Manitowoc MLC90A-1 Operator's Manual
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Manitowoc MLC90A-1 Operator's Manual

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MLC90A-1/MLC100-1
Operator Manual

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Summary of Contents for Manitowoc MLC90A-1

  • Page 1 Manitowoc MLC90A-1/MLC100-1 Operator Manual...
  • Page 3 NOTICE The serial number of this crane and applicable attachments 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 MLC90A-1/MLC100-1 OPERATOR MANUAL General..............2-21 Location .
  • Page 7 MLC90A-1/MLC100-1 OPERATOR MANUAL TABLE OF CONTENTS Engine Oil, Gear Oil, and Hydraulic Oil ..........3-52 AC Power Supply .
  • Page 8 TABLE OF CONTENTS MLC90A-1/MLC100-1 OPERATOR MANUAL Disconnect Equalizer from Boom Butt ..........4-35 Configure RCL/RCI for Crane Operation .
  • Page 9 MLC90A-1/MLC100-1 OPERATOR MANUAL TABLE OF CONTENTS Remove Crane Counterweight (continued) ......... 4-75 Disassemble Crane Counterweight .
  • Page 10 TABLE OF CONTENTS MLC90A-1/MLC100-1 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK TOC-vi Published 12-10-19, Control # 258-05...
  • Page 11 Manitowoc Dealer........
  • Page 12 MLC90A-1/MLC100-1 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 12-10-19, Control # 258-05...

  • Page 13: Crane Data

    OUTLINE DIMENSIONS See the end of this section for outline dimensions. CHANGE OF OWNERSHIP REGISTRATION If you are the new owner of a Manitowoc crane, please register it with Manitowoc Crane Care so we can contact you if the need arises.

  • Page 14: Identification And Location Of Components

    INTRODUCTION MLC90A-1/MLC100-1 OPERATOR MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS Item Description Drum 1 (whip hoist) Drum 2 (main hoist) Drum 3 (optional aux hoist) Drum 4 (boom hoist) Upper Boom Point or Fixed Jib (not shown) Lower Boom Point Hook-and-Weight Ball...
  • Page 15 MLC90A-1/MLC100-1 OPERATOR MANUAL INTRODUCTION Item Description Item Description Counterweight Pins Swing Drive Fuel Tank Drum 4 Drive Hydraulic Tank A/C Condenser Battery Box Hydraulic Oil Cooler Tier 4 DEF Tank Drum 3 Drive Engine Air Cleaner Main Control Valve Pump Drive and Pump...

  • Page 16: English And Metric Conversions

    INTRODUCTION MLC90A-1/MLC100-1 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 17 MLC90A-1/MLC100-1 OPERATOR MANUAL INTRODUCTION To Convert Symbol Application Symbol Multiply By 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 Ton (2,000 lb.)
  • Page 18 INTRODUCTION MLC90A-1/MLC100-1 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 12-10-19, Control # 258-05...

  • Page 19: Section 2

    Personnel Handling Policy ............2-22 Manitowoc...
  • Page 20 MLC90A-1/MLC100-1 OPERATOR MANUAL Pedestal/Barge Mounted Cranes ........... 2-23 Pedestal Mounted Crane .

  • Page 21: 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 22 SAFETY INFORMATION MLC90A-1/MLC100-1 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 23: Safety And Information Signs

    MLC90A-1/MLC100-1 OPERATOR MANUAL SAFETY INFORMATION Table 2-1 Common Safety Symbols Emergency Cab Exit Lift Do Not Lift Prohibited M104626 M104627 M104628 Table 2-2 Miscellaneous Symbols Engine Coolant Diesel Fuel Engine Coolant Engine Oil Level Hydraulic Filter Hydraulic Oil Vent M100271...
  • Page 24 SAFETY INFORMATION MLC90A-1/MLC100-1 OPERATOR MANUAL Material Item Description Steps (both crawlers) Non-skid grating Steps (stowed) Non-skid grating Steps (working) Non-skid grating Platform (both sides) Non-skid grating Carbody Counterweight Non-skid paint Steps Non-skid grating Handrails Enclosure Platforms Non-skid strips Crane Counterweight (not shown)

  • Page 25: Crane Access Points

    When personnel use ladders to get on or off the crane, their serious injury or death. 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 26: Operator Manual/Capacity Chart Storage

    If the serial numbers of your manuals and capacity charts do not match the serial numbers of the crane, contact your Manitowoc dealer for the proper manual or capacity charts. WARNING Do not operate the crane if the proper Capacity Chart is Fall Hazard! not in the cab.

  • Page 27: 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 28 SAFETY INFORMATION MLC90A-1/MLC100-1 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 29: 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 30: Lifting/Moving Load

    SAFETY INFORMATION MLC90A-1/MLC100-1 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 31: 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 32: 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 33: 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 34: Category 2 Operational Aids

    SAFETY INFORMATION MLC90A-1/MLC100-1 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 35: 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 36: Electrocution Hazard Devices

    SAFETY INFORMATION MLC90A-1/MLC100-1 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 37: 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 38 SAFETY INFORMATION MLC90A-1/MLC100-1 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 39: 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 40 SAFETY INFORMATION MLC90A-1/MLC100-1 OPERATOR MANUAL View A WRONG – DANGEROUS! If boom is off ground and supported by boom rigging, and there is no blocking under boom sections, boom will collapse when lower pins are removed. View B WRONG – DANGEROUS!

  • Page 41: Boom Disassembly Safety

    MLC90A-1/MLC100-1 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 42: 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 43: 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 44: 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 45: 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 46: 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 47: Section 3

    Batteries..............3-52 Manitowoc...
  • Page 48 MLC90A-1/MLC100-1 OPERATOR MANUAL Engine Oil, Gear Oil, and Hydraulic Oil ......... . . 3-52 AC Power Supply .
  • Page 49 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 12-10-19, Control # 258-05...

