cab 4. Attach the handrail (11) to the cab rear platform (9, View E) with the safety pins (12). Figure 4-13 for the following procedure. NOTE The handrail and cab rear platform have matching 1.
Page 164 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Hair-Pin Cotter (31) Window Cover: Front Window Cover: Right Front Window Cover: Right Rear Window Cover: Roof Window Cover: Rear Window Cover: Left Figure 4-15 4-18 Published 11-20-19, Control # 234-19...
Page 165: Remove Window Covers
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Remove Window Covers Deploy Right Side Rear View Mirror If equipped, remove and store the operator cab window This mirror is optional. covers. See Figure 4-15. Figure 4-17 for the following procedure. Raise RCL Light to Working Position 1.
Page 166 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Left-Front Platform Quick-Release Pin (2) Pin with Safety Pin (2) Platform Brace (2) Left-Front Ladder Quick-Release Pin (2) Padlock Support Arm Storage Bracket (2) Pin with Hair-Pin Cotter (2) Quick-Release Pin (1)
Page 167: Move Rotating Bed Left-Front Platform To Working Position
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Move Rotating Bed Left-Front Platform to 2. Unhook the left-front ladder (5, View FS) from the storage brackets (9). Working Position 3. Place the ladder to the side temporarily. Figure 4-18 for the following procedure.
Page 168 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Handrail Handrail Handrail (5) Handrail Handrail (2) Telescopic Handrail Handrail Safety Pin (2 each handrail) Left-Rear Platform Identification Number Valve Cover Platform (3) Figure 4-19 4-22 Published 11-20-19, Control # 234-19...
Page 169: Install Rotating Bed Handrails
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Rotating Bed Handrails Figure 4-19 for the following procedure. The rotating bed has eleven handrails. The heaviest handrail weighs 9 kg (20 lb). Use a tagline to lift each handrail into position. For proper installation, match the identification number (10) on the handrail with the identification number on the platform.
Page 170 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View D — ROTATING BED WORKING View A — STORED View B— ROTATING BED WORKING View E — STANDALONE Item Description Left-Rear Platform View C — STANDALONE Top Ladder Bottom Ladder Ladder Hook (2)
Page 171: Using Rotating Bed Left-Rear Ladder (Past)
The ladder has been provided only for accessing and The pins must be in the upper holes B so the ladder servicing the Manitowoc MLC300 crane. Any other use is cannot fold during removal. neither intended nor approved. 2. Remove the padlock (8).
Page 172 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View D ROTATING BED WORKING View A — STORED View C STANDALONE View B ROTATING BED WORKING and STANDALONE Item Description Left-Rear Platform Top Ladder Bottom Ladder Ladder Hook (2) Pin with Hair-Pin Cotter (2)
Page 173: Using Rotating Bed Left-Rear Ladder (Current)
The ladder can be connected The ladder has been provided only for accessing and to the rear of the VPC-MAX beam. See the MLC300 servicing the Manitowoc MLC300 crane and VPC-MAX VPC-MAX Operator Manual for instructions.
Page 174 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Assist Crane Requirements: – 9 072 kg (20,000 lb) Capacity – 8,2 m (26 ft 9 in) Hook Height with Manitowoc Slings – 7 m (23 ft) Minimum Radius Item Description Live Mast Boom Hoist (Drum 4)
Page 175: Remove Live Mast Package From Trailer
3. Connect the other end of the lifting slings (6, View A) to The purpose of the hinge support (4, View B) is to prevent the lifting lugs (7) on the live mast (1) with the Manitowoc excessive bending in the mast legs when the mast supplied shackles (8).
Page 176 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A View B View E (2 places) Item Description Live Mast Boom Hoist (Drum 4) Boom Hoist Equalizer Mast Hinge Support Stand (2) Lifting Sling (3): 2,8m (9 ft) long Lifting Lug (3)
Page 177 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-25 for the following procedure. Using the forklift, lift the mast hinge support (4) into position on the right outboard side of the 12 m (39.4 7. If the live mast will be installed directly onto the crane ft) insert (13).
Page 178 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Live Mast Keeper Pin with Safety Pin (4) Mast Hinge Pin Equalizer Hinge Pin Pin with Safety Pin (4) Boom Hoist Mounting Frame View A1 Alignment Lug (2) STORED Alignment Ring (2)
Page 179: Install Live Mast Package
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Live Mast Package b. The alignment lugs (13, View D) on the boom hoist equalizer (14) engage the alignment rings (15) on Figure 4-26 for the following procedure. the rotating bed lugs (16).
Page 180 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Item Description Item Description Boom Hoist Equalizer Safety Pin Hydraulic Hose (2) Quick-Release Pin Hydraulic Couplers (2) Shims Shims Electric Cable (WRM1) Safety Pin Hydraulic Hose (5) Receptacle (WRR1-J3) Hydraulic Couplers (5)
Page 181 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION b. Store the pin (7, View B). • Connect the dust caps to the storage couplers. 15. Proceed as follows (two places) at the boom hoist (6, 18. Connect the electric cable (13, View E) from the rotating View A): bed to the receptacle (14) on the boom hoist.
Page 182 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A View B View F SHIPPING View C View D View E WORKING Figure 4-28 4-36 Published 11-20-19, Control # 234-19...
