Page 1 Manitowoc MLC300 with Fixed Position Counterweight Operator Manual...
Page 3 NOTICE The serial number of the crane and applicable attachments (i.e. luffing jib) 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 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL General..............2-23 Location .
Page 7 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL TABLE OF CONTENTS Free Fall Brake Pedal Hydraulic Pressure Test........3-73 Free Fall Brake Operational Test.
Page 8 TABLE OF CONTENTS MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Deploy Cab Rear Platform ........... . . 4-17 Move Cab Tilt Stop Pins to Working Position .
Page 9 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL TABLE OF CONTENTS Connect Electric Cables from Boom Butt to Crane ........4-91 Install Boom Top Camera and Connect Electric Cables .
Page 10 TABLE OF CONTENTS MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Anchoring Wire Rope to Wedge Socket ......... . 4-150 Anchoring Wire Rope to Button Socket .
Page 11 Manitowoc Dealer........
Page 12 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 08-14-19, Control # 256-05...
Page 13: Section 1
• A colored arrow (2) and dot (3) on the right top and right If you are the new owner of a Manitowoc crane, please front sides of the carbody indicate the FRONT of the register it with Manitowoc Crane Care so we can contact you...
Page 14 INTRODUCTION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 08-14-19, Control # 256-05...
Page 15: Identification And Location Of Components
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL INTRODUCTION IDENTIFICATION AND LOCATION OF COMPONENTS Item Description Drum 0 (rigging winch) Drum 1 (main hoist) Drum 2 (aux hoist) Drum 3 (aux hoist) Drum 4 (boom hoist) Boom Butt Drum 6 (luffing or auxiliary hoist)
Page 16 INTRODUCTION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Item Description Item Description Operator Cab Counterweight Tray Retainer (2) Swing Drive (1 is standard) Batteries (inboard right side) Crawler Fuel Tank Crawler Drive Mast Equalizer Intermediate Roller Load Pin (right side only)
Page 17 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL INTRODUCTION Item Description Drum 2 (aux hoist) Mast-Assist Arm and Cylinder (2) Drum 3 (aux hoist) Drum 4 (boom hoist) Hydraulic Tank Pump Drive with Pumps (under guards) Cooler Assembly (under guards) Engine (under guards)
Page 18: English And Metric Conversions
INTRODUCTION MLC300 FIXED POSITION COUNTERWEIGHT 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 FIXED POSITION COUNTERWEIGHT 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...
Page 20 INTRODUCTION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 08-14-19, Control # 256-05...
Page 21: Section 2
Personnel Handling Policy ............2-24 Manitowoc...
Page 22 MLC300 FIXED POSITION COUNTERWEIGHT 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 FIXED POSITION COUNTERWEIGHT 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...
Page 25: Safety And Information Signs
MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 26 SAFETY INFORMATION MLC300 FIXED POSITION COUNTERWEIGHT 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)
Page 27 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SAFETY INFORMATION Figure 2-1 continued Manitowoc Published 08-14-19, Control # 256-05...
Page 28: Crane Access Points
Manitowoc has provided ladders and platforms at the When personnel use ladders to get on or off the crane, their locations shown in Figure 2-1.
Page 29: Personal Fall-Protection
MLC300 FIXED POSITION COUNTERWEIGHT 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!
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 FIXED POSITION COUNTERWEIGHT 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
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SAFETY INFORMATION Land all suspended loads, if possible, under brake boom rigging) must be securely blocked to prevent the or power control. boom, jib, or mast sections from dropping. b. Apply all brakes and locking devices.
Page 34: Lifting/Moving Load
SAFETY INFORMATION MLC300 FIXED POSITION COUNTERWEIGHT 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.
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 FIXED POSITION COUNTERWEIGHT 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).
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 FIXED POSITION COUNTERWEIGHT 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.
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 FIXED POSITION COUNTERWEIGHT 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 FIXED POSITION COUNTERWEIGHT 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 –...
Page 45: Boom Disassembly Safety
MLC300 FIXED POSITION COUNTERWEIGHT 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
Travel Operation ............. 3-76 Manitowoc...
Page 52 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Shutdown Procedure or Leaving the Crane Unattended........3-78 Cold Weather Operation .
Page 53 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 08-14-19, Control # 256-05...
Page 54: Standard Hand Signals For Controlling Crane Operations
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 55 MLC300 FIXED POSITION COUNTERWEIGHT 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 FIXED POSITION COUNTERWEIGHT 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 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-2. Symbol Identification — Control Consoles Engine Run Light, Consoles M100159 M100165 Engine Start Light, Position M100160 M100291 Engine Stop Light, Work (and camera) M100161 M100166 Lighter M100142 M100167...