  • Page 50: Standard Hand Signals For Controlling Crane Operations

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5. Table 3-1. Standard Hand Signals for Controlling Crane Operations M100118 M100119 M100120 M100121 M100122 M100123 M100124 M100125...
  • Page 51 MLC90A-1/MLC100-1 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 52: Symbols Used On Control Consoles

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 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 Air Conditioner Cylinders, Extend and Retract...
  • Page 53 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-2. Symbol Identification — Control Consoles Energize Lights, Console M100154 M100165 Engine Run Light, Position M100159 M100291 Engine Start Light, Work (and camera) M100160 M100166 Engine Stop Lighter M100161 M100167 M100142a M100170...
  • Page 54 OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Table 3-2. Symbol Identification — Control Consoles Pin, Disengage Swing M100177 M100186 Pin, Engage Swing Left M100178 M100189 Regen (Tier 4), Inhibit Swing Right M100285 M100190 Regen (Tier 4), Initiate Travel Forward—Left Crawler...
  • Page 55 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-2. Symbol Identification — Control Consoles Windshield Washer, Front Windshield Washer, Overhead Manitowoc Published 12-10-19, Control # 258-05...

  • Page 56: Operating Controls

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS Figure 3-1. Cab Controls and Indicators Published 12-10-19, Control # 258-05...
  • Page 57 3-20 for more information. Satellite Antenna Contact your Manitowoc dealer for CraneSTAR information. The beacon rotates and the alarm sounds whenever the crane’s Rated Capacity Limiter (RCL) Light capacity is near an overload condition (when RCL system is ON). See page 3-25.
  • Page 58 OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Rear View Mirror (optional left side) Adjustable to provide a view to the rear of the crane. Drum Mirror Adjustable to provide a view of the drums. Rear View Mirror (optional right side) Adjustable to provide a view to the rear of the crane.
  • Page 59 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-11 Published 12-10-19, Control # 258-05...

  • Page 60: Left Console

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Left Console Table 3-4. Left Console Item Name Description Maximum current draw is 10A. For fuse location, see Section 3 of the Service 12VDC Power Source Manual. Item Description Engage this switch to raise or lower the rear riser.
  • Page 61 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-4. Left Console Boom Control Handle: Boom Hoist Operation on page 3-37. • Move the control handle BACK to RAISE the boom. The boom hoist brake releases and speed changes in relation to control handle movement.

  • Page 62: Right Console

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Right Console Table 3-5. Right Console Item Name Description When this button is depressed, the crane engine shuts off, the brakes apply, and the currently operated crane functions come to a complete stop.
  • Page 63 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-5. Right Console The engine ignition switch has the following positions: • Stop (A) • Run (B) Engine Ignition Switch • Start (C) Rated Capacity Limiter (RCL) Displays load lifting information and alerts the operator to overload conditions.
  • Page 64 OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Table 3-5. Right Console A separate switch is provided for each crane function — swing (A), drum 1 (B), drum 2 (C), drum 3 (D), drum 4 (E), and travel (7). • Press the TOP of the rocker to PARK the corresponding crane function. With...
  • Page 65 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-5. Right Console For drum and control handle identification, see Figure 3-2 on page 3-16. For non-free fall load drums, see Load Drum Operation—Liftcrane Full Power on page 3-40. For free fall load drums, see Load Drum Operation—Liftcrane Free Fall on...
  • Page 66 OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Table 3-5. Right Console Travel Operation on page 3-44. 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 67 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-5. Right Console To activate this switch, the Boom Butt Configuration must be selected in the RCL/RCI Display. See Section 4 in the Operator Manual for gantry raising and lowering instructions. • Press and hold the TOP of the rocker to EXTEND the gantry cylinders (raise gantry).

  • Page 68: Overhead Console

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Overhead Console Table 3-6. Overhead Console Item Name Description • CLOCKWISE faster. Blower Fan Speed Switch • COUNTERCLOCKWISE slower. • CLOCKWISE hotter. Temperature Switch • COUNTERCLOCKWISE cooler. • LEFT end, heater. • RIGHT end, air conditioner.
  • Page 69 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-6. Overhead Console • Press the TOP of the rocker to TURN ON the cab work lights. • Press the BOTTOM of the rocker to TURN OFF the cab work Cab Work Lights Switch lights.
  • Page 70 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. The exhaust system regen inhibited icon indicates the after-treatment system active (automatic) regeneration is prevented because the inhibit switch is in the inhibit position.

  • Page 71: Foot Pedals

    MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 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 72: Seat Controls

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Seat Controls Table 3-8. Seat Controls Item Name Description • Push to the LEFT to UNLOCK the seat. Fore-Aft Control Lever • Use your body weight to slide the seat to the desired position.

  • Page 73: Other Operation Aids

    MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Other Operation Aids Crane Level Indicates crane levelness from front to rear and from side to Boom Angle Indicator side. The level is mounted on the right-front wall of the The boom angle indicator...

  • Page 74: Battery Disconnect Switch

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Battery Disconnect Switch CAUTION Engine Damage! To avoid possible engine fault codes and undesirable operation, make sure the engine ignition switch has been off five minutes before disconnecting the batteries. Do not rely on this switch to protect the crane’s electronic systems when welding.

  • Page 75: Crane Cameras

    MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Crane Cameras Table 3-9. Crane Camera Locations Item Name Camera Points at LOAD from boom point or from jib point Camera Points to REAR (tail swing) Camera Points at DRUM 3/4 Camera Points at DRUM 1/2...

  • Page 76: Crane Camera Monitor

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Crane Camera Monitor Table 3-10. 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 77: Remote Control

    MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES REMOTE CONTROL Table 3-11. Identification and Operation of Remote Controls To operate the remote control (1): • The electric cable (2A) must be connected to the receptacle (2B) in the left enclosure. • The Boom Butt Configuration must be selected in the RCL/RCI Display.
  • Page 78 OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Table 3-11. Identification and Operation of Remote Controls This switch allows the gantry raising cylinders to extend and retract automatically in conjunction with the boom hoist when using the Drum 4 (boom hoist) thumb-wheel control (item 5 on remote control).