Page 183: Install Drum 3
• Match the identification numbers on the hoses with the identification numbers on the couplers for proper The MLC300 live mast and self-erect cylinder can be used to connection. lift the drum off the trailer. • Connect the dust caps to the storage couplers.
Page 184 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A — Shipping/Working Configuration without Drums 2 and 3 Item Description Front Platform Rear Platform Retaining Ring (qty 4) Bushing (qty 4) Pin (qty 4) Plate (qty 4) Safety Pin (qty 4) Safety Pin (qty 4)
Page 185 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION View C — Shipping/Working Configuration with Drums 2 Installed View D — Removed/Shipping/Working Configuration with Drums 2 and 3 Installed Figure 4-29 continued Manitowoc 4-39 Published 11-20-19, Control # 234-19...
Page 186 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-40 Published 11-20-19, Control # 234-19...
Page 187: Camera Connections
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Camera Connections Figure 4-30 shows Manitowoc recommended connections to the camera (CCTV) switchers on the front of the rotating bed. The crane owner can rearrange the connections as desired to meet operator preference. Item...
Page 188: Activate Setup Mode
See the RCL/RCI Operation Manual for step is performed. instructions. • Main Display to monitor the live mast angle and to view operating faults. See the MLC300 Main Display CAUTION Operation Manual for instructions. Mast Damage! • MAST ASSIST ARMS SWITCH to raise and lower the mast assist arms independently of the live mast.
Page 189: Live Mast Operating Precautions
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION • BOOM CONTROL HANDLE to raise and lower the live b. Extend the handrail (6, Figure 4-19 on page 4-22) mast while using it as a boom for crane assembly and from the stored position and pin it in the working disassembly.
Page 190: Attach Lifting Slings To Self-Erect Cylinder
The lifting capacity from one hole is the same as it is from two holes. See the Liftcrane Mast Handling Capacities chart for lifting capacities at Figure 4-5 on page 4-6 various radii and live mast angles. Refer to for the capacity of the Manitowoc supplied lifting slings and shackles. Item Description Self-Erect Cylinder...
Page 191: Lubricate Crawler-To-Carbody Machined Surfaces
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Entire Surface Crawler Carbody Entire Under Surface Both Views Typical Four Places Figure 4-33 Lubricate Crawler-to-Carbody Machined crawlers and the carbody — surfaces marked with an asterisk (*) in Figure 4-33. Surfaces Failing to perform this step will result in loud noises coming...
Page 192 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL TOP Holes Figure 4-32 on page 4-44 – See BOTTOM Holes View A Item Description Trailer (single-drop deck) View B Crawler Self-Erect Cylinder Lifting Slings (3 legs) Shackle (3): 20,5 t (23 USt) Lifting Link (3)
Page 193: Install First Crawler
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION 1. Position the trailer (1, View C) carrying the crawler (2) on Swing Limit for Handling First Crawler the desired side of the crane at the specified radius. Over Side of Carbody on Jacks The side of the crawler with one lifting link must face the crane.
Page 194 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL TOP Holes Item Description Not Used Crawler Self-Erect Cylinder Lifting Slings (3 legs) Shackle (3): 20,5 t (23 USt) Lifting Link (3) Top Holes BOTTOM Hitch Pin with Hair Pin Cotter (1) Holes (in bottom holes)
Page 195 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-36 for the remaining steps. 19. At the inboard lifting link (6, View A), move the hitch pin (7) from the top holes (8) in the bracket to the bottom 13. Lower the crawler, raise the live mast, and swing as holes in the bracket.
Page 196 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Trailer (single-drop deck) First Crawler Installed and Lowered to Ground Second Crawler 7,3 m (24 ft) Radius Figure 4-37 Item Description Ladder Bracket (2) Quick-Release Pin (2) Figure 4-38 4-50 Published 11-20-19, Control # 234-19...
Page 197: Install Second Crawler
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Second Crawler 3. If the second crawler is being lifted from the same side of the carbody as the first crawler, swing 180°. Figure 4-37 for the following procedure. 4. Repeat First Crawler Installation steps –...
Page 198 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Carbody Jack (4) Pin (4) Jack Pad (4) Storage Pin (4) Working Hole Storage Hole View A View C View B Figure 4-39 4-52 Published 11-20-19, Control # 234-19...
Page 199: Store Carbody Jacks
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Store Carbody Jacks Figure 4-39 for the following procedure. 1. Using the remote control, fully retract the carbody jack (1, View B). 2. Store the jack pad (3) as shown in View C. 3. Remove the connecting pin (2, View B) from the working hole (A).
Page 200 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Platform Assembly Quick-Release Pin (2) Shipping Hole Working Hole Folding Platform Hair-Pin Cotter Link Stud View A SHIPPING View B WORKING View C WORKING View D SHIPPING View E SHIPPING Figure 4-41...
Page 201: Deploy Carbody Side Platforms
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Deploy Carbody Side Platforms 4. Rotate the folding platform (3) to the working position (View C). The carbody side platform assemblies (1, View A) are Remove the hair pin cotter (4, View D) pin (5) and shipped in the closed position attached to the carbody.
Page 202 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Lifting Capacity Item Description 3 175 kg (7,000 lb) Trailer VPC Trolley Energy Chain Energy Chain Support Strut Pin with Hair-Pin Cotters Safety Pin Pin with Hair-Pin Cotter Hydraulic Hoses Hose Storage Bracket with Couplers...