Page 58 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 59: Symbols Used On Remote Control
MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 60 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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)
Page 61 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-3. Symbol Identification — Remote Control Pins, Live Mast Hinge Speed, Slow M102450 M100184 Signal, Transmission Winch, Rigging M102441 M101687 Speed, Fast Winch, Rigging (Pay Out/Haul In) M100183 M101687b...
Page 62: Operating Controls
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS Figure 3-1. Cab Controls and Indicators 3-10 Published 08-14-19, Control # 256-05...
Page 63 MLC300 FIXED POSITION COUNTERWEIGHT 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 3-28 for more information. Free Fall Brake Pedals page 3-29 for more information.
Page 64 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Adjustable rear-view mirror. Standard mirror is mounted on the cab. An Rear View Mirror optional mirror is mounted on the right-front side of rotating bed. Store the setup remote control in this compartment. The door latch can Storage Compartment be locked with the provided key.
Page 65 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Turn the knob CLOCKWISE to CONNECT the battery circuit. Turn the knob COUNTERCLOCKWISE to DISCONNECT the battery circuit for the following reasons: • When servicing the crane’s electrical control system.
Page 66 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL page 3-32 for more information. Boom Angle Indicator 3-14 Published 08-14-19, Control # 256-05...
Page 67 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-15 Published 08-14-19, Control # 256-05...
Page 68: Left Console
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 69 MLC300 FIXED POSITION COUNTERWEIGHT 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 70: Right Console
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Right Console Table 3-6. Right Console 3-18 Published 08-14-19, Control # 256-05...
Page 71 Not Used Displays operating conditions, faults, and diagnostic information. See the Main Display MLC300 Main Display Operation Manual for detailed information. Manitowoc 3-19 Published 08-14-19, Control # 256-05...
Page 72 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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 73 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-6. Right Console Alternatively, each of the crane functions can be parked in the Main Display Speed and Torque Settings Screen. See the Main Display Operation Manual for instructions.
Page 74 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 75 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-6. Right Console Travel Operation on page 3-76. The following directions of travel are with the front of the rotating bed and the front of carbody facing the same direction.
Page 76 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 77 • 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 78 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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 79 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-27 Published 08-14-19, Control # 256-05...
Page 80: Foot Pedals
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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 81 MLC300 FIXED POSITION COUNTERWEIGHT 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 82: Seat Controls
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Seat Controls Table 3-8. Seat Controls Item Name Description Seat Riser on Left Console page 3-16 for operating instructions. • Push the lever to the LEFT to UNLOCK the seat.
Page 83: Climate Control Keypad
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Climate Control Keypad Table 3-9. Climate Control Keypad Item Name Description Temperature Set Switches Increments the set point 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 84: Other Operator Aids
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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 85 MLC300 FIXED POSITION COUNTERWEIGHT 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°...
Page 86: Crane Cameras
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Crane Cameras Table 3-10. Crane Camera Locations Item Name Camera Points at LOAD from boom point or from luffing jib point Camera Points at DRUM 6 Camera Points at DRUM 1...
Page 87: Crane Camera Monitor
MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 88 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-36 Published 08-14-19, Control # 256-05...
Page 89: Motion Warning Alarms
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES MOTION WARNING ALARMS Table 3-12. Motion Warning 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 90: Service Lights
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SERVICE LIGHTS Table 3-13. Service Light Components Drum Description Service Work Light (2) On-Off Switch Load Center Receptacle (4) 3-38 Published 08-14-19, Control # 256-05...
Page 91 MLC300 FIXED POSITION COUNTERWEIGHT 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 on the rear Portable Service Light shelf in the operator cab. Each light has an extension cord and magnetic base that allows the light to be mounted and pointed in the desired direction.
Page 92: Remote Control Activation
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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 3-40...
Page 93 3-40) 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 94: Remote Control Operation
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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. 3-42 Published 08-14-19, Control # 256-05...
Page 95 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 96 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 97 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 98 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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 •...
Page 99: 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 100 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL The following table describes the operating limits this crane is equipped with. When a limit is reached, the operating limit fault is activated and the corresponding fault icon appears in the fault bar of the Main Display Working Screen.
Page 101 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Operating Limit Icon Function Parked This limit prevents the selected crane function from being operated until the park switch is turned off (un- parked). M102772 M104949 Free Fall Lowering Over Speed This limit does not stop operation.
Page 102 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 103 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 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 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 FIXED POSITION COUNTERWEIGHT 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 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-54 Published 08-14-19, Control # 256-05...