  • Page 79: Operating Limits Identification

    MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES OPERATING LIMITS IDENTIFICATION The following table lists the operating limits this crane is equipped with and identifies which of those limits are bypassable. 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 80 OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Operating Limit Icon Free Fall Lowering Over Speed This limit does not stop operation. It alerts the operator if the load on either Drum 1 or 2 is being lowered faster than 150 rpm, which can result in accelerated wear and shortened service life of the free fall brake.

  • Page 81: Cab Window Operation

    MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES P2389b P2515 Squeeze Latch and Pull to Open Unlatch and Rotate Out to Open Item Description Latch (right-side and roof window) Latch (rear window) Figure 3-6. Cab Windows CAB WINDOW OPERATION Figure 3-6.

  • Page 82: Crawler Blocking

    Perform the preventative maintenance checks and At low ambient temperatures, dynamic loads (impact and lubrication requirements listed in Sections 5 and 6 of shock) can affect the steels used in Manitowoc cranes the this manual. when operating in cold weather. Read and comply with...

  • Page 83: Startup Procedures

    1. If used, unplug or turn off the engine block heater, engine oil pan heater, hydraulic tank heaters, and any other crane heaters. NOTE Manitowoc recommends the use of the Cold Weather Package to aid startup when the ambient temperature will be 0°C (32°F) and below. See...
  • Page 84 OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL NOTE You will not be able to increase engine speed until 10. Once the engine starts, it is normal for faults to appear in the hydraulic oil temperature is warmed to at least the Alerts Bar of the Main Display Working Screen.

  • Page 85: Operating Procedures

    MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES OPERATING PROCEDURES 2. Make sure the automatic boom stop is set at the proper angle (82°). For detailed instructions, see the Automatic NOTE The following operating procedures assume the Boom Stop Adjustment topic in Section 4 of the Service following: Manual.

  • Page 86: Swing Operation

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Swing Operation 2. Turn off the swing park switch. CAUTION WARNING Avoid Boom/Swing Drive Damage Tipping Hazard Do not apply the swing holding brake or turn on the swing To prevent the crane from tipping, adhere to any swing park switch while swinging.
  • Page 87 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-39 Published 12-10-19, Control # 258-05...

  • Page 88: Load Drum Operation-Liftcrane Full Power

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Load Drum Operation—Liftcrane Full Power • Drum 1 and 2 High Speed Operation is enabled by adjusting the programmable speed limiter on the Speed and Torque Settings Screen over 100% (see F2315 for Speed and torque Settings Screen operation).

  • Page 89: Load Drum Operation-Liftcrane Free Fall

    MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Free fall cannot be turned on until the Right Side Enclosure Above Pumps drum is un-parked. If the drum is not un- parked, the “function parked” icon will appear in the Free Fall Enable Screen of the main display.

  • Page 90: Free Fall Drum Slip And Pedal Response

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL 6. If the load will be suspended for any length of time, latch down the free fall brake pedal and turn on the drum park switch. WARNING NOTE The drum brakes will apply and free fall for both...

  • Page 91: Load Drum Operation-Clamshell

    MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES pushed forward to hoist or lower the load with hydraulic RAISING BUCKET power. 1. Pull the holding line handle back to raise the bucket at Pedal response can be adjusted to suit operator feel. A high the desired speed.

  • Page 92: Travel Operation

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Travel Operation WARNING Tipping Hazard The travel surface must be firm and uniformly supporting. Refer to the Maximum Allowable Travel Specifications chart in the Capacity Chart Manual for: • Travel specifications with load •...
  • Page 93 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES travel in the direction opposite of control handle 8. To make a SHARP RIGHT TURN, reverse step movement. 9. To make a GRADUAL LEFT TURN (Figure 3-17), move Travel cruise can be turned on once the crane is both crawler handles to front from the neutral position.

  • Page 94: Shutdown Procedure Or Leaving The Crane Unattended

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL SHUTDOWN PROCEDURE OR LEAVING Low Clearance Travel Boom Configurations THE CRANE UNATTENDED Low clearance travel is allowed for the following boom configurations: WARNING Fully Rigged Boom Moving Load/Tipping Crane Hazard Figure 3-19 on page 3-46.
  • Page 95 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES View A Dimension 1,52 m (5 ft) 4,30 m (14 ft 1 in) 4,14 m (13 ft 7 in) 0 to 2° View B Item Description Counterweight (Series 1 or 2) Fully Rigged Boom – 19 m (62.3 ft)

  • Page 96: Preparing Fully Rigged Boom For Low Clearance Travel

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL 8. Using the gantry cylinders switch on the right console, extend the gantry cylinders until the counterweight handling links (11, View D and E) and the tie-down links WARNING (12) are taut. Structural Damage Hazard 9.
  • Page 97 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES View A View B Item Description Counterweight (Series 1 or 2) Cantilevered Boom Inserts (see Table) Tie-Back Links Equalizer Gantry Blocking Gantry Cylinder (Qty 2) View C Safety Pin (Qty 2) Collar (Qty 2)

  • Page 98: Preparing Cantilevered Boom Inserts For Low Clearance Travel

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Table 3-13. Maximum Cantilevered Boom Inserts 5. Rotate the counterweight handling links (11, View D) toward the counterweight and align the holes in the 12 m counterweight handling links with those in the tie-down Length (9.8 ft)
  • Page 99 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-51 Published 12-10-19, Control # 258-05...

  • Page 100: Cold Weather Operation

    The static load-carrying limitations of the steels used in Manitowoc cranes are not affected by cold weather. An explosion and serious burns may result if ether is Manitowoc’s capacity charts are acceptable for use in cold sprayed into the engine air intake. weather.
  • Page 101 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES View C View B View A View C Figure 3-21. AC Generator Manitowoc 3-53 Published 12-10-19, Control # 258-05...