Page 203: Prepare Vpc Trolley
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Prepare VPC Trolley 9. Attach a sling from the fork of the forklift or from an assist crane to the lifting link (14, View B) on the energy chain Disregard this procedure if the VPC trolley was shipped on (3).
Page 204 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL NOTE All views are typical two places at rear of rotating bed. Item Description Trolley Installation Guide (2) Safety Pin (2) Pin with Hair-Pin Cotter (4) Pin (2) Stop Block (2) Wear Pad Bracket (2) View B —...
Page 205: Install Vpc Trolley
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install VPC Trolley 1. Remove the trolley installation guides (1, View A) from the working/shipping position. 2. Place the trolley installation guides to the side until after the trolley is installed. DANGER 3. Remove the pins (3, View A), the pins (4), the stop...
Page 206 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A View B 158 mm (6-7/32 in) Less Than 0,5 mm (0.02 in) Item Description VPC Trolley Wear Pad Scraper Bracket with Screws and Lock Washers Wear Pad Gauge View C Storage Stud (4)
Page 207 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-44 for the following steps. Repeat the steps until you have the proper clearance at each wear pad. 7. Inspect and, if needed, adjust the VPC trolley wear pads (2, View A) prior to each installation of the VPC trolley.
Page 208 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Figure 4-43 on page 4-58 VPC Trolley Energy Chain Hydraulic Hoses (7) Electric Cable Trolley Roller (4) Trolley Rail (2) Drive Pinion (2) Gear Rack (2) Bulkhead View A — REAR CAN Terminator Plug...
Page 209 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-45 for the following steps. 18. Disconnect the dust caps from the shipping position (View D) and thoroughly clean the hydraulic couplers on 9. Position the forks from a forklift under the VPC trolley (7) the bulkhead (15, View D).
Page 210 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description VPC Trolley Limit Switch: VPC Trolley Minimum Position Limit Switch: VPC Trolley Maximum Position FRONT of Crane Dimension View of Limit Switches Looking 1 000 mm 39.37 in Outward through Left Access 3 915 mm 154.13 in...
Page 211: Vpc Trolley Limit Switch Checks
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION VPC Trolley Limit Switch Checks In the main display (Figure 4-47), the maximum position (B) limit switch icon (3) must indicate that Perform the VPC trolley limit switch checks each time the the limit switch is TRIPPED.
Page 212 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Trailer (flat deck) Counterweight Tray Self-Erect Cylinder Lifting Slings (4 legs) Shackle (4): 20,5 t (23 USt) Lifting Lug (4) Figure 4-32 on page 4-44 6,5 m (21 ft) Radius Figure 4-48...
Page 213: Remove Counterweight Tray From Trailer
"Boom and Jib Rigging — General" on page 4-74 Remove Counterweight Boxes from Trailer instructions. If the MLC300 will be used to assemble the boom and jib, If desired to expedite removal, the MLC300 live mast and install the counterweight tray and counterweight boxes self-erect cylinder can be used to remove the counterweight AFTER the boom and jib are assembled.
Page 214 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A VPC Arrangement View B VPC-MAX Arrangement Item Description Item Description Shackle (2): 20,5 t (23 USt) Pin with Cotter Pin (4) Lifting Sling (2): 2,8m (9 ft) long Pin with Cotter Pin (2)
Page 215: Prepare Counterweight Tray
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Prepare Counterweight Tray 6. Repeat step 1 through step 5 for the other mounting frame. Perform the following steps if needed. See Figure 4-50. 7. Connect two shackles (1, View B) and two lifting slings 1.
Page 216 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description VPC Trolley Counterweight Tray Keeper Plate (4) Quick-Release Pin (4) Counterweight Tray Pin (4) Lifting Pendant (4) Lifting Plate (2) View B 11 765 kg Assist Crane Sling (2) (25,937 lb) Lifting Lug (4)
Page 217: Install Counterweight Tray
(8) from the assist crane with the lifting plates (7). The MLC300 must be supported on crawlers before 8. Attach the other end of the lifting pendants (6, View C) to the tray can be installed.
Page 218 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A Series 1 Shown View B Series 1 Shown Series Item 2 Quantity Each Side Total Item Description Counterweight Tray Counterweight Box — 10 000 kg (22,046 lb) each Synthetic Lifting Slings (2)
Page 219: Install Counterweight Boxes
The counterweight chain assemblies are designed an assist crane. to minimize counterweight movement during travel 1. Travel the VPC trolley forward using the switch on the and operation permitted by Manitowoc’s operating remote control until the distance from the front edge (A, instructions. Figure 4-53) of the counterweight tray to the edge (B) of b.
Page 220: Boom And Jib Rigging - General
See the Crane • Mast assist arms (2) fully raised. Weights topic in Section 1 the MLC300 Operator Manual for • Lifting link (6) attached to the self-erect cylinder (5). the weights of boom and jib components.
Page 221: Blocked Crawlers
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Blocked Crawlers Item Description To prevent the crane from tipping, some boom and jib Boom or Jib Chord lengths must be raised and lowered over blocked crawlers. Boom or Jib Number See the appropriate boom or jib capacity chart for blocked...