Page 107: Drum And Control Handle Identification
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES DRUM AND CONTROL HANDLE IDENTIFICATION Drum Description Main Hoist Auxiliary Front Hoist (optional) Auxiliary Rear Hoist (optional) Boom (Mast) Hoist Luffing or Auxiliary Hoist Tagline Winch (optional) Rigging Winch (optional)
Page 108 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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.
Page 109: Right Cab Window Operation
MLC300 FIXED POSITION COUNTERWEIGHT 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 FIXED POSITION COUNTERWEIGHT 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)
Page 111: Ladder Installation
3. Install the pins (5, View B). The ladder has been provided only for accessing and Removing Ladder servicing the Manitowoc MLC300. Any other use is neither intended nor approved. 1. Lower the bottom ladder (3) to the working/standalone position as shown in View B and install the pins (5).
Page 112: Operating In Wind
Section 4 of Failing to observe this precaution can cause the crane to the MLC300 Operator Manual, and in Section 4 of the tip or the boom and/or jib to collapse. Death or serious MLC300 Luffing Jib Manual.
Page 113: Startup Procedures
CAUTION other crane heaters. Machinery Damage Hazard NOTE Manitowoc recommends the use of the Cold Before operating the crane at the start of each shift: Weather Package to aid startup when the ambient temperature will be 0°C (32°F) and below.
Page 114 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 4. Make sure the hydraulic tank shutoff valves are open as shown in Figure 3-12. CAUTION Pump Damage Do not start the engine until the hydraulic tank shutoff valve is open. Otherwise, the pumps could cavitate and be damaged.
Page 115 TO START icon will appear in the Main normal. Display indicating that the pre-heater is NOTE For fault identification, see the MLC300 Main Display warming the engine’s air intake. Operation Manual. The length of time the wait to start icon remains on depends on ambient temperature.
Page 116: Operating Procedures
3. Make sure the automatic boom stop is set at the proper angle. For detailed instructions, see the Automatic Luffing Hoist Operation Boom Stop Adjustment topic in Section 4 of the MLC300 The location of the boom and luffing jib control handles Service Manual.
Page 117 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Boom Stop Adjustment topic in Section 4 of MLC300 Service Manual. 4. Make sure the automatic jib stops are set at the proper angles. For detailed instructions, see the Automatic Jib Stop Adjustment topic in the MLC300 Luffing Jib Operator Manual.
Page 118: Swing Operation
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Swing Operation Screen topic in the Main Display Operation Manual for detailed instructions. 4. If not previously done, perform the crane Startup WARNING Procedure. See page 3-61. Tipping Hazard 5. Turn off the swing park switch.
Page 119 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-67 Published 08-14-19, Control # 256-05...
Page 120 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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 3-19. Load Drum Control Handles Item...
Page 121: Load Drum Operation (Without Free Fall Or With Free Fall Disabled)
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Load Drum Operation (without free fall or with • With both tandem drums unparked, the left handle on the right console (Figure 3-19) controls both free fall disabled) drums simultaneously and automatically adjusts The location of the load drum handles varies depending on speed to keep the load block level.
Page 122 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Drum 2 Drum 3 Locking Pin Selector Handle (Drum 2) Selector Handle (Drum 3) Figure 3-21. Free Fall Selector Valves Menu Free Fall Screen Selection Screen Free Fall Icon Identification...
Page 123: Load Drum Operation (With Free Fall Enabled)
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Load Drum Operation (with free fall enabled) NOTE The remaining steps assume you already know how to navigate in the main display. The location of the load drum control handles varies d.
Page 124 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL d. As the load nears the desired position, slowly move Leave the drum control handle in off and release the the drum control handle toward off to slow down the free fall brake with the brake pedal to lower the load load.
Page 125: Free Fall Brake Pedal Hydraulic Pressure Test
Free Fall Brake Operational Test Figure 3-23. Drum 2 or 3 Control Information Screen A free fall operational test must be performed weekly as instructed in Section 2 of your MLC300 Service Manual. Manitowoc 3-73 Published 08-14-19, Control # 256-05...
Page 126: Clamshell Operation
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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.
Page 127 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-75 Published 08-14-19, Control # 256-05...
Page 128: Travel Operation
OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Travel Operation CAUTION Accelerated Crawler Wear WARNING To reduce the wear and tear of the crawler components (treads, rollers, frames), try not to allow dirt to pile up at Tipping Hazard the tumbler and the front roller ends of the crawlers.
Page 129 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 2. When traveling with load, position the boom at or 7. To make a SHARP LEFT TURN (Figure 3-26), move the above the boom angle given in the Maximum Allowable right crawler control handle forward from the neutral Travel Specifications chart.
Page 130: Shutdown Procedure Or Leaving The Crane Unattended
Changing weather conditions including but not limited to: Manitowoc cranes are not affected by cold weather. wind, ice or snow accumulation, precipitation, flooding, Manitowoc’s capacity charts are acceptable for use in cold lightning, etc. should be considered when determining the weather.