  • Page 102: Ac Power Supply

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL Legend for Figure 3-21 Install and securely tighten the mounting hardware. Item Description d. Connect the power supply cable (2) to the Generator (diesel driven 5 kW, 120/240VAC) receptacle (5). Lifting Ring (Qty 4)
  • Page 103 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Item Description Engine Coolant Heater Engine Oil Heater Hydraulic Tank Heater Battery Pad Heater (2) Battery Pad Heater Thermostat Figure 3-21 on page 3-51 Load Center (see Figure 3-22. Cold Weather Heaters Manitowoc...

  • Page 104: Cold Weather Heaters

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL COLD WEATHER HEATERS A thermostat (located under heater cover) is factory-set to turn the heater on at 31°C (87°F) and off at 100°F To preheat critical components and lubricant sumps during a (38°C).
  • Page 105 MLC90A-1/MLC100-1 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Electrical Control Panel Behind Operator Seat in Cab Manitowoc 3-57 Published 12-10-19, Control # 258-05...

  • Page 106: Fuses And Circuit Breakers

    OPERATING CONTROLS AND PROCEDURES MLC90A-1/MLC100-1 OPERATOR MANUAL FUSES AND CIRCUIT BREAKERS Item Description Power Supply Converter — 24/12VDC, 30A Main Circuit Breaker — 120A Diagnostic Receptacle Program Receptacle Crane Bus — 15A Circuit Breaker Key — 15A Circuit Breaker Radio — 15A Circuit Breaker Cab Main and RCL Displays —...
  • Page 107 Connect Boom Butt to Boom Top Electric Cables ........4-37 Install Boom Top Position Light and Wind Speed Indicator (option) ..... . 4-39 Manitowoc Published 12-10-19, Control # 258-05...
  • Page 108 MLC90A-1/MLC100-1 OPERATOR MANUAL Install Boom Top Camera (option) ..........4-39 Install Boom Block-Up Limit Components .
  • Page 109 MLC90A-1/MLC100-1 OPERATOR MANUAL Load Trailers ..............4-79 Remove Hook-and-Weight Ball .
  • Page 110 MLC90A-1/MLC100-1 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-iv Published 12-10-19, Control # 258-05...

  • Page 111: Boom And Jib Assembly Drawings

    Manitowoc-provided with the crane. steps, ladders, and platforms.

  • Page 112: Assembly And Disassembly Area

    PARTS STORAGE HANDLING COMPONENTS Parts Box The major components are equipped with lifting lugs. The Manitowoc provides a parts box that can be lifted with a lifting lugs are identified by the following symbol in the forklift. assembly and disassembly illustrations.

  • Page 113: Lifting Sling

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION LIFTING SLING 135 mm (5-5/16 in) 28 mm 250 mm (1-3/32 in) (9-27/32 in) 1 370 mm (4 ft 6 in) 39,1 mm (1-5/8 in) 50,8 mm (2 in) 23,9 mm (15/16 in) Item Description Lifting Sling: 3-leg chain —...
  • Page 114 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Shipping Configuration CAUTION • Max shipping width = 3.7 m (12 ft) Avoid Wire Rope Damage! • Max shipping height = 4.1 m (13 ft 6 in) To avoid wire rope damage, the boom butt must be •...

  • Page 115: Shipping Configuration

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION SHIPPING CONFIGURATION • Boom butt sheaves for single part rigging line from front drum The crane ships in the configuration shown in Figure 4-3. The boom butt can be used to handle, assemble, and...

  • Page 116: Self-Erect Controls

    SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Right Console Remote Control Item Description Remote Control Receptacle Power Switch Emergency Stop Switch Gantry Cylinders Switch Sync Switch (Drum 4 and gantry cylinders) Boom Hoist Control (thumbwheel) Counterweight Pins Switch Crawler Cylinder Switch...

  • Page 117: Pin And Connecting Hole Cleanliness

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION PIN AND CONNECTING HOLE • Connecting and disconnecting electric cables. The potential for operating faults or damage to the electric CLEANLINESS components exists if the engine is not stopped. To prevent dirt from damaging closely machined surfaces of...
  • Page 118 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View A View B STORED View C View E Item Description View F Trailer Safety Pin (qty 8) Storage Lug Step (qty 8) Hitch Pin with Hair-Pin Cotter (qty 5 left) Hitch Pin with Hair-Pin Cotter (qty 7 right)

  • Page 119: Crane Assembly

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION CRANE ASSEMBLY Figure 4-5. 1. From under the cab: Prepare Trailer for Unloading Remove the hitch pins (6, View E). Figure 4-5. b. Slide the platforms (7, View E) out to the working 1. Position the trailer (1, View A) on a firm level surface.
  • Page 120 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Cab Cover (optional) Rear View Mirror (optional on cab) Rear View Mirror (optional right side) Figure 4-6 4-10 Published 12-10-19, Control # 258-05...

  • Page 121: Prepare Cab

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Prepare Cab Figure 4-6 for the following steps. 1. Remove and store the cab cover. 2. Rotate the rear view mirror (2) to the operating position and adjust it as required. 3. Rotate the rear view mirror (3) to the operating position and adjust it as required.
  • Page 122 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description View A Quick-Release Pin or Safety Pin STORED (qty 6 right side, qty 6 left side) View B WORKING Handrail, Left Handrail, Left-Front Handrail, Left-Rear Handrail, Right-Single Handrail, Right Handrail, Right-Rear View C...

  • Page 123: Raise Handrails

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION WORKING STORED View E (Right Side WORKING) Figure 4-7 continued Raise Handrails d. Raise the left-front handrail (3) to the working position (View D) and install the quick-release or safety pins (1, View B) to secure the handrail (3) in CAUTION the working position.
  • Page 124 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View A 457 mm (18 in) View B View E View C Item Description Counterweight Links (both sides) Safety Pin (qty 2) Collar (qty 2) Pin (qty 2) View D Gantry Gantry Cylinder Backhitch Links...