Page 222 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A View B View C View D View E View F Item Description Boom Section (typical) (also see item 7, View G) Boom and Luffing Jib STRAPS STORED Lifting Lug (4, if equipped) (for shackles of lifting sling hooks)
Page 223: Handling Components
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Handling Components Handle the boom and jib sections with care to avoid CAUTION damaging the lacings and chords. Lacing Damage! All boom and jib sections have lifting lugs as shown in Ensure the boom straps and links...
Page 224 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View B Lifting Arrangement for All Inserts View A 6,5 m (21 ft) Radius Standard Width OR 3.5 m Wide WORKING View E STORED View C Item Description SHIPPING Shackle (2): 25 t (28 USt)
Page 225: Boom #500 Assembly
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION BOOM #500 ASSEMBLY Position the trailer (4) carrying the insert (5, View A) on the desired side of the crane at the specified radius. NOTE The first insert must be the 12 m (39.4 ft) insert with WARNING sheaves.
Page 226 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Important: Pins are not required in these holes. NOTE The first three inserts after the boom butt can be either standard width inserts OR 3.5 m wide inserts, depending on the Boom Rigging Drawing being used.
Page 227 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION 7. Repeat step 2 page 4-79 for the next insert (10). 13. If necessary per the Boom Rigging Drawing being used, perform the following steps as the boom inserts are Figure 4-58 for the following steps.
Page 228 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A View B Item Description Intermediate Wire Rope Guide Pin and Cotter Pins (2) Wear Pad (2) Insert Adjacent Insert Pin with Cotter Pins (2) Storage Bracket (2) Figure 4-59 4-82 Published 11-20-19, Control # 234-19...
Page 229: Install Intermediate Wire Rope Guide
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Intermediate Wire Rope Guide Disconnect the lifting slings. Proceed to install the remaining boom inserts (5, View If the intermediate wire rope guide is required per the Boom Rigging Drawing in use, install the wire rope guide as follows:...
Page 230 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View E View D View C Butt View F View B Item Description Lifting Lug (2) Socket (2) Insert (closest to butt) Connecting Pin with safety pins (2) Adjacent Insert Drop-Down Suspension Beam Assembly...
Page 231: Install Drop-Down Suspension
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Drop-Down Suspension 7. Store the standard strap links in the parts box or on the suspension beam (View F) after the strap links (10) are If the drop-down suspension is required per the Boom removed.
Page 232 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View B View A 6,5 m (21 ft) Radius Important: Pins are not required in these holes. Item Description View C Shackle (2): 25 t (28 USt) Lifting Sling (4): 2,8 m (9 ft) long...
Page 233: Install Boom Top
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Boom Top 3. Lower the boom top (15, View E) until the bottom connector holes are aligned. Figure 4-62 for the following steps. 4. Remove the pins (13, View E) from the storage tubes 1.
Page 234 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A View B SHIPPING WORKING View C SHIPPING Item Description Synthetic Lifting Sling (1)(owner furnished) Wire Rope Guide Chord Rope Guard with Safety Pins Strut (2) Pin with Safety Pin (2) Position Light and Wind Speed Indicator Assembly...
Page 235: Raise Boom Top Wire Rope Guide
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Raise Boom Top Wire Rope Guide 3. Install the other safety pin in the top hole of the bracket (9, View D). Figure 4-63 for the following procedure. 4. Connect the electric cable (11, View D) from the boom 1.
Page 236 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Jib Backstay Straps, If Equipped (typical) View A2 SHIPPING View B2 WORKING View A1 SHIPPING View B1 WORKING Item Description View C Strap Link Pin with Safety Pins Bracket Pin with Collar, Retaining Pin, and Cotter Pins...
Page 237: Connect Boom Straps
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Connect Boom Straps 1. Remove retaining pins (3, View A1 or A2) and store them in the brackets (4, View B1 or B2). Figure 4-65 for the following procedure. 2. Remove pin (5, View A1 or A2).
Page 238 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View B View A View C View D Item Description Boom Top Lower Boom Point View E Sheave Cluster (1 or 3) Lifting Ring (2) Pin with Cotter Pins (2) Pin with Lug (4)
Page 239: Install/Remove Lower Boom Point
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install/Remove Lower Boom Point Removing Lower Boom Point Sheave Clusters Figure 4-66 View E, for the following procedure. Figure 4-66 for the following procedure. 1. Remove the rope guard (8). If removed, install the lower boom point as follows.
Page 240 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A Item Description Upper Boom Point Lifting Lug (if equipped) Pins with Safety Pins (2) Block-Up Limit Lug Pins with Safety Pins (2) Electric Cable Receptacle - ATTACHMENTS Shorting Plug Electric Cable - CAN NET OUT...
Page 241: Install Upper Boom Point
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Upper Boom Point 7. Connect the electric cable (5) from the upper boom point to the WBT1-J2 receptacle (6) on the boom top (View A). The electric cable is stored on the brackets on the left side of the upper boom point.
Page 242 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Inboard Side View B without Drum 6 Upper Lower View C with Drum 6 View A 6,5 m (21 ft) Radius Legend is on the following page. Upper Lower Inboard Side View H STORED...