Page 131: Wire Rope
For extreme cold, refer to Approved Lubricants for Operation off, leaving rope without lubrication. in Arctic Climate in the MLC300 Lubrication Guide. Manitowoc 3-79 Published 08-14-19, Control # 256-05...
Page 132 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL From Below View D From Below View C View E View B View A Figure 3-29. Cold Weather Heaters 3-80 Published 08-14-19, Control # 256-05...
Page 133: 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 3-29 supplied APU can be started from inside the operator cab.
Page 134 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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)
Page 135: 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 136 OPERATING CONTROLS AND PROCEDURES MLC300 FIXED POSITION COUNTERWEIGHT 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 137 Install Drum 3..............4-35 Manitowoc...
Page 138 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Camera Connections ............4-39 Activate Setup Mode .
Page 139 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Disconnect Boom Butt Hydraulic Hoses ......... . 4-102 Activate Setup Mode .
Page 140 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Specifications ............. . 4-158...
Page 141: Boom And Jib Assembly Drawings
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION SECTION 4 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 142: 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 143: Personal Fall-Protection
See the Crane Weights topic in Section 1 for the weights of and disassembly, personnel shall wear fall-protection individual crane components. equipment. See the MLC300 Product Guide in Section 1 for outline and • Anchors and lifelines are designed to handle only one shipping dimensions.
Page 144: Parts Box
• To install the counterweight tray and counterweight boxes. See on page 4-58 Install Counterweight Manitowoc provides a parts box that can be lifted with a Boxes on page 4-63. forklift. The MLC300 is equipped with the following self-erect The following types of parts are shipped in the parts box:...
Page 145 MLC300 FIXED POSITION COUNTERWEIGHT 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) (2) (see Figure 4-5 on page 4-6...
Page 146: Lifting Slings
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Lifting Slings 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 147: Shackles And Lifting Link
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Shackles and Lifting Link Description Item Shackle: 25 t (28 USt) Two Supplied by Manitowoc Item 225,0 8.86 57,0 2.25 313,0 12.34 106,0 4.19 73,0 2.88 51,0 2.00 127,0 5.00 Description...
Page 148: Remote Control
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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 149: Activating Remote Control
Activate the remote control in the Mode Selection Group The remote control will “go to sleep” after 10 minutes of non- of the Main Display. See the MLC300 Main Display use. If this happens, press the communication switch on the Operation Manual for instructions.
Page 150: Pin And Connecting Hole Cleanliness
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL PIN AND CONNECTING HOLE CLEANLINESS Item Description To prevent dirt from damaging closely machined surfaces of Coupler pins and connecting holes: Nipple • Thoroughly clean all pins and connecting holes. O-ring (not visible) •...
Page 151: Pre-Start Checks
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Electric System Examples of locations of caps and plugs: • hanging lanyards Check that all shorting plug is attached as shown in Figure 4-10 on page 4-11. The engine may not start and •...
Page 152 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-12 Published 08-14-19, Control # 256-05...
Page 153: Swing Limits
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION SWING LIMITS Refer to Table 4-2 for swing limits during crane assembly and disassembly. • In all cases, Drums 2 and 3 can be either installed or removed. • In all cases, the grade in any direction must not exceed 1% (0.5°).
Page 154 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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 155: Crane Assembly
MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 156 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 157: Deploy Cab Rear Platform
MLC300 FIXED POSITION COUNTERWEIGHT 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 158 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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 08-14-19, Control # 256-05...
Page 159: Remove Window Covers
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Remove Window Covers 1. Loosen the thumb screw (1). 2. Move the mirror (2) from the shipping notch (3a) to the If equipped, remove and store the operator cab window working notch (3b).
Page 160 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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)
Page 161: Move Rotating Bed Left-Front Platform To Working Position
MLC300 FIXED POSITION COUNTERWEIGHT 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 162 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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 08-14-19, Control # 256-05...
Page 163: Install Rotating Bed Handrails
MLC300 FIXED POSITION COUNTERWEIGHT 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.
Page 164 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL View D — ROTATING BED WORKING View A — STORED View B— ROTATING BED WORKING View E — STANDALONE Item Description View C — STANDALONE Left-Rear Platform Top Ladder Bottom Ladder...
Page 165: Using Rotating Bed Left-Rear Ladder
The ladder has been provided only for accessing and Removing Ladder servicing the Manitowoc MLC300 crane. Any other use is neither intended nor approved. 1. Lower the bottom ladder (3) to the working/standalone position as shown in View B and install the pins (5).