  • Page 125: Start Engine

    Travel Crane off Trailer Raise Gantry Figure 4-8. Manitowoc recommends that the gantry be raised while the WARNING crane is on the trailer. Tipping Crane Hazard! To prevent tipping, do not swing (keep upperworks inline CAUTION with lowerworks) until the crane is traveled off the trailer.
  • Page 126 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Crawler (qty 2) Stop Block with Safety Pin (qty 4) Locking Pin with Retaining Pin and Lynch Pins (qty 4) Carbody Extension (qty 4) Alignment Pin (qty 4) Safety Pin (qty 8)

  • Page 127: Extend Crawlers

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION 3. Stop extending the crawler when the alignment pins (5, View B) are engaged in the guide pockets of the crawler (1) frames. WARNING 4. Install the locking pins (3, View B) in the working Crush Hazard! position.
  • Page 128 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Trailer Hook-and-Weight Ball Drum 1 Load Line Drum 1 Load Line (stored in boom butt) Guide Sheaves Button Socket Button Socket (pinned to rotating bed) View A View B View A Figure 4-11...

  • Page 129: Install Hook-And-Weight Ball

    Refer to the Liftcrane Boom Butt Capacities at the end of this section for lifting capacities. • The crane counterweight tray and each carbody counterweight has three lifting lugs. Use the Manitowoc supplied chain lifting sling (Figure 4-2 on page 4-3) to handle the crane and carbody counterweight boxes and tray.
  • Page 130 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View A Item Description Trailer WARNING 3 m Boom Insert Falling Load Hazard! 6 m Boom Insert To prevent the pendants from falling off the boom top 12 m Boom Insert during transport, the boom top pendants must be securely...
  • Page 131 MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Item Description Jib Butt (shipping package) Jib Top Center of Gravity Jib Insert 4 164,6 mm (13 ft 8 in) 1 854,4 mm (6 ft 1 in) 2 717,6 mm (8 ft 11 in)
  • Page 132 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Chain Lifting Sling Hook-and-Weight Ball Carbody Counterweight (2) Boom Butt at Min Angle of 64° Counterweight Handling Sheave Sheave Indicator Pin with Hair-Pin Cotters (4) Hooked Lug (4) View A 64° View E...

  • Page 133: Assemble Boom And Jib

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Assemble Boom and Jib 5. Raise the boom butt to approximately 80°. 6. Pay out the load line from Drum 1 and reposition the The boom and jib can be assembled with this crane’s boom load line behind the counterweight handling sheave (5, butt or with an assist crane.
  • Page 134 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Chain Lifting Sling (Manitowoc furnished) Hook-and-Weight Ball Counterweight Tray Counterweight Box • Qty 2 for Series 1 • Qty 4 for Series 2 Connecting Pin with Safety Pins (Qty 4 or 8)

  • Page 135: Assemble Crane Counterweight

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Assemble Crane Counterweight b. Using two legs of the chain lifting sling (1, View C), lift the counterweight box (4) at the two connecting Figure 4-15. pins (5). The can be used to assemble the crane counterweight using...
  • Page 136 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL 50 mm (2 in) View C View B View A Item Description Boom Butt at 81° Boom Stop Spring Compressed (qty 2) Boom Stop Outer Tube (Qty 2) Boom Stop Inner Tube (Qty 2)

  • Page 137: Activate Remote Control

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION 1. Prepare the boom stops. CAUTION DANGER Structural Damage to Crane! Crush Hazard! Use extreme care when compressing the boom stops Avoid being crushed by moving parts: during the following steps. Do not compress the boom •...
  • Page 138 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Crane Counterweight Handling Pendants (Qty 4) Handling Links (Qty 2) Pendant Pins with Safety Pins (Qty 4) Adjustable Handling Link (Qty 2) Front Handling Link (Qty 2) View A 1180 mm (46.5 in)

  • Page 139: Install Crane Counterweight (Continued)

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Install Crane Counterweight (continued) • The handling links (3) will be centered over the crane counterweight (1). Use the remote control for the remaining steps. This will • The crane will be at the approximate dimension allow the installer to stand at the rear of the crane and view given in View A.
  • Page 140 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View D View E Item Description Crane Counterweight Handling Pendants (Qty 4) Handling Links (Qty 2) Pendant Pins with Cotter Pins (Qty 4) Not Used Counterweight Pin (Qty 2) Pad (Qty 2) Arrow Alignment Decal...
  • Page 141 MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Install Crane Counterweight (continued) 16. Verify that the counterweight pins are fully engaged. 17. Slowly lower the gantry (boom down using the Drum 4 Figure 4-17. thumbwheel on the remote control) to lower the crane 11.
  • Page 142 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Boom Butt Boom Insert Top Connectors Tumbler or Roller Blocking Top Connector Pins with Safety Pins Upper Boom Point Stands STORED (2 places) View B View A CAUTION Avoid Sheave Damage! Use extreme care while swinging so the rope guide under the boom butt does not hit the crawlers (or carbody counterweight if installed).

  • Page 143: Remove Hook-And-Weight Ball

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Remove Hook-and-Weight Ball 5. Check the appropriate capacity chart to see if the crawlers need to be blocked to raise the boom. If so, After you are done using the for self-assembly, remove the proceed as follows: hook-and-weight ball from the boom butt.
  • Page 144 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Boom Hoist Wire Rope Equalizer Equalizer Rails Tie-Back Pin with Flat Washer and Locking Pin (Qty 2) Insert Pendant (Qty 2) Pendant Pin (Qty 2) Intermediate Suspension Pendant (Qty 2) View F...

  • Page 145: Connect Boom Pendants To Equalizer

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Connect Boom Pendants to Equalizer Disconnect Equalizer from Boom Butt Figure 4-20. 1. Boom down to slacken the boom hoist wire rope (1, View WARNING C) until the equalizer (2, View B) is resting firmly on the...
  • Page 146 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View A: Electric Cable in Boom Top View B: Camera Cable Stored in Boom Butt View C: Boom Cable Stored Figure 4-22 Boom Wiring in Boom Butt 4-36 Published 12-10-19, Control # 258-05...