Page 243: Connect Boom Butt To Crane
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION legend for Figure 4-68 2. Remove the boom butt (4, View A) from the trailer (5): Item Description Position the trailer (5, View A) carrying the boom Shackle (2 or 6): 25 t (28 USt) butt (4) on the desired side of the crane at the Lifting Sling (4): 1 m (3.3 ft) long —...
Page 244 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View C View A View B View D View E View F Item Description Handling Pendant (2) Hitch Pin with Hair-Pin Cotter Boom Butt Live Mast Self-Erect Cylinder Lifting Link Hooked Connector (2) Fixed Horizontal Pin (2)
Page 245: Connect Boom Butt To Boom
Prevent the crane from tipping: • For boom lengths longer than 66 m (216.5 ft), use the live mast and Manitowoc supplied lifting • Block the crawlers — if required per the capacity slings and shackles to close and open the boom chart —...
Page 246 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View B FULLY RAISED View A FULLY LOWERED View D View C Item Description Mast Assist Arm (2) Live Mast Self-Erect Cylinder Lifting Link View E Storage Lug (2) Pin with Cotter Pins (2)
Page 247: Connect Mast Straps To Boom Straps
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Connect Mast Straps to Boom Straps 5. Remove the pins (8, View D) from storage. 6. Rotate the links (9, View D) rearward and pin them to the Figure 4-70 for the following steps.
Page 248 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View F View A View E View B View C View D Figure 4-71 4-102 Published 11-20-19, Control # 234-19...
Page 249: Connect Hydraulic Hoses From Crane To Boom Butt
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Legend for Figure 4-71 4. Make sure the boom hinge pin hydraulic hoses (3, View D) are disconnected from the couplers (4) on the rotating Item Description bed. Hydraulic Hoses (from crane) Hydraulic Couplers (on boom butt)
Page 250 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View C View B View A Item Description Camera Camera Shaft Bracket Hair-Pin Cotter Electric Cable (WBT3) Eyebolt View D Bracket Boom Top Electric Cable (WBR3) Cable Reel Electric Cable (WBB5) Camera Switchers Figure 4-72...
Page 251: Install Boom Top Camera And Connect Electric Cables
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Boom Top Camera and Connect 4. Connect the electric cable (5, View C) to the bracket (7, View D) in the boom top (8). Electric Cables 5. Pay out electric cable (9, View B) from the cable reel Figure 4-72 for the following procedure.
Page 252 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL STORED Multiple Part STORED 1-Part Item Description Position Indicator Light Wind Speed Indicator Limit Switch (lower and upper boom point) Chain Weight with 2-Chain Attachments Lift Plate Hook-and-Weight Ball Weight with 1-Chain Attachment Lift Block...
Page 253: Install The Boom Load Lines
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install the Boom Load Lines • Wire Rope Installation on page 4-161 • Load Line Reeving on page 4-171 1. Route the load lines up the boom. See Figure 4-114 on page 4-170. •...
Page 254 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A View F All Views Typical Two Places Item Description Intermediate Suspension Pendant (2) 12 m (39.4 ft) Intermediate Suspension Insert Pendant Button (7 each pendant) Socket Locking Pin with Hair-Pin Cotter (2) Socket (2).
Page 255: Prepare Intermediate Suspension Pendants
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Prepare Intermediate Suspension Pendants 3. Remove the socket locking pins (4, View B) and raise the sockets (5) from the shipping position to the rigging Figure 4-74, for the following procedure3. position (View C).
Page 256: Raise Boom
 Left-rear rotating bed ladder is folded in stored position or removed. NOTE Refer to the MLC300 Luffing Jib Operator Manual for  All tools and other items are removed from boom and jib. the pre-raising checks and raising procedure when equipped with a luffing jib.
Page 257: Shipping Crane Components
Check all safety devices for proper operation (see the holes in the boom top. Install the connecting pins. Section 3 of the MLC300 Operator Manual). Figure 4-67 on page 4-94.
Page 258: Crane Disassembly
SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Electric Cables from Cable Reels in Boom Insert Stored on Top End of Boom Butt Electric Cables from Boom Butt to Rotating Bed Stored on Bottom End of Boom Butt Figure 4-77...
Page 259: Lower Boom
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Lower Boom Remove Block-Up Limit Components Remove the block-up limit weights and chains (see Figure 4-73 on page 4-106) and store them as shown. • The chain and weight for the lower boom point are WARNING stored on brackets in the boom top.
Page 260 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View B FULLY RAISED View A FULLY RAISED View D View C Item Description Mast Assist Arm (2) Live Mast Self-Erect Cylinder Lifting Link View E Storage Bracket (2) Pin with Cotter Pins (2)
Page 261: Activate Setup Mode
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Activate Setup Mode Perform the steps under Setup Mode on page 4-9. WARNING Disconnect Mast Straps from Boom Straps Falling Load Hazard! Figure 4-79 for the following steps. Do not exceed a maximum mast angle of 156°. The mast could fall suddenly.
Page 262 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View C View A View B View D View E Item Description Handling Pendant (2) Hitch Pin with Hair-Pin Cotter Boom Butt View F Live Mast Self-Erect Cylinder Lifting Link Hooked Connector (2) Fixed Horizontal Pin (2)
Page 263: Disconnect Boom Butt From Boom
For boom lengths longer than 66 m (216.5 ft), use • Use only the self-erect cylinder to raise the boom butt the live mast and Manitowoc supplied lifting during the following steps. slings and shackles to close and open the boom as instructed in F2293 at the end of this section.