Page 166 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 167: 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 168 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 169 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-24 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 170 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Item Description Item Description Live Mast Rotating Bed Lug (2) Keeper Pin with Safety Pin (4) Alignment Pin (4) Mast Hinge Pin Alignment Notch (4) Equalizer Hinge Pin Rotating Bed Frame...
Page 171: Install Live Mast Package
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Install Live Mast Package 7. Using the remote control, engage the mast hinge pins (3, View B) and install the locking pins (2). Figure 4-25 for the following procedure. 8. Continue to lower the live mast package until: 1.
Page 172 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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)
Page 173 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION b. Store the pin (7, View B). • Connect the dust caps to the storage couplers. 14. Proceed as follows (two places) at the boom hoist (6, 17. Connect the electric cable (13, View E) from the rotating View A): bed to the receptacle (14) on the boom hoist.
Page 174 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL View A View B View F SHIPPING View C View D View E WORKING Figure 4-27 4-34 Published 08-14-19, Control # 256-05...
Page 175: Install Drum 2
• 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 176 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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)
Page 177 MLC300 FIXED POSITION COUNTERWEIGHT 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 4-28 continued Manitowoc 4-37 Published 08-14-19, Control # 256-05...
Page 178 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-38 Published 08-14-19, Control # 256-05...
Page 179: Camera Connections
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Camera Connections Figure 4-29 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.
Page 180: Activate Setup Mode
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Item Description Live Mast Mast Assist Arm and Cylinder (2) Boom Hoist Boom Hoist Wire Rope Equalizer Mast-to-Boom Straps Self-Erect Cylinder Lifting Link Storage Bracket Transport Position Vertical Operating Angle for Installing Crawlers...
Page 181: Live Mast Operating Precautions
MLC300 FIXED POSITION COUNTERWEIGHT 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 182: 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 183: Lubricate Crawler-To-Carbody Machined Surfaces
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Entire Surface Crawler Carbody Entire Under Surface Both Views Typical Four Places Figure 4-32 Lubricate Crawler-to-Carbody Machined crawlers and the carbody — surfaces marked with an asterisk (*) in Figure 4-32.
Page 184 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL TOP Holes Figure 4-31 on page 4-42 – 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)
Page 185: Install First Crawler
MLC300 FIXED POSITION COUNTERWEIGHT 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 186 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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)
Page 187 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-35 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.
Page 188 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Item Description Trailer (single-drop deck) First Crawler Installed and Lowered to Ground Second Crawler 7,3 m (24 ft) Radius Figure 4-36 Item Description Ladder Bracket (2) Quick-Release Pin (2) Figure 4-37...
Page 189: Install Second Crawler
MLC300 FIXED POSITION COUNTERWEIGHT 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 4-36 for the following procedure. 4. Repeat First Crawler Installation steps –...
Page 190 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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 4-38 4-50 Published 08-14-19, Control # 256-05...
Page 191: Store Carbody Jacks
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Store Carbody Jacks Figure 4-38 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.
Page 192 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 193: Deploy Carbody Side Platforms
MLC300 FIXED POSITION COUNTERWEIGHT 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 194 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Item Description Trailer Counterweight Tray Lifting Lug (4) Shackle (4): 20,5 t (23 USt) Lifting Slings (4) 4 m (13 ft) long Shackle (2): 25 t (28 USt) Self-Erect Cylinder Radius: 6,4 m (21 ft) see Liftcrane...
Page 195: Remove Counterweight Tray From Trailer
NOTE One or two boxes can be lifted at a time. If the MLC300 will be used to assemble the boom and jib, install the counterweight tray and counterweight boxes AFTER the boom and jib are assembled. The MLC300 will be much easier to maneuver without crane counterweight.
Page 196 Lifting Pendant (2) Lifting Plate (2) Assist Crane lifting Slings Lifting Lug (4): for use with lifting pendants Lifting Lug (4): for use with Manitowoc synthetic lifting slings Lifting Lug (4): for use with Manitowoc synthetic lifting slings and shackles View C...
Page 197: Prepare For Counterweight Installation
The weight of the tray is 20 000 kg (44,092 lb). The following steps are performed at Manitowoc when the counterweight tray retainers (1) are installed: For ease of counterweight tray handling and lifting,...
Page 198 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 20 000 kg (44,092 lb) FRONT REAR Item Description 7,4 m (24 ft) Counterweight Tray Lifting Pendant (4) Lifting Plate (2) Assist Crane Sling (2) Lifting Lug (4) Hand-Held Tagline Lifting Lug (4)
Page 199 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Install Counterweight Tray 3. Attach hand-held taglines (6) to the lifting lugs (7) on the rear corners of the tray. Have ground personnel control Figure 4-44 for the following steps. swinging of the tray with the taglines.