  • Page 147: Connect Boom Butt To Boom Top Electric Cables

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Legend for Figure 4-22. 2. Prior to connecting the electric cables, remove the dust caps or shorting plugs, and thoroughly clean the cable Item Description connectors. Boom Extension Cable (WBBI-P2) 3. Apply dielectric grease to the cable connectors.
  • Page 148 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View G — RIGHT View A View B View F — WRONG View C Lower Boom Point Upper Optional Boom Lower Point Boom Point View D View E Figure 4-24 (1-3 places) (1-3 places)

  • Page 149: Install Boom Top Position Light And Wind Speed Indicator (Option)

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Legend for Figure 4-24 8. Connect the electric cable (6, View B) from the boom top to the electric cable (7) from the anemometer. Item Description Make sure the electric cable from the anemometer is...
  • Page 150 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View A View B View C View E View D Figure 4-25 4-40 Published 12-10-19, Control # 258-05...

  • Page 151: Install Jib Top Position Light And Wind Speed Indicator (Option)

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Install Jib Top Camera (option) Legend for Figure 4-25 Item Description 1. Remove the camera (9, View A, Figure 4-25) from Position Light and Anemometer Bracket storage in the parts box. Camera Bracket Mounting Screws, Lock Washers, and Nuts (Qty 2) 2.
  • Page 152 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL 2. Connect the chain (16, View E) to the actuator cable (15) 4. Make sure the locking flag is stored in the limit switch as from the limit switch (14) at the jib point.

  • Page 153: Deactivating/Activating A Block-Up Limit Switch

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION 1. Remove the locking flag (2, View A) from the storage slots in the limit switch (1). WARNING 2. Slip the locking flag (2, View B) over the actuator cable (3). Two-Blocking Hazard 3. Engage the locking flag (2, View C) with the limit switch Two-blocking is the condition in which the load block or (1).
  • Page 154 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Lower Boom Point with Upper Boom Point Dead-End Link (far side) Button Socket with Pin Swivel (optional, not shown) Block-Up Limit Components Load Block: 100 t (110.2 USt) 4 Sheave 75 t (82.7 USt) 3 Sheave 25 t (27.6 USt) 1 Sheave...

  • Page 155: Install Load Lines

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Install Load Lines Route the load lines up the boom (and jib, if equipped) and over the desired guide sheaves in the boom top WARNING (and jib top, if equipped). See Figure 4-27 and the Load Falling Load Hazard! Line Reeving Diagrams at the end of this section.

  • Page 156: Boom And Jib Rigging - General

    SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Boom or Jib Chord Boom or Jib Number Manitowoc Part Number View B View A Manitowoc Manufacturing Code Chord Identification Pendant Diameter Length Manitowoc Purchase Order Number Wire Rope Type Set Number Manufacturer’s Number...

  • Page 157: Handling Boom And Jib Sections

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Handling Boom and Jib Sections • Handle the boom sections with care to avoid damaging the lacings and chords. • Use synthetic lifting slings (crane owner furnished) to lift the boom sections. WARNING The jib sections do not have lifting lugs.
  • Page 158 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View D (STORED) View E View A Item Description Insert: 3m, 6m, or 12 m View B Blocking View C Top Connector Bottom Connector Top Connecting Pin with Safety Pin Bottom Connecting Pin with Safety Pin...

  • Page 159: Boom #290 Assembly

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION BOOM #290 ASSEMBLY Determine location intermediate suspension links (7, View D) as specified in the Boom Rigging Drawing. b. Leave the top connecting pins (5, View B) stored. WARNING Remove the special top connecting pin (8, View D) Crush Hazard! from each intermediate suspension link (7).

  • Page 160: Install Boom Pendants

    SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Boom Top Pendant: 6,9 m Links (stored in parts box) Pin with Cotter Pins Insert Pendant: 3m, 6 m, 12 m Pendant Pin with Cotter Pin View B View A Figure 4-32 Install Boom Pendants b.

  • Page 161: Install Intermediate Suspension Pendants

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION 2. Lift the upper boom point (1) into position at the end of the boom top (2). 3. Remove the connecting pins (3) from the upper boom point. 4. Align the top connecting holes in the upper boom point with those in the boom top and install the top connecting pins (3).
  • Page 162 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Shaft with Safety Pin Cap Screw, Flat Washer, and Lock Nut (Qty 2) Rope Guard Adjusting Screw, Flat Washers, and Nuts (Qty 2) Figure 4-35 Item Description U-Bolt with Flat Washers, Lock...

  • Page 163: Install Optional Rope Guard

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Install Optional Rope Guard 1. Remove the u-bolts (1) from the tagline assembly (2). 2. Lift the tagline assembly (2) into position at the desired Figure 4-31. location in the boom. The tagline assembly weighs If equipped with the optional rope guard, install it as follows:.
  • Page 164 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL 711 mm (28 in) Item Description Jib Bottom Jib Stop Plate (Qty 2) Boom Top Blocking View A Pin with Safety Pins (Qty 2) Pin with Safety Pins (Qty 4 each jib section) Jib Insert (Qty 1 or 2 if installed)

  • Page 165: Jib #117 Assembly

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION JIB #117 ASSEMBLY Install Jib Inserts See the #117 Jib Rigging Drawing at end of this section for jib makeup. The jib bottom (1, Figure 4-37) is shipped as an assembled WARNING! unit consisting of the following: Collapsing Jib Hazard! •...
  • Page 166 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Jib Bottom Boom Top Jib Insert (if equipped) Jib Strut Jib Top Pendant (Qty 2) Link (Qty 2) Pin with Cotter Pin (Qty 1 or 2 each pendant) Jib Insert Pendant (Qty 2 or 4 if installed)

  • Page 167: Install Jib/Backstay Pendants

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Install Jib/Backstay Pendants Pin the backstay pendants (10) to the strut links (11) with the pendant pins (7) and cotter pins. Figure 4-38. b. Lay the backstay pendants on the ground alongside the boom top.
  • Page 168 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View A View B View C View E View D View F View G Figure 4-39 4-58 Published 12-10-19, Control # 258-05...