Page 264 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View B without Drum 6 Upper Lower View C with Drum 6 View A 6,5 m (21 ft) Radius Legend is on the following page. Upper Lower View H STORED View D DISENGAGED View G...
Page 265: Disconnect Boom Butt From Crane
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION legend for Figure 4-81 5. Remove the hitch pins (10, View E) to UNLOCK the boom hinge pins from the engaged position. Item Description Shackle (2 or 6): 25 t (28 USt) 6. Raise the boom butt to horizontal (View F).
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Page 267: Disassemble Boom
Personal Fall-Protection on page 4-3. page 4-91. 6. Disassemble the boom sections. Reverse the steps If the MLC300 will be used to disassemble the boom, remove under Assemble Boom Inserts on page 4-79. the counterweight boxes and tray before proceeding. See:...
Page 268 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A Series 1 Shown View B Series 1 Shown Series Item 2 Quantity Each Side Total Item Description Counterweight Tray Counterweight Box — 10 000 kg (22,046 lb) each Synthetic Lifting Slings (2)
Page 269: Remove Counterweight Boxes
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Remove Counterweight Boxes The ratchet on each turnbuckle must be flipped in one direction to tighten the turnbuckle and in the opposite Figure 4-82 for the following procedure. direction to loosen the turnbuckle. NOTE The counterweight boxes (2) must be removed with 3.
Page 270 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description VPC Trolley Counterweight Tray Keeper Plate (4) Quick-Release Pin (4) Counterweight Tray Pin (4) Lifting Pendant (4) Lifting Plate (2) View B 11 765 kg Assist Crane Sling (2) (25,937 lb) Lifting Lug (4)
Page 271: Remove Counterweight Tray
6. Disconnect the electric cable (16, View H) from the tray of the tray. at the electric cable in the right rear corner of the trolley The MLC300 must be supported on crawlers when (1). the tray is removed. 7. Hoist with the assist crane so the lifting pendants (6, View A) are taut.
Page 272 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL NOTE All views are typical two places at rear of rotating bed. Item Description Trolley Installation Guide (2) Safety Pin (2) Pin with Hair-Pin Cotter (4) Pin (2) Stop Block (2) Wear Pad Bracket (2) View B —...
Page 273: Remove Vpc Trolley
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Remove VPC Trolley NOTE Disregard this procedure if the VPC trolley is not being removed for shipping. DANGER If the VPC trolley is not being removed for shipping, Tipping Hazard! use the remote control to travel the VPC trolley (1,...
Page 274 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Figure 4-85 on page 4-126 VPC Trolley Energy Chain Hydraulic Hoses (7) Electric Cable Trolley Roller (4) Trolley Rail (2) Bulkhead CAN Terminator Plug View A — REAR Hose Storage Bracket with...
Page 275 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-87 for the remaining steps. 14. Remove the trolley installation guides (1, View D, Figure 4-85 on page 4-126). 6. Unpin and remove the hose storage bracket (15, View D) from the right side of the rotating bed. Place the 15.
Page 276 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Lifting Capacity Trailer 3 175 kg (7,000 lb) VPC Trolley Energy Chain Energy Chain Support Strut Pin with Hair-Pin Cotters Safety Pin Pin with Hair-Pin Cotter Hydraulic Hoses Hose Storage Bracket with...
Page 277: Prepare Vpc Trolley For Shipping
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Prepare VPC Trolley for Shipping b. Install the energy chain supports (12 and 13, View B) in the shipping positions. NOTE Disregard this procedure if the VPC trolley is not Lower the energy chain onto the supports as shown being removed for shipping.
Page 278 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View B Front of Each Crawler View A1 Rear of Each Crawler PAST Item Description Storage Couplers Hydraulic Hoses Electric Cable Storage Receptacle Figure 4-89 View A2 Rear of Each Crawler CURRENT 4-132 Published 11-20-19, Control # 234-19...
Page 279: Store Carbody Side Platforms
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Store Carbody Side Platforms 3. Install dust caps on the carbody hydraulic couplers (7 places each crawler). Reverse the installation steps to store the carbody side 4. Install dust caps on the carbody electric receptacles (2...
Page 280 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Figure 4-32 on page 4-44 In Top Holes View B In Bottom Holes View A View C View E View D 7,3 m (24 ft) Radius Item Description Item Description First Crawler Collar Second Crawler...
Page 281: Remove First Crawler
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Remove First Crawler 4. Using the remote control, fully retract the jacking cylinders next to the second crawler (2, View C). Figure 4-90 for the following procedure. The opposite side crawler must be on the ground.
Page 282 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL NOTE The item numbers in this illustration correspond to the item numbers in Figure 4-90. Item Description Second Crawler Lifting Link (3) Lifting Slings (3 legs) Shackle (3): 20,5 t (23 USt) Self-Erect Cylinder...
Page 283: Remove Second Crawler
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Remove Second Crawler 1. Using the remote control, extend the jacking cylinders next to the second crawler (2, View A, Figure 4-91) until the first stage of each cylinder is fully extended. Swing Limit for Handling Second Crawler...
Page 284 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A FULLY RAISED View B Item Description Live Mast Mast-Assist Arm and Cylinder (2) Self-Erect Cylinder Lifting Link Storage Bracket (2) Figure 4-93 4-138 Published 11-20-19, Control # 234-19...