Page 200 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL View A View B Item Description Counterweight Tray Hooked Lugs (4) Rail (2) Rotating Bed Counterweight Retainer (2) Retaining Pin Safety Pin (2) Storage Bracket (2) Connecting Lug (2) Figure 4-47...
Page 201 NOTE An alternate installation method is to hold the counterweight tray in position with the assist crane Disconnect the lifting plates (10) from the assist and travel the MLC300 in reverse to install the tray. crane lifting slings (11) and place the lifting plates into the storage pockets.
Page 202 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL View A Series 3 Shown View C Series Item 2 Quantity Each Side Total View B Series 3 Shown Item Description Counterweight Tray Counterweight Box — 10 000 kg (22,046 lb) each...
Page 203: Install Counterweight Boxes
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Install Counterweight Boxes 2. Attach synthetic lifting slings (3, View E) around the lifting lugs (4) on the counterweight boxes (2). Two Figure 4-48 for the following procedure. boxes may be lifted at one time.
Page 204: Boom And Jib Rigging - General
See the Crane • Mast assist arms (1) fully raised. Weights topic in Section 1 the MLC300 Operator Manual for • Lifting link (5) attached to the self-erect cylinder (4). the weights of boom and jib components.
Page 205: Blocked Crawlers
MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 206 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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 or lifting sling hooks)
Page 207: Handling Components
MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 208 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL View B Lifting Arrangement for All Inserts View A Standard Width OR 3.5 m Wide WORKING View E STORED View C View E-E STORED Item Description Shackle (2): 25 t (28 USt)
Page 209: Boom #500 Assembly
MLC300 FIXED POSITION COUNTERWEIGHT 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 desired radius. Do not exceed radius (R). NOTE The first insert must be the 12 m (39.4 ft) insert with WARNING sheaves.
Page 210 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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 211 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 7. Repeat step 2 page 4-69 for the next insert (10). 12. Disconnect the lifting slings. Figure 4-53 for the following steps. 13. If necessary per the Boom Rigging Drawing being used, perform the following steps as the boom inserts are 8.
Page 212 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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 213: Install Drop-Down Suspension
MLC300 FIXED POSITION COUNTERWEIGHT 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 214 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL View B View A 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 Self-Erect Cylinder...
Page 215: Assemble Boom Top To Inserts
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Assemble Boom Top to Inserts 22. Lower the boom top (15, View E) until the bottom connector holes are aligned. Figure 4-56 for the following steps. 23. Remove the pins (13, View E) from the storage tubes 20.
Page 216 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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)
Page 217: Raise Boom Top Wire Rope Guide
MLC300 FIXED POSITION COUNTERWEIGHT 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 4-57 for the following procedure. 4. Connect the electric cable (11, View D) from the boom 1.
Page 218 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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 219: Connect Boom Straps
MLC300 FIXED POSITION COUNTERWEIGHT 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 4-59 for the following procedure. 2. Remove pin (5, View A1 or A2).
Page 220 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 221: Install/Remove Lower Boom Point
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Install/Remove Lower Boom Point Removing Lower Boom Point Sheave Clusters Figure 4-60 View E, for the following procedure. Figure 4-60 for the following procedure. 1. Remove the rope guard (8). If removed, install the lower boom point as follows.
Page 222 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 223: Install Upper Boom Point
MLC300 FIXED POSITION COUNTERWEIGHT 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 224 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Inboard Side View B without Drum 6 Upper Lower View C with Drum 6 View A Legend is on the following page. Upper Lower Inboard Side View H STORED View D...
Page 225: Connect Boom Butt To Crane
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION legend for Figure 4-62 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)
Page 226 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL View C View A View B View D View E Item Description View F Handling Pendant (2) Hitch Pin with Hair-Pin Cotter Boom Butt Live Mast Self-Erect Cylinder Lifting Link Hooked Connector (2)
Page 227: Connect Boom Butt To Boom
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION NOTE For the MLC300 with fixed position counterweight, 8. Check the appropriate capacity chart to see if the ALL boom lengths can be closed and opened using crawlers need to be blocked to raise the boom. If so, the self-erect cylinder.
Page 228 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL FULLY RAISED View B 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 229: Connect Mast Straps To Boom Straps
MLC300 FIXED POSITION COUNTERWEIGHT 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 4-64 for the following steps.
Page 230 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL View F View A View E View B View C View D Figure 4-65 4-90 Published 08-14-19, Control # 256-05...
Page 231: Connect Hydraulic Hoses From Crane To Boom Butt
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Legend for Figure 4-65 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)
Page 232 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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)
Page 233 MLC300 FIXED POSITION COUNTERWEIGHT 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 4-66 for the following procedure.