  • Page 169: Raise Jib Strut

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Legend for Figure 4-39. 3. Pin the backstay pendants as follows: • For the 10° offset, pin the backstay pendants (10, Item Description View A) to the backstay lugs (17) on the boom top Jib Bottom with the pendant pins (7) and cotter pins.

  • Page 170: Raise Boom

    SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL RAISE BOOM Boom Raising Procedure 1. Verify that the pre-raising checks have been performed. Pre-Raising Checks 2. SLOWLY start to boom up: Perform the following checks before raising the boom and jib: Have an assistant watch the boom pendants as the boom rises.

  • Page 171: Shipping Crane Components

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION SHIPPING CRANE COMPONENTS • To avoid damage to components: Use synthetic tie-downs to secure components as It is the owner/user’s responsibility to ensure the following: shown in Figure 4-40, View A. • All trailer loads comply with local, state, and federal If chain tie-downs are used, install protective covering transportation requirements.
  • Page 172 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Stop Plate (Qty 2) Boom Top 711 mm Figure 4-41 (28 in) 4-62 Published 12-10-19, Control # 258-05...

  • Page 173: Crane Disassembly

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION CRANE DISASSEMBLY boom sections and the equalizer is resting on the boom butt rails as shown in Figure 4-20 on page 4-34. Before proceeding, read and understand all of the topics on page 4-1...
  • Page 174 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View A View B View E View D View C View F View G Figure 4-42 4-64 Published 12-10-19, Control # 258-05...

  • Page 175: Store Strut Stops

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Legend for Figure 4-42. 4. Install the pin (19, View D) in the inner stop tube (18A). 5. Lower the strut stop onto the jib strut (4, View C). Item Description Jib Bottom Deploy Strut Raising Arm...
  • Page 176 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Boom Hoist Wire Rope View E Equalizer Equalizer Rails Intermediate Suspension Pendant (Qty 2) Tie-Back Link (Qty 4) Tie-Back Pin with Flat Washer and Locking Pin (Qty 2) Boom Butt Lug (Qty 2)

  • Page 177: Connect Equalizer To Boom Butt

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION NOTE If the jib strut will be lowered with the whip line, store 1. Boom down to slacken the boom hoist wire rope (1, View the strut stops (page 4-65) and lower the strut...
  • Page 178 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Boom Butt Boom Insert Bottom Connector Pin (Qty 2) View B View A (STORED) View C View D Figure 4-44 4-68 Published 12-10-19, Control # 258-05...

  • Page 179: Open Boom

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Open Boom 2. Boom up only enough to support the boom when the bottom connector pins (3, View B) are removed. Figure 4-44. 1. During the following step, the boom will pivot about the...
  • Page 180 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Equalizer Insert Pendant (Qty 2) Pendant Pin (Qty 2) Boom Butt Boom Insert Top Connector Pin with Safety Pin (Qty 2) Rope Guide View A View B Figure 4-45 4-70 Published 12-10-19, Control # 258-05...

  • Page 181: Disconnect Boom Pendants From Equalizer

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Disconnect Boom Pendants from Equalizer 4. Travel the crane in reverse, away from the boom sections. CAUTION WARNING Avoid Sheave Damage! Moving Object Hazard! Once the boom butt is disconnected from the boom, Prevent serious crushing injury:...
  • Page 182 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL 50 mm (2 in) View B View A View C View D Figure 4-46 4-72 Published 12-10-19, Control # 258-05...

  • Page 183: Remove Crane Counterweight

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Legend for Figure 4-46. Item Description Boom Butt at 81° WARNING Boom Stop Spring Compressed (qty 2) Crush Hazard! Boom Stop Outer Tube (Qty 2) Moving parts can cut or crush. Boom Stop Inner Tube (Qty 2)
  • Page 184 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View B View A Item Description Boom Butt Boom Stop (Qty 2) Hold-Back Pin with Hair-Pin Cotter (qty 2) Gantry Handling Pendant (Qty 4) Handling Link (Qty 2) Pendant Pin with Cotter Pin (Qty 4)

  • Page 185: Remove Crane Counterweight (Continued)

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Remove Crane Counterweight (continued) 16. Store the handling pendants (5, View A) and the links (8A and 8B) on the counterweight tray. 8. Slowly continue to raise the gantry until the weight of the 17.
  • Page 186 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Chain Lifting Sling Hook-and-Weight Ball Carbody Counterweight (2) Boom Butt at Min Angle of 64° Counterweight Handling Sheave Sheave Indicator Pin with Hair-Pin Cotters (4) Hooked Lug (4) View A 64° View E...

  • Page 187: Remove Carbody Counterweight

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Remove Carbody Counterweight CAUTION For Series 1, disregard this procedure. Avoid Boom Butt Damage! NOTE The following procedure uses the boom butt. Do not lower the boom butt below 64° while handling the To provide sufficient clearance if you use an assist counterweight from the handling sheave.
  • Page 188 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Trailer Hook-and-Weight Ball Drum 1 Load Line Drum 1 Load Line (stored in boom butt) Guide Sheaves Button Socket Button Socket (pinned to rotating bed) Tie-Back Hole (Qty 2) Figure 4-49 4-78...