Page 285: Lower Live Mast To Transport Position
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Lower Live Mast to Transport Position 3. During the lowering procedure, monitor the MAST ANGLE in the crane status information bar of the Main Figure 4-93 for the following procedure. Display Working Screen. 4. Increase engine speed to the desired RPM.
Page 286 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A View B View F SHIPPING View C View D View E WORKING Figure 4-94 4-140 Published 11-20-19, Control # 234-19...
Page 287: Remove Drum 2
Rotating Bed Lugs 5. Connect the other end of the lifting slings (2, View A) to Pin with Cotter Pins (2) the lifting lugs (3) on the drum (1) with the Manitowoc Hitch Pin with Hair-Pin Cotter (2) supplied shackles (4).
Page 288: Remove Live Mast Package
SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Item Description Item Description Boom Hoist Equalizer Safety Pin Hydraulic Hose (2) Quick-Release Pin Hydraulic Couplers (2) Shims Shims Electric Cable (WRM1) Safety Pin Hydraulic Hose (5) Receptacle (WRR1-J3) Hydraulic Couplers (5)
Page 289 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION 5. Disconnect the electric cable (17, View H) from the a wire tie. receptacle (18) on the rotating bed. b. Disconnect four hydraulic hoses (11, View E) from 6. Disconnect the two hydraulic hoses (15, View H) from the couplers (12) on the boom hoist.
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Page 291 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Assist Crane Requirements: – 9 072 kg (20,000 lb) Capacity – 8,2 m (26 ft 9 in) Hook Height with Manitowoc Slings – 7 m (23 ft) Minimum Radius Item Description Lifting Sling (3): 2,8m (9 ft) long...
Page 292 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Live Mast Keeper Pin with Safety Pin (4) Mast Hinge Pin Equalizer Hinge Pin View A1 Pin with Safety Pin (4) STORED Boom Hoist Mounting Frame Alignment Lug (2) Alignment Ring (2)
Page 293 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-98 for the remaining steps. 16. To assist in accessing the pins (5, View C) in the next step, you can extend the VPC trolley (17, View F) 12. Hoist with the assist crane just enough to tension the rearward NO MORE THAN 813 mm (32 in) from the stop lifting slings.
Page 294 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A View B View E (2 places) Item Description Live Mast Boom Hoist (Drum 4) Boom Hoist Equalizer Mast Hinge Support Stand (2) Lifting Sling (3): 2,8m (9 ft) long Lifting Lug (3)
Page 295: Install Live Mast Package On Trailer
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Live Mast Package on Trailer Support the mast hinge support (4, View F) with the forks from a forklift. The mast hinge support weighs Figure 4-99 for the following procedure. 82 kg (181 lb).
Page 296 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Live Mast Boom Hoist (Drum 4) Boom Hoist Equalizer Mast Hinge Support Stand (2) Lifting Sling (3): 2,8m (9 ft) long Lifting Lug (3) Shackle (3): 20,5 t (23 USt) Blocking View A...
Page 297 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION 4. Position the trailer carrying the live mast package in the 6. Lower the live mast package so the stands (5, View B), assembly area. the mast hinge support (4), and the boom hoist (2) are firmly contacting the deck of the trailer.
Page 298 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Handrail Handrail Handrail (5) Handrail Handrail (2) Telescopic Handrail Handrail Safety Pin (2 each handrail) Left-Rear Platform Identification Number Valve Cover Platform (3) Figure 4-101 4-152 Published 11-20-19, Control # 234-19...
Page 299: Store Rotating Bed Left-Rear Platform And Handrails
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Store Rotating Bed Left-Rear Platform and 1. Starting at the desired handrail (1-7), remove the safety pins (8). Handrails 2. Lift the handrail out of the pockets in the platform. Figure 4-101 for the following procedure.
Page 300 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Left-Front Platform Quick-Release Pin (2) Pin with Hair-Pin Cotter (2) Platform Brace (2) Left-Front Ladder Quick-Release Pin (2) Padlock Support Arm Storage Bracket (2) Pin with Hair-Pin Cotter (2) Quick-Release Pin (1)
Page 301: Move Rotating Bed Left-Front Ladder To Working Position
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Move Rotating Bed Left-Front Ladder to the padlock (7, View ES) to connect the left-front ladder to the ladder support arm (8). Working Position Move Rotating Bed Left-Front Platform to Figure 4-102 for the following procedure.
Page 302 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL View A SHIPPING Item Description Item Description Operator Cab Operating Lugs Hitch Pin with Hair-Pin Cotter Cab Rear Platform Support Arm Quick-Release Pin (2) Pin with Hair-Pin Cotter Handrail View C Turnbuckle Safety Pin (3)
Page 303: Store Right Side Rear View Mirror
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Store Right Side Rear View Mirror 6. Close and lock the cab door. 7. Reactivate the remote control. See Activating Remote This mirror is optional. Control on page 4-9. Reverse the installation steps to store the mirror (see Deploy 8.
Page 304 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL WARNING Falling Load Hazard! These lugs are for factory use only. Do not attempt to lift the rotating bed and carbody with them. The lugs could break, allowing the rotating bed and carbody to fall.