Page 234 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Item Description Upper Monitor in Cab Upper Camera Switcher (on rotating bed) Not Used Not Used Drum 6 Camera Drum 1 Camera Lower Monitor in Cab Lower Camera Switcher (on rotating bed)
Page 235 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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...
Page 236: Install The Boom Load Lines
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Install the Boom Load Lines • Wire Rope Installation on page 4-146 • Load Line Reeving on page 4-156 1. Route the load lines up the boom. See Figure 4-105 on page 4-155.
Page 237 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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 238: Prepare Intermediate Suspension Pendants
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 4-68, for the following procedure3.
Page 239: Raise Boom
 All tools and other items are removed from boom and jib.  Electrical boom stop is properly installed, operational, NOTE Refer to the MLC300 Luffing Jib Operator Manual for and adjusted to proper angle. the pre-raising checks and raising procedure when equipped with a luffing jib.
Page 240: Shipping Crane Components
Check all safety devices for proper operation (see the chords — never over the lacings. Keep the tie-downs Section 3 of the MLC300 Operator Manual). as close to the blocking as possible (View A) to prevent bending the chords.
Page 241: Crane Disassembly
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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...
Page 242: Lower Boom
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Lower Boom • The chain and weight for the upper boom point are stored on brackets on the upper boom top. 1. Swing the boom to either side of center and lower the...
Page 243 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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 244: Activate Setup Mode
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Activate Setup Mode Perform the steps under Setup Mode on page 4-9. WARNING Disconnect Mast Straps from Boom Straps Falling Load Hazard! Figure 4-73 for the following steps. Do not exceed a maximum mast angle of 156°. The mast could fall suddenly.
Page 245 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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)
Page 246: Disconnect Boom Butt From Boom
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL NOTE For the MLC300 with fixed position counterweight, ALL boom lengths can be closed and opened using the self-erect cylinder. WARNING If desired, the live mast and Manitowoc supplied Crushing Injury Hazard!
Page 247 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION View B without Drum 6 Upper Lower View C with Drum 6 View A Legend is on the following page. Upper Lower View H STORED View D DISENGAGED View G WORKING...
Page 248: Disconnect Boom Butt From Crane
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL legend for Figure 4-75 4. Connect the hydraulic hoses (7, View G) from the boom butt to the hydraulic couplers (9) on the front of the Item Description rotating bed. Shackle (2 or 6): 25 t (28 USt) Lifting Sling (4): 4 m (13 ft) long 5.
Page 249 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-109 Published 08-14-19, Control # 256-05...
Page 250: Disassemble Boom
Personal Fall-Protection on page 4-3. page 4-79. 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 4-69. the counterweight boxes and tray before proceeding. See:...
Page 251 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION View A Series 3 Shown View C Series Item 2 Quantity Each Side Total View B Series 3 Shown Item Description Counterweight Tray Counterweight Box — 10 000 kg (22,046 lb) each...
Page 252: Remove Counterweight Boxes
3. Remove the counterweight boxes in the following NOTE If desired, the counterweight boxes can be installed onto a trailer using the MLC300 live mast as shown sequence: Figure 4-42. Reverse the steps for removing the counterweight tray from a trailer on page 4-55.
Page 253 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 20 000 kg (44,092 lb) 7,4 m (24 ft) Item Description Counterweight Tray Lifting Pendant (4) Lifting Plate (2) Lifting Lug (4) Assist Crane Sling (2) Hand-Held Tagline Lifting Lugs (4)
Page 254: Remove Counterweight Tray
For ease of counterweight tray handling and lifting, (4) on the counterweight tray. Manitowoc provides two lifting pendants (2), a lifting 4. Attach hand-held taglines (6) to the lifting lugs (7) on the plate (3), and two lifting lugs (4) on each side of the rear corners of the tray.
Page 255 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION View B View A Item Description Counterweight Tray Hooked Lugs (4) Rail (2) Rotating Bed Counterweight Retainer (2) Retaining Pin Safety Pin Storage Bracket (2) Figure 4-78 Connecting Lug (2) Manitowoc...
Page 256 NOTE An alternate removal method is to hold the NOTE If desired, the counterweight tray can be installed counterweight tray in position with the assist crane onto a trailer using the MLC300 live mast as shown and travel the MLC300 forward away the tray. Figure 4-41.
Page 257 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION View B Front of Each Crawler View A1 Rear of Each Crawler PAST Item Description Storage Couplers Hydraulic Hoses Electric Cable Storage Receptacle Figure 4-80 View A2 Rear of Each Crawler CURRENT...