  • Page 189: Load Trailers

    Refer to the Liftcrane Boom Butt Capacities at the end of this section for lifting capacities. Use the Manitowoc supplied chain lifting sling (Figure 4-2 on page 4-3) to handle the crane and carbody counterweight boxes and tray.
  • Page 190 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Crawler (qty 2) Stop Block (qty 4) Locking Pin with Retaining Pin and Lynch Pins (qty 4) Carbody Extension (qty 4) Alignment Pin (qty 4) Safety Pin (qty 8) Shim (qty 4)

  • Page 191: Retract Crawlers

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Retract Crawlers • It may be necessary to swing the upperworks to increase the clearance between the crawler and Figure 4-50. carbody so the shims can be removed. • Alternatively, holding the crawler positioning switch in the extend position will cause the crawlers to tip slightly, thereby providing more clearance.
  • Page 192 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL View A 457 mm (18 in) View B View E View C Item Description Counterweight Links (both sides) Safety Pin (qty 2) Collar (qty 2) Pin (qty 2) View D Gantry Gantry Cylinder Backhitch Links...

  • Page 193: Prepare Trailer For Loading

    5. Lower the boom butt onto blocking View A) so the boom 3. Lower the trailer deck to the ground. butt is at least 457 mm (18 in) above the trailer deck. Manitowoc recommends that the gantry be lowered after the crane is traveled onto the trailer. CAUTION...

  • Page 194: Secure Operator Cab

    SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Secure Operator Cab The following instructions also assume that the boom butt has been disconnected from the boom and the is being used 1. If not already done, disable and store the remote control to disassemble the boom sections.

  • Page 195: Jib #117 Disassembly

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION JIB #117 DISASSEMBLY The following instructions assume: DANGER • Boom and jib have already been lowered to the ground. Collapsing Boom Hazard! • Strut stops have been stored. To prevent death or serious injury, do not stand on, inside, or under the jib sections during jib disassembly.

  • Page 196: Wire Rope Installation

    SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL WIRE ROPE INSTALLATION Seizings NOTE The wire rope manufacturer’s recommendations take Wire Rope Type Required precedence over the following information. Preformed Wire Rope Specifications Non-preformed See the Wire Rope Specifications Chart in the Capacity...
  • Page 197 MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Drums 1, 2, and 4 Remove half of the guard from the drum. Reinstall the guard. Install the clamp bar above the wire rope. Make sure there is no rope seizing under the clamp bar.

  • Page 198: Winding Wire Rope Onto Drum

    SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL 1. Remove the wire rope from the shipping reel: Mount the wire rope shipping reel (1, Figure 4-56) on a shaft (2) supported at both ends by jacks (3) or blocks. b. Provide a brake at the shipping reel so that the wire rope can be wound tightly on the drum.
  • Page 199 MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION View A View B Item Description Wraps of first layer tight against drum flanges and each other Wedge Tight against drum flange for 3/4 of diameter Voids and loose wraps in first layer will cause sever wear of wire rope...
  • Page 200 SETUP AND INSTALLATION MLC90A-1/MLC100-1 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 201: Anchoring Wire Rope To Wedge Socket

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION Anchoring Wire Rope to Wedge Socket 2. Allow the dead end of the wire rope to extend past the end of the socket the amount shown. Figure 4-58 3. Allow the wire rope to assume its natural lay.
  • Page 202 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL Item Description Rigging Line Connector Wire Rope with Button Pad Eye No. 1 Pad Eye Item Inch Wire Rope without Button Approximate Capacity 553 kg (1220 lb) 9,65 Shackle 6,35 Rigging Line 22,40 Rope Clips...

  • Page 203: Anchoring Wire Rope To Button Socket

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION General Some rotation-resistant wire rope supplied by Manitowoc is equipped with a pad eye welded to the leading end of the wire rope or to the button on the end of the wire rope.
  • Page 204 SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL CANNOT route wire rope from this sheave to upper point. CAN route wire rope from these sheaves to upper point. Configuration Description Two Load Lines Two Load Lines Three Load Lines Three Load Lines with Pile Driving Leads...

  • Page 205: Load Line Reeving

    MLC90A-1/MLC100-1 OPERATOR MANUAL SETUP AND INSTALLATION LOAD LINE REEVING WARNING WARNING Avoid Death or Serious Injury! Falling Load Hazard! Exercise care when block is standing in vertical Use only a load block or hook-and-weight ball with a position, as the potential for tipping exists.

  • Page 206: Load Block Tieback

    SETUP AND INSTALLATION MLC90A-1/MLC100-1 OPERATOR MANUAL LOAD BLOCK TIEBACK General Holes (1, Figure 4-62) on the front of the rotating bed can be used to tieback the load block (3) when not in use. Item Description Hole: 52,5 mm (2-1/16 in) (Qty 2)

  • Page 207: Section 5

    Lube and Coolant Product Guide ........... . . 5-1 Manitowoc...
  • Page 208 MLC90A-1/MLC100-1 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK. 5-ii Published 12-10-19, Control # 258-05...

  • Page 209: Lube And Coolant Product Guide

    MLC90A-1/MLC100-1 OPERATOR MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION See F2314 at the end of this section. LUBE AND COOLANT PRODUCT GUIDE See the publication at the end of this section. Manitowoc Published 12-10-19, Control # 258-05...
  • Page 210 LUBRICATION MLC90A-1/MLC100-1 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK. Published 12-10-19, Control # 258-05...
  • Page 211 Fiberglass Maintenance ............6-1 Manitowoc...
  • Page 212 MLC90A-1/MLC100-1 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK. 6-ii Published 12-10-19, Control # 258-05...

  • Page 213: Inspection And Maintenance Checklist

    MLC90A-1/MLC100-1 OPERATOR MANUAL MAINTENANCE CHECKLIST SECTION 6 MAINTENANCE CHECKLIST INSPECTION AND MAINTENANCE CHECKLIST See F2317 at the end of this section. FIBERGLASS MAINTENANCE See Bulletin W04-009 at the end of this section. Manitowoc Published 12-10-19, Control # 258-05...
  • Page 214 MAINTENANCE CHECKLIST MLC90A-1/MLC100-1 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK. Published 12-10-19, Control # 258-05...
  • Page 215 Manitowoc Dealer........
  • Page 216 MLC90A-1/MLC100-1 OPERATOR MANUAL Operating in Wind ............. . . 3-33 Operating Limits Identification .

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