Page 305: Install Carbody-Rotating Bed Module On Trailer
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Install Carbody-Rotating Bed Module on Using the remote control, fully retract the carbody jacks (View D). Trailer 8. Store the jack pads (7, View B). Each jack pad weighs Figure 4-105 for the following procedure.
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Page 307: Wire Rope Installation
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION WIRE ROPE INSTALLATION Before cutting the wire rope, apply seizings on both sides of the point where the cut will be made. Then cut the wire rope NOTE The wire rope manufacturer’s recommendations take with a torch, rope cutter, or abrasive cut-off wheel.
Page 308: Anchoring Wire Rope To Drum
SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Don’t Allow End of Wire Rope to Extend Out of Socket Opening Item Description Wire Rope Pocket in Drum Barrel Straight Wedge Seizing Figure 4-107 Anchoring Wire Rope to Drum Item Description Item Description...
Page 309 MLC300 OPERATOR MANUAL SETUP AND INSTALLATION d. Avoid dragging the wire rope in the dirt or around objects that can scrape, nick, cut, or crush the wire rope. 2. Carefully inspect the drums and all rope guides, rollers, and sheaves for defects that can cause the wire rope to wear or be cut.
Page 310 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL T (Rope Clip Nut Torque) Wire Rope/Clip Size Item Description inch 1-1/8 1-1/4 Seizing (mm) (22,23) (25,4) (28,58) (31,75) Dead End Torque Live End in Straight Line with Socket * ft/lb Socket (kN/m) (0,30)
Page 311: Anchoring Wire Rope To Wedge Socket
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION Anchoring Wire Rope to Wedge Socket 7. After the socket is pinned in place, hoist the load slowly so the wedge seats tightly. Do not shock load the socket and wedge. WARNING Falling Load Hazard! WARNING •...
Page 312 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Item Description Rigging Line Connector Wire Rope with Button Pad Eye No. 1.5 Pad Eye Item Inch Wire Rope without Button Approximate Capacity 553 kg (1220 lb) 16,00 Shackle 6,35 Rigging Line 25,40 Rope Clips...
Page 313: Pad Eye Usage For Wire Rope Reeving
This slackening is caused by the normal stretch that occurs in a new wire rope under tension Some rotation-resistant wire rope supplied by Manitowoc is and periodically throughout the wire rope’s life from release equipped with a pad eye welded to the leading end of the of the load.
Page 314: Rigging Winch Operation
TO TURN RIGGING WINCH OFF — 1. Scroll to the rigging winch selection screen (4) in the TO TURN RIGGING WINCH ON — Main Display. See MLC300 Main Display Operation 1. Scroll to the rigging winch selection screen (4) in the Manual for instructions.
Page 315: Operating Rigging Winch
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION 2. Use either the jog dial on the right console or the scroll NOTE Use the engine throttle to increase and decrease keys on the Main Display to highlight the OFF (O) icon rigging winch line pull and to control line slack at the (6) in the selection box.
Page 316 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Refer to the Reeving Diagrams at the end of this section for rope routing over the boom top wire rope guide (7). Item Description Drum 1 Drum 2* Drum 3* Wire Rope Guide on 12 m (3.5 ft) Insert Wire Rope Guide in 12 m (3.5 ft) Insert...
Page 317: Load Line Reeving
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION LOAD LINE REEVING Duplex Hook Attach the load so it is balanced equally on the hook. The lifting slings must be within the angles given in Figure 4-115 WARNING to achieve maximum hook capacity. The duplex hook has a...
Page 318 SETUP AND INSTALLATION MLC300 OPERATOR MANUAL Upper Boom Point Two Drum Reeving One Drum Reeving Multiple Parts of Line Lower Boom Point — PAST Upper Boom Point Single Part of Line Lower Boom Point CURRENT NOTE The location of the sheave cluster (6) can vary depending on reeving.
Page 319: Load Block Tieback
MLC300 OPERATOR MANUAL SETUP AND INSTALLATION LOAD BLOCK TIEBACK General Tieback hole (1, Figure 4-117) is provided on the front of the rotating bed for tying back the load block when not in use. Specifications Sling Length The sling must be long enough to connect it to the shackles in the tieback hole and to the hook of the freely suspended load block.
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Page 321: Section 5
Lube and Coolant Product Guide ........... . . 5-1 Manitowoc...
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Page 323: Lube And Coolant Product Guide
MLC300 OPERATOR MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION See F2280 at the end of this section. LUBE AND COOLANT PRODUCT GUIDE See the publication at the end of this section. Manitowoc Published 11-20-19, Control # 234-19...
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Page 325 Fiberglass Maintenance ............6-1 Manitowoc...
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Page 327: Inspection And Maintenance Checklist
MLC300 OPERATOR MANUAL MAINTENANCE CHECKLIST SECTION 6 MAINTENANCE CHECKLIST INSPECTION AND MAINTENANCE CHECKLIST See F2273 at the end of this section. FIBERGLASS MAINTENANCE See Bulletin W04-009 at the end of this section. Manitowoc Published 11-20-19, Control # 234-19...
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Page 329 Maintenance Checklist ............. 6-1 Manitowoc...
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Manitowoc MLC300 Operator's Manual

Section 1

Section 2

Section 3

Section 4

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Summary of Contents for Manitowoc MLC300