Page 258: Store Carbody Side Platforms
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 259 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Figure 4-31 on page 4-42 In Top Holes View B In Bottom Holes View A View C View E View D Item Description Item Description First Crawler Collar Second Crawler Hitch Pin with Hair-Pin Cotter (2)
Page 260: Remove First Crawler
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Remove First Crawler 4. Using the remote control, fully retract the jacking cylinders next to the second crawler (2, View C). Figure 4-81 for the following procedure. The opposite side crawler must be on the ground.
Page 261 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION NOTE The item numbers in this illustration correspond to the item numbers in Figure 4-81. Item Description Second Crawler Lifting Link (3) Lifting Slings (3 legs) Shackle (3): 20,5 t (23 USt)
Page 262: Remove Second Crawler
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Remove Second Crawler 1. Using the remote control, extend the jacking cylinders next to the second crawler (2, View A, Figure 4-82) until the first stage of each cylinder is fully extended.
Page 263 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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 4-84 Manitowoc 4-123 Published 08-14-19, Control # 256-05...
Page 264: Lower Live Mast To Transport Position
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 4-84 for the following procedure. Display Working Screen.
Page 265 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION View A View B View F SHIPPING View C View D View E WORKING Figure 4-85 Manitowoc 4-125 Published 08-14-19, Control # 256-05...
Page 266: 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 267: Remove Live Mast Package
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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)
Page 268 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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.
Page 269 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-129 Published 08-14-19, Control # 256-05...
Page 270 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT 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...
Page 271 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION Item Description Item Description Live Mast Rotating Bed Lug (2) Keeper Pin with Safety Pin (4) Alignment Pin (4) Mast Hinge Pin Alignment Notch (4) Equalizer Hinge Pin Rotating Bed Frame...
Page 272 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Figure 4-89 for the remaining steps. The live mast package will hang approximately 6° out of level (rear higher than front) when lifted. 12. Hoist with the assist crane just enough to tension the lifting slings.
Page 273 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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...
Page 274: Install Live Mast Package On Trailer
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 4-90 for the following procedure.
Page 275 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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)
Page 276 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 277 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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 4-92 Manitowoc 4-137 Published 08-14-19, Control # 256-05...
Page 278: Store Rotating Bed Left-Rear Platform And Handrails
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 4-92 for the following procedure.
Page 279 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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)
Page 280: Move Rotating Bed Left-Front Ladder To Working Position
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 4-93 for the following procedure.
Page 281 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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...
Page 282: Store Right Side Rear View Mirror
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 283 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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 284: Install Carbody-Rotating Bed Module On Trailer
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 4-96 for the following procedure.
Page 285 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-145 Published 08-14-19, Control # 256-05...
Page 286: Wire Rope Installation
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 287: Anchoring Wire Rope To Drum
MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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 4-98 Anchoring Wire Rope to Drum Item Description...
Page 288 SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 289 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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...
Page 290: Anchoring Wire Rope To Wedge Socket
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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.
Page 291 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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...
Page 292: 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 293: 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 294: Operating Rigging Winch
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 295 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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 296: Load Line Reeving
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL 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 4-106 WARNING to achieve maximum hook capacity. The duplex hook has a...
Page 297 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL SETUP AND INSTALLATION 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 298: Load Block Tieback
SETUP AND INSTALLATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL LOAD BLOCK TIEBACK General Tieback hole (1, Figure 4-108) is provided on the front of the rotating bed for tying back the load block when not in use. Specifications Sling Length...
Page 299: Section 5
Lube and Coolant Product Guide ........... . . 5-1 Manitowoc...
Page 300 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK. 5-ii Published 08-14-19, Control # 256-05...
Page 301: Lube And Coolant Product Guide
MLC300 FIXED POSITION COUNTERWEIGHT 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 08-14-19, Control # 256-05...
Page 302 LUBRICATION MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK. Published 08-14-19, Control # 256-05...
Page 303 Fiberglass Maintenance ............6-1 Manitowoc...
Page 304 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK. 6-ii Published 08-14-19, Control # 256-05...
Page 305: Inspection And Maintenance Checklist
MLC300 FIXED POSITION COUNTERWEIGHT 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 08-14-19, Control # 256-05...
Page 306 MAINTENANCE CHECKLIST MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK. Published 08-14-19, Control # 256-05...
Page 307 Manitowoc Dealer........
Page 308 MLC300 FIXED POSITION COUNTERWEIGHT OPERATOR MANUAL Operating Controls And Procedures ..........3-1 Operating Controls .

Manitowoc MLC300 Operator's Manual

Section 1

Section 2

Section 3

Section 4

Quick Links

Related Manuals for Manitowoc MLC300

Summary of Contents for Manitowoc MLC300